Quality Assurance at Multiproduct Assembly Workstations


Challenge: Streamlining Production on Assembly Bins

Minimizing errors in the assembly process is crucial for companies to improve productivity and eliminate waste. In a recent application, the manager of an automotive company wanted a way to streamline productivity in their assembly cells. Operators were frequently grabbing from the wrong bin location because there was no picking system. Due to low visibility, it was difficult for operators to tell where the correct parts were, hurting productivity and increasing production costs. The manager wanted to find a way to improve the training and picking processes as well as various product rework costs. Read more to learn how the Pick-to-Light Solution Kit improved pick sequences and ensured a high level of quality at multiproduct assembly workstations.

Solution: Improved Productivity with Pick-to-Light Solutions Kit

The manager invested in Pick-to-Light Solutions Kit along with PTL110 pick-to-light devices to solve their problematic pick process. Immediately, their company started seeing improved results.

The Pick-to-Light Solutions Kit is an integrated solution that consists of an enclosure, a DXM controller, a HMI, plus direct connections for PTL110 devices and power. The combined solution visually guided operators to pick the right parts, in the right quantities and in the right sequence. This reduced errors and defects and increased productivity by eliminating a common source of wasted time like checking and re-checking instructions. Having the entire Pick-to-Light solution made training new operators an easier and simpler process, ultimately saving the manager time and money.  

Key Benefits of the Pick-to-Light Solutions Kit

Reduce costs with simple mounting and installation

The Pick-to-Light Solutions Kit is an integrated solution that consists of an enclosure, a DXM controller, a HMI, plus direct connections for PTL110 devices and power. The integrated device and power decrease installation costs, improves picking sequences, and ensures flexible pick functionality. The combination of Pick-to-light devices and the Pick-to-Light Solutions kit help manufacturers reduce the risk of error in the assembly process, boosting product quality and reducing labor cost.

Fast, scalable solution to maximize productivity

The Pick-to-Light Solutions Kit is powered by PICK-IQ, a purpose-built serial bus protocol that maintains high speeds even in networks with high device count. Direct connection between the box and PICK-IQ devices provide the ideal solution for production lines and fulfillment stations that require many pick points while maintaining a rapid pace to exceed productivity targets.


The Pick-to-Light Solutions Kit is an ideal easy-to-add solution in industries that require highly visible indication, such as automotive and general assembly. In addition to having all the components necessary for time-saving installation, it improves safety, productivity, and quality in a wide variety of applications including:

  • Pick-to-light assembly
  • Order fulfillment
  • Put-to-light stocking
  • Kitting
  • Sequencing
Pick-to-Light Solutions Kit
Pick-to-Light Solutions Kit

Banner's new Pick-to-Light Solutions Kit for improved productivity in picking systems is an easy-to-use solution to reduce error during the assembly process.

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