The InSystems P2L Sensor for Pick-to-light Systems

P2LSensor für Pick-to-light Montagesysteme und beleglose KommisionierungInSystems has developed a new Pick-to-Light (P2L) sensor which offers great advantages to component supply architecture due to its shape and technology. Using the P2L sensor makes it possible to design material provision shelves in more ergonomic ways, with more even levels and shorter distances for workers to cross.

The reacting distance is teachable (adjustable according to needs) and can be adapted to circumstances such as container shapes and filling levels. The teaching process is automated.

There are two P2L sensors available: digital and with CAN bus. Both models can also be ordered as ESD-models. More details can be found under Details and in the FAQ.

Pick-to-Light / Pick-by-Light systems

What they are and what they do

Pick-to-Light and Pick-by-Light describes for a procedure which guides workers through assembly or consignment processes via light signals. The P2L sensor always shows which step is to be taken next and monitors how it is then carried out. Should a worker reach into the wrong container, he will be made aware of this and, depending on programming, the system will require appropriate actions to be taken such as corrections or ejecting a component for later refitting works.

Which advantages does a Pick-to-Light system offer?

For one, Pick-to-Light systems allow for significant reductions in the time needed for assembly processes. The pick-up order of materials is set by the flow of materials computer, which manages assembly recipes or translates ERP-system commissioning orders. This means that, especially when working on products with a particularly high level of variety, workers are enabled to concentrate fully on the assembly process without having to fuss over job time tickets, parts lists or assembly drawings.  The worker’s hands are kept free and necessary assembly directions are given on a display.

Another great advantage of Pick-to-Light systems is the level of process reliability they offer. Following the Poka Yoke principle, as many sources of error as possible are eliminated. Assembly components of very small sizes involved in many product variants are especially prone to complications, and a Pick-to-Light system can help to constantly monitor and document such delicate processes.


A Pick-to-Light system can help significantly to optimise manual assembly processes regarding cost and quality and are a valuable tool to remain competitive.