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Pick To Light/Put To Light Systems

Overview

Falcon Autotech is one of the largest suppliers of Pick To Light/Put To Light systems and has developed its unique range of highly redundant and robust Pick to Light/Put to Light modules that can be coupled with Falcon’s WCS system or can be controlled by a third party application over standard APIs seamlessly. These tiny power houses can run for years at a stretch and are based on highly energy efficient platform leading to lower running costs for organizations.
 

OUR PTL MODULE

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CORE COMPONENTS OF A PTL SYSTEM

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LIGHT MODULES

Falcon’s Gen-2 Pick/Put to Light Modules offer sleek and ergonomic designs and constitute of a 3-digit alpha numeric display, four configurable functional buttons and one main command Push-Lit Button with LED.

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DUCT

Cavity based duct design to ensure a clean wiring system. This also attributes to the flexible light mount positions adapting to the need of dynamic bin sizes required to accommodate SKU variability with changing business needs.
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CONTROL BOXES

Main control panel of the system that executes the commands and acts as a communication bridge between the light units and the WCS.

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ControlIT: FALCON’S WCS SOFTWARE PACKAGE

Think tank where the logic of the system resides. It offers a plethora of features that can accommodate various business rules resulting in higher efficiencies and integrates with host systems such as WMS /ERP.

OPTIONAL COMPONENTS

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RACKS

Fully customisable; multiple rack designs available including pigeon holes, vertical bag holders, carton/tote holders, flow racks, etc.

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CONVEYORS

Can be integrated with conveyor systems for easy movement of orders/items from pick/put zones to other areas in the warehouse.

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HAND SCANNERS

Fully integrated wireless handheld barcode scanners used by the operators to scan each item with ease.

 
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PRINTERS

Provision of integrating various brands of label printers in each zone. Automatic trigger received by the printers upon completion of orders.

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PERIPHERAL DISPLAYS

Special zone display screens showing meta-data of the system. This screen can be used to display different types of information such as carton category, contents, special instructions associated with the scanned items, etc.

 

BENEFITS OF OUR PPTL SYSTEM

Process Deskilling

Simple and easy to learn SOPs of operation help in faster induction of new operators.

Higher Accuracy

Higher accuracy in order processing due to system guided Pick/Put operations.

Improved Productivity

Improved productivity as time to search for a Pick/Put location is eliminated.

Reduced Training

Intuitive and effortless operation of the system results in lower operator training costs.

USPs of our PPTL System

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Number of lights installed
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Sq. ft. lit
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Proven use cases

100% zone free architecture: users can define zones on the fly.

Slidable light modules in the duct: adapt to the changing bin sizes within minutes.

Four fully customisable command buttons to address custom process needs.

Dynamic mapping and unlimited plan configurations supported with click of a button.

PPTL APPLICATIONS

Everything you could ever need to complete your next project on time and within your budget.
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PACKET SORTATION FOR POSTAL / COURIER AND EXPRESS COMPANIES

An economical option to achieve high accuracy for sortation of individual parcels using custom business logics.
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MULTI-LINE ORDER CONSOLIDATION FOR E-COMMERCE COMPANIES

Simplifies the complex process of handling eaches. Enables batch-picking and light-guided order consolidation resulting in accurate order fulfilment.
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ORDER PICKING FOR FOOD, FMCG, PHARMACEUTICALS COMPANIES

Offers the flexibility of handling variable and high number of SKUs maintaining the desired turn around time using Falcon’s Pick to Light solution.
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STORE ORDER FULFILMENT FOR FASHION AND GROCERY RETAILERS

Achieve higher picking rates and order fulfilment accuracies by batch picking and consolidating store orders in multiple waves.
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SPARE PARTS DISTRIBUTION FOR AUTOMOBILE, CONSUMER ELECTRONICS, AND HEAVY MACHINERY COMPANIES

Timely and accurate consolidation of orders for Dealers, Distributors or stores using Falcon’s Put To Light Solution.
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KITTING FOR AUTOMOTIVE, CONSUMER ELECTRONICS, AND HEAVY MACHINERY
COMPANIES

Eliminate the hassle of indistinguishable child parts by the naked human eye and ensure feeding the accurate kits to the assembly line resulting in unaltered daily production plans.
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CLUSTER PICKING: MULTI ORDER PICK CART

Introducing Falcon’s Mobile Picking Carts offering benefits of batch picking using Falcon’s Wireless Put to Light Modules specially designed for eaches handling.
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SOFTWARE SUITE

Falcon’s Proprietary Software Suite to complement its Pick/Put To Light units serves as processing engine for Communication with the hardware nodes and data exchange with backend ERP/WMS systems. The suite is designed to support all common integration technologies ranging from Web Services, APIs, FTP, ODBC, XML Payloads, and many more.

 
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BUSINESS LOGIC DEFINITION

Define Custom rules to control which light glows when and displays what.

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PICK/PUT ZONE DEFINITION

Ability to resize and create new zones on the fly.

 
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USER PRODUCTIVITY ANALYSIS

Manage your workforce better by knowing the star performers based on productivity data.

 
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DATA INTEGRATION

Secure and easy to setup communication lines with host IT systems such as WMS and ERP.

 
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MIS AND REPORTING

Eagle’s eye view on your operations with custom reports right on your browser, mobile or tablet. Slice into data to the granularity you want.

 
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EVENT ALERTS

Define custom SMS/EMAIL alerts on specific events to minimize downtime and increase worker and resource utilization.

 

OTHER KEY FEATURES OF PPTL SOFTWARE

Supports multiple use cases – Pick to Light, Multi Order Pick to Light, Put to Light Wall, Sort to Light, Kitting and many more.

Supports various system inputs and outputs – scanners, sensors, manifest printers, and many more.

Ability to define custom business logics – cut off timings, quantity/weight and volume thresholds, etc.

Supports user – zone mapping to collect and analyze workforce productivity.

Supports dynamic light mapping.

Supports unlimited wave Configurations.

Resources

Open positions

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Our Locations

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Resources

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