How RFID / Bluetooth Work in Pick-to-Light Systems
1. RFID (Radio Frequency Identification)
Working :
- RFID tags (passive or active) are attached to inventory items.
- RFID readers placed at key locations (like shelves or conveyors) detect these tags.
- When a picker approaches a location, the system verifies the item via RFID and activates the appropriate Pick-to-Light indicator
2. Bluetooth Beacons (BLE - Bluetooth Low Energy)
Working :
- BLE beacons emit signals at regular intervals.
- A smartphone or BLE reader detects the proximity of the picker or asset.
- When the picker is near the right location, the beacon communicates with the system to light up the appropriate pick location using PTL.
Integration with Pick-to-Light
| Component | Role in System Integration |
|---|---|
| RFID | Auto-identifies items and shelves for error-free picking |
| BLE Beacons | Detect picker proximity/location to trigger lights |
| PTL Lights | Visually guide the picker to the right item or shelf |
| WMS/ERP Software | Controls logic, inventory, and data sync across systems |
Use Case
Smart Warehouse Order Picking
Scenario :
- A warehouse uses RFID tags on bins and items.
- PTL lights on shelves are triggered based on the order.
- Pickers follow lights, and RFID confirms if the right item is picked.
- BLE beacons guide the picker through optimal paths in real-time.
Industry Applications
| Industry | Application Example |
|---|---|
| E-commerce / Retail | Fast order picking and returns handling |
| Automotive | Assembly line parts selection and tracking |
| Pharmaceuticals | Error-proof picking of medication batches |
| Electronics | Handling high-mix, low-volume inventory |
| Logistics / 3PL | Efficient warehouse management across multiple clients |
| FMCG / Consumer | Goods High-speed, error-free order fulfillment |
USP (Unique Selling Propositions)
- Contactless Operation: RFID and BLE eliminate the need for manual scanning.
- Accuracy Boost: Near 100% pick accuracy with automated item verification.
- Speed Optimization: PTL + RFID/BLE reduces pick time per item drastically.
- Real-Time Location Tracking: BLE enables picker tracking to prevent delays or errors.
- Scalable & Modular: Can be added in sections; works for small or large setups.
Key Benefits
| Benefit | Description |
|---|---|
| Speed | Reduces picking time by up to 40–60% |
| Accuracy | Minimizes picking errors with automatic tag verification |
| Reduced Labor Cost | Less training required; faster onboarding of new workers |
| Productivity | Enables higher throughput with the same number of workers |
| Data Visibility | Real-time inventory and operations tracking for better decision-making |
| Integration Friendly | Easily integrates with ERP/WMS like SAP, Oracle, Zoho, or custom software |
Blog
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