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Material Handling Information - Put-to-Light Consolidation
   
Sortation Systems
Put-to-Light Consolidation
The put-to-light consolidation system is a space-efficient, economical method for consolidating orders for a variety of small parts. The put-to-light system supports high-speed manual sortation with near 100% accuracy.
Product Type
  • Put-to-light manual sortation system.
Product Components
  • Rack frame.
  • Tri-color lighting system.
  • Product identification system.
  • PLC control software.
Product Variations
  • Number of consolidation locations.
  • Number of consolidation systems.
  • Bar code.
  • RF communications.
Integration Options
Technology Overview
  • Features
    • Tri-color lights indicate sorting locations, order completion, misplaced items.
  • Benefits
    • Highly accurate sortation.
    • Saves floor space.
  • Advances over previous technology
    • Flexibility for sorting a variety of item sizes.
    • Prevents product damage.
Operations
  • Input
    • Control software assigns shipping boxes for each rack location, matches the customer's order to the location.
    • Worker identifies item using bar code scanner or RF communications.
    • Green light indicates sorting location.
    • Photo eyes at each rack location verify the item is placed in the correct box or alert control software if the item is misplaced.
    • Any misplaced item must be retrieved and stored correctly before any more items can be processed.
  • Output
    • Amber light indicates order is complete.
    • Box is pulled from the rack and sent to shipping.
Applications
  • Recommended applications by product type:
    • Order consolidation.
    • Order picking by line item.
  • Replacement applications:
    • Manual consolidation.
    • Tilt tray sorter.
Problems Solved
Case Study Applications
  • MBS
  • Motorola LMPS
Solution Worksheets
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