Lightning Pick’s Light-Directed Picking Solutions Boost Omni-Channel Fulfillment Speed, Accuracy

Broad range of automated technologies—displayed in Booth 1037c—improve one or multiple order fulfillment processes single and multi-DC networks.

GERMANTOWN, WI (December 7, 2015) — A full range of standalone or integrated light-directed picking solutions that improve both accuracy and speed in order fulfillment for omni-channel retail operations will be showcased by Lightning Pick, a Matthews Automation Solutions’ brand, at MODEX 2016 in Booth 1037c. The technologies improve one or multiple fulfillment processes within a single distribution center (DC) or across multiple locations in a distribution network. Featured are:

Lightning Pick omnichannel picking

LP Pick pick-to-light

LP Pick: Ideal for picking fast- and medium-velocity stock keeping units (SKUs) in forward pick areas and pick modules, Lightning Pick’s flagship pick-to-light solution facilitates team-based picking of broken case quantity order fulfillment. Consisting of a series of light-directed picking modules that indicate location of a required and quantity, LP Pick improves picking speed and accuracy while reducing the amount of time spent walking between items required by an order. The lights also eliminate errors associated with picking from paper lists. Six different light module families are offered to accommodate a variety of applications.

LP Put put-to-light putwall

LP Put put-to-light put wall

LP Put: For light-directed order sortation of batch-picked, mixed SKUs into unique e-commerce customer orders, Lightning Pick’s dual-sided put-to-light put wall system utilizes light-directed picking modules for high-speed, automated sortation. Constructed as a series of shelves divided vertically into multiple openings (or “cubbies”), each space represents a unique customer order. Openings on both front and back are equipped with a light-directed picking module. After a tote filled with mixed products arrives from the storage section of a warehouse, an operator at the sortation side of the put wall scans an item’s barcode. Lights illuminate to indicate the put location and quantity required to fill that order. The operator sorts the products into the designated locations, and then presses a button to confirm that the order is complete. This triggers corresponding lights on the pack-out side to illuminate, letting packers know when a completed order can be taken away for final packing.

pack-to-light for retail store replenishment

LP Pack pack-to-light for retail store replenishment

LP Pack: For breaking of full cases of inventory down to less-than-case quantities, Lightning Pick’s pack-to-light light-directed picking system (also sometimes called “put-to-light” or “put-to-store”) supports replenishment of items at individual retail stores. After operator scans the barcode attached to a full case, light modules illuminate at box positions associated with stores requiring that item, and indicate the quantity needed. Different colored LEDs direct the operator to the store positions/boxes above or below the track of light modules. The operator quickly and accurately puts/packs the items into that store’s box, and then extinguishes the light to confirm the action. Upon completion of required picks, full cartons are pushed off onto a takeaway conveyor for transport to sealing stations for outbound shipping.

Lighting Pick picking Cart

LP Cart mobile picking cart

LP Cart: Ideal for facilities with a vast number of SKUs that cannot be categorized by specific velocity, Lightning Pick’s line of multi-shelf mobile picking carts are ideal for e-commerce, third-party logistics (3PL) service providers and operations without conveyors. LP Cart automates batch picking for fulfillment of multiple, one- to two-line orders at the same time during a single pass through the warehouse, while following the shortest route. When the picker arrives at a storage area, the cart’s light-directed picking modules indicate which items should be distributed to each bin riding on the cart. Patented Perpetual Picking batch optimization software tracks each cart’s real-time location in the warehouse (as opposed to assuming the cart is navigating a pre-determined route) and directs the picker to collect additional, single-line picks along the travel path while navigating to the completed order drop point.

Omnichannel QC

QC Workstation

QC Workstations: Used to confirm pick accuracy and quality prior to shipping and/or to facilitate returns processing, Lightning Pick’s line of workstations provide an automated method of confirming a parcel’s contents. Each station features a network-connected PC, hand-held barcode scanner, touchscreen LCD display, flatbed scanner, and ergonomically mounted tabletop. As items are scanned, integrated software displays details about the expected and actual contents of the container on the touchscreen. A running comparison of the items scanned versus the expected quantities is continually updated, and audio and visual feedback is presented, increasing speed and accuracy. Mis-picks, over-picks, incorrect and missing products are all flagged on the screen, while optional operator messages prompt input of customer-specific error codes and/or descriptive text. Upon completion of the process, a detailed report can be printed on any nearby, network-connected printer.

Videos and components of Lightning Pick’s LP Pick, LP Put, LP Pack, LP Cart and QC Workstations installed in omni-channel operations can be seen at Booth 1037c throughout MODEX 2016 in Atlanta, Georgia—April 4-7, 2016. For more information, contact Joe Pelej at 262.250.2143, or by email at [email protected], or visit

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Lightning Pick, a Matthews Automation Solutions’ brand, delivers advanced pick-to-light, put-to-light, pack-to-light, batch picking carts, light sleds and other paperless picking, kitting, assembly and sortation systems from two locations in Germantown and Ixonia, Wisconsin. Our globally recognized automated technologies drive increased productivity, quality and efficiency across Lean supply chains—from manufacturing through order fulfillment. In 2014, Lightning Pick added the sales, support and service of all Pick-MAX light-directed products, formerly by IPTI.


Matthews Automation Solutions—a division of Matthews International Corporation—designs, manufactures and distributes a wide range of marking, coding and industrial automation technologies and solutions. Manufacturers, suppliers and distributors worldwide rely on Matthews’ integrated systems to identify, track, control and pick products at the highest levels of accuracy and throughput. For handling challenges in manufacturing, packaging or distribution, Matthews’ combined expertise delivers the integrated solution that meets an organization’s needs today, and grows with them tomorrow. These automated and semi-automated marking, coding, control, sortation, picking and verification technologies and software streamline manufacturing, distribution and order fulfillment processes to maximize productivity.

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