Reducing Production Errors with a Pick-to-Light System

Wireless Q45 push button devices for part picking

Application: Error proofing on bins

Challenges: Cabled solutions do not work on mobile racks

Solution: Banner Engineering's Q45 Wireless Sensor

Benefits: Q45 Wireless Sensor does not require cables and has bright indication

A supplier of door panels to a global car manufacturer wanted to implement a pick-to-light system to reduce errors and the lost time that results from picking the wrong part during assembly.

The customer needed a solution that could be implemented on four mobile gravity flow racks with 48 bins on each rack.

Because the flow racks are mobile, a wired system was not feasible.


Wireless Q45 push button devices were installed on each bin. The PLC sends a signal via the Gateway that illuminates the green LED on the Q45 to indicate which part should be selected. Line workers select the part and push the button to confirm to the controller that the correct part has been selected.

When incorrect parts are selected, the red LED illuminates, immediately signaling to the line workers that the incorrect part was selected and they should look for the Q45 displaying the green light.

The customer bought 197 wireless Q45 Push Button devices and seven GatewayPro radios, resulting in a reduction in errors and an increase in productivity since installing the system.

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Q45 Wireless Sensors
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The Sure Cross® Q45 is the first self-contained wireless standard photoelectric solution for the most challenging control and monitoring needs. Easily add a scalable wireless sensor network to improve efficiency by monitoring and coordinating multiple machines and processes without pulling cables.

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