Pick-by-Light, Pick-by-Voice or Pick-by-Robot: Which Is Best for Your Warehouse?
Reading time: 12 minutes
Modern warehouses face the challenge of processing increasing order volumes quickly and accurately. Digital order picking systems help warehouse operatives locate items faster, reduce errors and manage processes more efficiently.
Technologies such as Pick-by-Light, Pick-by-Voice and robotic order picking are now among the most important solutions for automated warehouse operations.
In this comprehensive guide, Jungheinrich provides an overview of the most important order picking solutions, outlining their advantages, limitations and ideal use cases to help you identify the best one for your warehouse.
What Is Pick-by-Light?
Pick-by-Light is a visually guided order picking system. Displays or light signals are installed at each storage location to indicate which items need to be picked and in what quantity.
Warehouse operatives follow the visual signals, retrieve the required goods and confirm the action directly at the storage location. This significantly reduces picking errors and increases picking speed.
How Does Pick-by-Light Work?
Pick-by-Light systems are typically integrated with a Warehouse Management System (WMS). When a picking order is generated, the WMS sends the relevant information to the Pick-by-Light controller, which activates the corresponding displays.
- Signal: An LED light illuminates at the correct storage location
- Display: The screen shows the required picking quantity
- Picking: The operative retrieves the goods
- Confirmation: The pick is confirmed by pressing a button
- Acknowledgement: The system records the pick and updates inventory levels
Advantages of Pick-by-Light
- Reduced error rates: Clear visual guidance minimises picking mistakes
- Higher picking performance: Intuitive operation and shorter travel distances speed up workflows
- Easy integration: Can be integrated into existing warehouse infrastructure
- Short training time: New employees can be trained quickly
Disadvantages of Pick-by-Light
- High initial investment: Hardware installation requires upfront capital
- Maintenance requirements: Displays and control units require regular servicing
- Dependence on power supply: Picking operations may be affected during power outages
- Limited suitability: Less suitable for very large, bulky or irregularly shaped items
What Is Pick-by-Voice? (Voice-Directed Picking)
Pick-by-Voice, also known as voice-directed picking, replaces paper picking lists and handheld scanners with headsets and speech recognition technology. The system provides spoken instructions about the l ocation and quantity of items, while the operative confirms each step verbally.
This hands-free and eyes-free approach significantly improves efficiency, reduces errors and enhances ergonomics, making Pick-by-Voice a key technology for modern warehouses.
How Does Pick-by-Voice Work?
- System start: The operative logs into the system
- Instruction: Storage location, item and quantity are communicated via voice
- Picking: The goods are retrieved accordingly
- Confirmation: The operative confirms verbally (e.g. check digit or quantity)
- Continuation: The next instruction is issued
Advantages of Pick-by-Voice
- Higher picking performance: Hands-free working can increase picking speed by up to 30%
- Error reduction: Accuracy rates of up to 99% are achievable
- Improved ergonomics: Reduced physical strain and fewer repetitive movements
- Flexibility: Quick onboarding of temporary or seasonal staff
- System integration: Seamless integration with existing WMS
- Optimised material flow: Real-time data supports process optimisation
Disadvantages of Pick-by-Voice
- Initial costs: Higher investment compared with traditional methods
- User acceptance: Some employees may require an adjustment period
- Language challenges: Multilingual teams may experience speech recognition issues
Five Reasons to Implement Pick-by-Voice in Your Warehouse
- Competitive advantage: Faster order processing and fulfilment
- Cost savings: Fewer errors, returns and rework
- Employee satisfaction: Improved ergonomics and ease of use
- Scalability: Easily adapts to business growth
- Future-ready technology: Continuous innovation and upgrades
What Is Pick-by-Robot? (Robotic Order Picking)
Order picking is often the biggest bottleneck in warehouse operations. Pick-by-Robot offers a fully automated alternative in which intelligent robots retrieve items and fulfil orders.
Pick-by-Robot — also referred to as robotic order picking — uses advanced image recognition, artificial intelligence and gripping technology to handle a wide range of products quickly and precisely.
Advantages of Order Picking Robots High throughput: Consistent automated picking performance
Low error rates: Minimal human intervention
Long-term cost reduction: Lower labour costs and reduced product damage
Flexibility: Adapts to changing order profiles
Improved working conditions: Employees are relieved of repetitive tasks
Challenges and Solutions with Pick-by-Robot
- High initial investment: Flexible financing and expert consulting can support implementation
- System integration: Seamless integration into existing warehouse infrastructure
- Product variability: AI-supported gripping systems handle a wide range of items
How Pick-by-Robot Works in Practice
- Order receipt: Customer orders are received by the system
- Route planning: Software calculates the optimal route
- Item recognition: Cameras identify the correct product
- Picking and placement: The robot retrieves the item and places it in a container
- Dispatch: The container is transported to shipping
Comparison of Order Picking Methods: Advantages and Disadvantages
| Order Picking Method | Key Advantages | Key Disadvantages |
|---|---|---|
| Pick-by-Light | High picking accuracy; fast and intuitive operation; short training time | High initial investment; maintenance requirements; limited suitability for bulky items |
| Pick-by-Voice | Hands-free operation; high productivity gains; excellent ergonomics | Higher acquisition costs; language and user acceptance challenges |
| Pick-by-Robot | Fully automated; highly scalable; very low error rates | High initial investment; complex integration; not suitable for all product types |
| Manual Order Picking | Low investment costs; flexible for small operations; easy to implement | Higher error rates; lower productivity; physically demanding |
Optimise Your Order Picking with Jungheinrich
Jungheinrich offers a comprehensive portfolio of order picking solutions, ranging from manual systems to fully automated technologies:
- Pick-by-Voice solutions
- Customised Pick-by-Light systems
- Order pickers and robotic picking solutions
- Warehouse automation technologies
- Warehouse management software
- Follow systems
Discover Jungheinrich’s order picking solutions and optimise your warehouse operations.