Pick-to-Light reduces production operator picking errors.

Pick-to- Light is Mitsubishi Electric’s guided operator system for reducing picking errors by manual operators. It is designed to be deployed across many industry areas that include; automotive, logistics, semiconductor and life science sectors. It significantly reduces the risk of quality issues occurring in manufacturing processes.

Mitsubishi‘s guided operator system has have been developed from the lean manufacturing principle of Poka Yoke, a Japanese term that translates as ‘mistake prevention’. Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to human errors as they occur.

Speedy implementation

The design of the system is relatively straightforward. Terminals are installed at the operator’s work station and connected via a dedicated cable that avoids the need to run multiple cables back to the main controller. Terminals are setup with an address writer, and using dedicated software they can be directly mapped to the controller. This allows the applications to be easily configured, programmed and maintained.

Flexible

The wide range of terminals available makes a Pick-to-Light solution suitable for almost any application. For example, photoelectric sensors provide options for applications where high picking speed is a necessity. Alternatively, for more cost sensitive applications an array of push button and lever type feedback actuators can be provided.

Terminals with opening/closing doors provide a physical barrier to selecting the wrong part, a highly effective method to eliminate mistakes. Additionally, some devices are fitted with a display to identify how many pieces should be picked from any bin, again increasing operator effectiveness.

Adaptable

At the heart of the guided operator are the Mitsubishi Electric controllers, with dedicated masters communicating with the network of terminals. Depending on the complexity of the application, simple control can be provided FX series PLCs or for more advanced applications the L series or Q series PLCs can be configured.

Through connecting other devices to the controller such as bar code scanners, electric screwdrivers or vision systems, guided operator stations can be tuned to the exact needs of the operator. Further enhancements can be achieved through the selection of Mitsubishi Electric GOT Series HMIs to display work instructions or alternatively drive and robotic technology can be integrated into the manufacturing cell.

Integrated

Often assembly tasks must fit into the wider operational environment of the plant. This is essential to avoid the issues of over and under production. It is also important to consider the resource planning for parts used in the picking operations.

To connect multiple picking applications within the plant, dedicated bridges connect stations over CC-Link and CC-Link IE networks. High speed data communication enables synchronisation of tasks, but also allows assembly cells to be distributed to the needs of the production site. Direct integration of MES technology permits the guided operator station to be connected to high level organisational systems.

Typical applications

Originally deployed by the automotive sector pick-to-light systems have found a wider audience across many other industry areas that require fast and accurate picking, parts replenishment, production cells and kitting. Many terminal types are available, from simple LED and pushbutton devices through door operated terminals.  Options for lever switch and photoelectric terminals are also available.

See online case study of pick to light here

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