Case Study: Implementing a Pack to Light Solution
in a Major Retail Distribution Center
by Greg Morneau

The team determined that the best approach would be to break up the phases in the following way:

Phase I:

• Support for 1012 store locations
• 140  10’ ducts each with 7 store lights, 4 8’ ducts each with 5 store lights and 4 5’ ducts, each with 3 store lights

Phase II:

• Support for 1,260 store locations
• 180 10’ ducts each with 7 store lights

Implementation Approach

First the implementation team needed a way to identify merchandise using information on the Lane Header.

Greg Morneau devised a system, and worked with host system developers to refine it, such that all potential merchandise profiles could be handled by combining allocation number, carton code, size or pre-pack code and lane number.  This Grab ID became the unique identifier for product for the PTL system and a barcode of the Grab ID was added to the lane header.  

The team also needed a method for attaching the light ducts to the existing shelving for Phase I. For Phase II the shelves would be replaced, so the method needed to be simple, inexpensive, and easy to replace. Hardware engineers from the Pack to Light vendor suggested using plastic zip lock ties for the initial phase. They also determined that several ducts would need to be cut in Phase I to handle interruptions in the existing shelving due to support columns. Figure 1 below shows the pack lane lights that were used.