In the case pack and non-conveyable process, the picker is to look at the labels that are pre-printed, go to the proper location, and retrieve the carton from that location. The picker then places the label onto the carton and either places it onto the moving conveyor, or places it onto the pallet or trailer being moved through the module. The problem occurs when the label that the picker is carrying is placed onto a carton that does not contain the items listed on the label. There are two reasons for this, either the picker selected a container from the wrong location, or the replenishment driver placed a pallet of merchandise into the wrong slot. In either case, training and auditing needs to occur to ensure that what the customer ordered is actually being shipped. The radio frequency (RF) scanners only read the label, and as far as the system can tell, the correct item is inside of the carton that the label is placed onto.
Pick-to-light systems, also known as computer aided picking systems (CAPS) are found in the repack department. This is where less than case lots of merchandise are placed into repack containers. The picker swipes his card at the beginning of the module, and enters the information from the labels being carried. These labels will be placed on each container after it is filled, and will be used in sequential order.
A light turns on at the slot where the merchandise is to be 'picked' from. The quantity to be picked is identified by the number being shown on the LED panel next to the light. When the picker is finished picking that item, the picker presses the 'finished' button. The next light down the module lights up, and so on. If a carton becomes full, the picker pushes the 'carton full' button, telling the system that the label is being placed onto the full carton. The system is now able to identify what should be in this particular carton. This process continues until the picker reaches the other end of the module, or the LED says END.
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