Traditional Pick-to-Light (PTL) systems have long been a cornerstone of efficient warehouse operations. It guides workers quickly to the right bin using visual cues. But, as fulfillment demands grow and accuracy becomes non-negotiable, guidance alone is no longer enough.
Today’s leading warehouse operators are evolving beyond PTL into intelligent picking systems where every interaction is tracked, validated, and optimized in real time.
By integrating BinSight™ with your existing PTL infrastructure, systems can move from passive instruction to active verification, creating a smarter, more reliable workflow from pick to fulfillment.
Here’s how a typical workflow operates:
1. Idle State
The LiDAR sensor continuously measures the baseline distance of the bin row on a rack, establishing a steady reference point. Each bin takes up an unique position in the row, thus can be addressed by their respective position within the row's total distance.
2. Pick Triggered
The PTL system illuminates the target bin, guiding the operator to the correct location.
3. User Interaction
As the operator reaches into a bin, the LiDAR detects a change in distance—capturing the interaction instantly. NO button pressing is required anymore.
4. Validation
The system verifies that the correct bin was accessed in real time, reducing reliance on manual confirmation.
5. Feedback Loop
All interaction data is recorded, enabling performance tracking, analytics, and ongoing optimization.
By combining PTL with 1D LiDAR, warehouses create a closed-loop system where every pick is measurable, trackable, verifiable in your AIoT systems.
Key Use Cases Across Warehouse Environments