Lightning Pick’s New Picking Light Sled for Optimized Cluster Picking

Light-directed picking sled enables several cartons to be grouped together for faster, more accurate order fulfillment

light-directed picking sledGERMANTOWN, WI (December 4, 2015) — Fast and accurate, the LP Light Sled is ideal for facilities seeking to maximize cluster picking speed in their order fulfillment operations. Lightning Pick, a Matthews Automation Solutions’ brand, will highlight the LP Light Sled at MODEX 2016 in Booth 1037c.

Easy to learn and use, the Light Sled combines the benefits of pick-to-cart, pick-to-conveyor, pick-to-light and put-to-light order fulfillment methodologies to maximize efficiency and accuracy in cluster picking of multiple orders simultaneously. The horizontal sled design enables several order cartons to be grouped together and travel conveniently on conveyor throughout the distribution center, stopping at each storage zone that contains items required by the orders on the sled. Sleds can be configured to pick a single stock keeping unit (SKU) to multiple orders, or multiple SKUs to one order.

To operate the system, Lightning Pick software’s cluster feature first allows users to build a group of orders and assign them to a specific LP Light Sled (which has light modules attached). As the sled enters each pick-to-light enabled storage zone within the facility, the operator stationed there scans the sled’s barcode. This triggers the required items’ light-enabled storage positions to illuminate and pick quantities to be displayed at each pick face location (representing the total sum of each item required for all orders in the cluster).

When the operator presses a location confirm button on the storage location’s pick-to-light module, corresponding lights on the sled automatically display the correct sortation quantities for the assigned order cartons. The operator proceeds to any location lighted in the zone, picks the displayed quantity, then distributes the items to each order as indicated by the modules on the sled. The process repeats, pick zone by pick zone, until all orders are complete. The cartons are then routed for outbound shipment, and the sled returns to the start of the picking zones.

“The LP Light Sled provides fulfillment operations with an economical and highly accurate solution to optimize and support a cluster picking methodology in either manual or existing pick-to-light order picking systems,” said Joe Pelej, Marketing Manager for Lightning Pick. “Having lights both within storage zones and on the sled provides an extra measure of verification that the right items are going to the right customers, while order processing time is greatly reduced.”

The sleds contain:

  • Rechargeable battery that provides power for a full 8-hour shift
  • 11 b/g WiFi-based communication between each sled’s pick-to-light controller and Lightning Pick software
  • Light modules designed for low power consumption
  • Rugged and lightweight aluminum frame construction
  • Printer option to print price or box labels

Lightning Pick’s demo version of the Light Sled station 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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