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Improving Accuracy in Manual Assembly Starts with the Pick
Manual assembly operations demand precision, especially in high-mix environments where each job may involve dozens of unique components. When an assembler has to scan paper instructions, memorize pick orders, or guess at part bins, mistakes are guaranteed to happen.
That’s where pick-to-light systems come in. These visual guidance systems are designed to eliminate guesswork by lighting up the exact location of the next component to pick. Once the assembler makes the correct pick, the system detects the action and immediately guides them to the next bin.
Pick-to-light systems guide operators with illuminated cues to ensure fast, accurate part selection.
Photo credit: Banner Engineering
This intuitive, visual workflow helps:
- Eliminate errors caused by part misidentification
- Speed up cycle times by reducing hesitation or re-checking
- Reduce the cognitive load on operators
- Enable poka-yoke (mistake-proofing) by enforcing correct pick sequences
But while pick-to-light systems are helpful on their own, they become far more powerful when integrated with your manufacturing execution system (MES).
Filmed at Assembly Show South 2025, Steve Wishau, Head of Product, introduces how PICO integrates with pick-to-light systems for manual assembly.
What Are Pick-to-Light Systems?
Pick-to-light (PTL) systems use illuminated indicators (often mounted on bins or racks) to guide operators during multi-step assembly tasks. Each light corresponds to a specific part location, and lights are triggered sequentially to match the correct bill of materials or process step.
Some systems also include sensors or buttons to confirm that the pick has been completed before progressing. These systems can vary in complexity, from simple light towers to advanced multi-bin networks with confirmation sensors, but they all share a common goal: reduce errors and speed up part selection during manual assembly.
PICO integrates with over 200 different tools and devices, and our team handles all the hardware integrations for customers. Customers can use any pick-to-light system they prefer; for this blog, we will focus on the pick-to-light system by Banner Engineering. You can find this integration in PICO's device library.
Why Integrate Pick-to-Light with Your MES?
When a pick-to-light system is integrated with a manufacturing execution system (MES) like PICO, it stops being a standalone tool and becomes part of a complete poka-yoke strategy for your assembly line.
Advantages of integrating pick-to-light systems with an MES
- Process Control with Poka-Yoke
The MES ensures that lights activate only for the correct parts based on the job at hand and prevents the operator from moving forward until the right pick is confirmed. - Dynamic, Job-Specific Instructions
As orders change, the MES dynamically drives the pick-to-light system based on real-time work instructions. No need to reprogram devices between runs. - Real-Time Traceability
Each pick is logged automatically, giving you granular traceability into which parts were picked, by whom, and when. - Fewer Errors, Faster Training
New operators can confidently follow the lights and step-by-step work instructions without memorization or supervision. - Closed-Loop Quality Control
When paired with other devices like torque tools or barcode scanners, the MES creates a closed-loop system that ensures every pick, place, and fasten happens as intended.
Pick-to-light module illuminated for part selection.
Why PICO is the Ideal MES for Pick-to-Light Systems
PICO is a modern, modular MES built specifically for manual assembly lines. Unlike legacy systems, PICO is brand-agnostic and designed to plug-and-play with over 200 smart tools and devices—including pick-to-light systems.
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- Vendor Neutral: Whether you use Banner, Turck, or another vendor, PICO can integrate seamlessly with your pick-to-light hardware.
- Modular by Design: Use only the features you need—from work instructions to traceability to pick-to-light integration and scale up when you're ready.
- Fast Deployment: If Banner is your preferred pick-to-light hardware, integration with PICO is readily available and can be instantly deployed on your shop floor. If you choose to use another brand, our team handles all device integrations for customers, so you don't have to worry about IT or engineering resources.
- Built for high-mix, high-variation work: Manufacturers receive the greatest value from PICO in environments where every job is different and operators need clear, reliable guidance.
With PICO, your pick-to-light system becomes more than a visual aid; it becomes a fully traceable, error-proofed, real-time extension of your assembly process.
Looking to eliminate errors and accelerate throughput in your manual assembly line?
Book a demo to learn how PICO connects seamlessly with pick-to-light systems to bring poka-yoke to life on your factory floor.
