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

Elimination of Paper Pick Tickets

Eliminating the need for paper pick tickets was a critical step in streamlining the DC process. The implementation team introduced the use of Blue Tooth scanners (see figure 2 below) to scan the Lane Header label Grab ID barcode. This first stage of the process identifies the order in the PTL system and illuminates the lights at the locations where stores have a demand for the merchandise. It also displays the required quantity on the LED display.

The user then packs the required quantity to the Store carton and presses the light to confirm the pick. When a carton is filled, the user pushes the carton out onto the conveyor system.

Figure 2: Blue Tooth Scanner.

The user opens a new carton by scanning the location barcode and the new carton label. This single action not only opens the new carton, but also closes the previous carton. The previous carton information is automatically sent to the host.

Technology Implementation

Zebra printers were selected to replace the existing dot matrix printers.  Zebra specializes in printers for barcode printing and enjoys a strong reputation in the industry for reliable printer technology. The lane header labels were redesigned to print as a 4” wide by 6” high label on the Zebra printer with the Grab ID barcode. Store Carton Labels were redesigned to print as a 4” wide by 2” high label on the Zebra printer. This provided highly readable lane headers and accurate carton labels that fit any carton.