Warehouse Picking Carts

Our smart picking carts are low-cost, high efficiency order fulfillment solutions, supporting batch or cluster picks of multiple orders simultaneously. Carts dramatically increase picking speed while improving worker efficiency and ergonomics by reducing the number of trips through the warehouse.

smart pick-to-light cart for warehouse fulfillment systems

Mobile, Wireless Pick-to-Light System

Pick-to-light cart systems are flexible, robust and easy-to-maintain. Easily integrated into your host system, you will quickly see improvements in throughput and cycle times.

pick-to-light devices on order fulfillment cart

Lights

Light devices on each cart indicate the required SKU’s storage location within the warehouse. The picker guides the cart to the first item location and scans its barcode, then route those picks to a single location to fulfill those orders. This prompts specific light modules on the cart to illuminate, displaying the number of units to be picked. Picked units are placed into their corresponding totes

Our interchangeable light devices feature “extended function” modes that present operators with more information while they’re traveling throughout the warehouse.

woman scanning SKU to put to lightning pick cart

Carts

Easy to learn and use, multi-shelf “smart carts” automate picking for fulfillment of multiple orders at the same time, following the shortest route through the warehouse.

The operator scans the product bar code which illuminates lights on the cart indicating the tote or shipping container to receive the product. (Optionally, product location labels or other additional quality control scans are available). Operators scan and sort products to the correct orders in the correct quantities.

man picks to an order fulfillment cart with pick-to-light

Integration

Lightning Pick software interfaces with the distribution center’s Warehouse Management System (WMS) and/or Warehouse Control System (WCS). It integrates with any WMS or WCS using almost any communication method: REST, sockets, etc., with JSON, XML or other.

Lightning Pick can send real-time pick and order information in a variety of methods to any WMS or WCS.

Software

Lightning Pick’s LP Dashboard offers manager-level insights into daily productivity across the facility or at individual picker levels.

The walk sequence is based on optimized fixed location sequencing or WMS specification within the orders.

Lightning Pick carts support multiple methods of order batching, from individual order/carton assignment on the cart itself, to WMS batching and request methods.

base of pick cart showing the battery systems and wifi controls

Connectivity & Power

Our carts are mobile solutions that support a variety of Wi-Fi connections with fast, reliable roaming. For scanners, Lightning Pick offers native support for fast, secure Bluetooth 5 mobile connectivity, or tethered USB scanners. Batteries and scanners can be changed quickly without downtime.

Hot-swappable, high-performance and lightweight Milwaukee™ M18 lithium batteries make for a trustworthy power system and easy maintenance (batteries can be procured at any hardware retailer).

carts are bespoke designed based on customer needs

Customization

Lightning Pick’s unique batch picking technology can be applied to virtually any type or style of picking cart, just one of many advantages of the Lightning Pick system.

Lightning Pick can support carton label printing at the cart or on wireless network printers. A printer add-on allows pickers to print order and manifesting documents, shipping labels and other required materials, making the cart an effective mobile pick/pack workstation.

Applications

  • Cluster or batch picking operations
  • E-commerce order fulfillment
  • Third party logistics DCs
  • Facilities with large SKU bases
  • Facilities without conveyor or AS/RS
  • Fulfillment operations without clear high-, medium- or low-velocity SKU profiles
icon-pickcart
woman using ergonomic warehouse picking smart cart

 

Why Choose Lightning Pick Smart Carts?

Enhanced Efficiency: Boost picking speed by 40%-200% and reduce travel time by up to 70%, transforming your throughput and cycle times.

Intuitive Technology: Wireless, mobile pick-to-light systems allow workers to pick to multiple totes on a single cart, streamlining complex workflows.

Cost-Effective Automation: Perfect for warehouses with large SKU counts, carts offer a scalable, economical alternative to traditional pick-to-light or Automated Storage and Retrieval Systems (AS/RS).

Future-Ready Design: Our carts are compatible with AGVs, AMRs, and conveyor-integrated sleds, ensuring your investment is prepared for tomorrow’s technology.

Customized for Your Needs: System design takes into account the unique product and order dimensions.

Safety: We prioritize safety and ergonomics, ensuring the carts are not only efficient, but also comfortable and safe for daily use.

VIDEO

Pick Carts Video

► See the LP Cart in Action

Get introduced to Lightning Pick’s patented Perpetual Picking system. This video shows how the software’s algorithms direct continuous batch picking of multiple orders through every pass of the warehouse.

CASE STUDIES

E-commerce Order Fulfillment

► 3PL: Capacity LLC Case Study

See how Lightning Pick’s picking carts and put walls seamlessly and flexibly integrate to boost e-commerce order fulfillment accuracy and throughput for a third-party logistic provider.

Vitamin and Supplement Picking

► Symbion Consumer Case Study

Symbion Consumer, an Australian vitamin supplement company boosted accuracy and performance – while cutting its labor requirements – by implementing a mobile picking cart system.

DATA SHEET

Data Sheet for Picking Carts

► Lightning Pick Carts

Simple, cost-effective and efficient, our mobile technology can be utilized on virtually any cart configuration. We’ll work with you to find the right cart for your application or develop a bespoke solution.

WHITE PAPER

Batch Picking

► Three Critical Features for Order Fulfillment Operations

Cart-based batch picking reduces travel time so more orders can be filled with lower pick errors or labor costs. This white paper will help identify if mobile picking carts are right for your operation.

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