Optimizing Multi-SKU Orders Using Pick-to-Light Labels

Many overseas e-commerce companies operate their own warehouses to gain better control over inventory, fulfillment speed, and customer experience. In the early stages, manual picking often works well enough. Orders are manageable, SKUs are limited, and pickers rely on paper lists or handheld devices to locate items.

However, as the business grows, this approach quickly shows its limits.

The Challenge: More SKUs, More Walking, Lower Efficiency

As product assortments expand, warehouses face several common challenges:

1.Rapid SKU growth increases storage complexity

2.Longer picking routes force workers to walk more between shelves

3.Higher error rates occur when pickers search for similar items

4.Training new staff takes longer, especially during peak seasons

In many self-operated e-commerce warehouses, pickers spend a large portion of their time simply finding locations rather than actually picking products. This not only slows down order fulfillment but also drives up labor costs.

Manual or paper-based picking methods struggle to scale with SKU growth.

Even when using handheld scanners or PDA systems, traditional picking still relies heavily on human interpretation:

Reading picking lists

Matching SKUs to shelf locations

Confirming items manually

As order volumes increase, these steps add friction to every pick. The result is longer fulfillment times, fatigue among workers, and inconsistent accuracy.

This is where visual guidance systems make a measurable difference.

The Solution: Pick-to-Light (PTL) Systems

Pick-to-Light systems introduce clear, visual instructions directly at the picking location.

Instead of searching for items, pickers are guided by illuminated indicators installed on shelves or bins. When an order is released:

• The correct location lights up
• The required quantity is clearly displayed or indicated
• The picker confirms the pick and moves on
• This eliminates guesswork and reduces decision time at every step.

Here’s how it works:

First,pickers batch-pick items by SKU instead of by order.

Second,the team scans each item and places it into the PTL sorting wall, where each shelf represents an order.

Third,the system shows exactly which shelf the item belongs to,once an order’s shelf has received all required items, the PTL light turns on.

Fourth,a staff member taps the light, and the system automatically prints the shipping label.

Last,the completed order gets boxed, labeled, and sent to the shipping station.

As global e-commerce continues to expand, warehouse efficiency becomes a competitive advantage. Self-operated warehouses can no longer rely on manual processes designed for smaller operations.

Pick-to-Light systems represent a practical, proven solution for companies facing SKU growth and rising fulfillment pressure. By reducing wasted motion and simplifying picking workflows, PTL helps warehouses keep pace with demand — without sacrificing accuracy or scalability.