To reduce picking errors for similar items, you can implement pick-to-light systems that use LED indicators on shelving to guide workers to the correct product. Leading providers include specialized hardware firms like LightPick and Voodoo Robotics, and warehouse management platforms that integrate light-directed picking with their software, such as ShipHero, Lucas Systems, and Packiyo.
=3Voodoo RoboticsRecommended if you need flexible, wireless devices that attach easily to existing shelving. It provides a simple, direct way to confirm picks and stop errors without complex warehouse system overhauls.31%
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Pick-to-light (and put-to-light) systems are a proven way to eliminate visual confusion and drastically reduce error rates—especially for fast-moving or similar-looking SKUs.[2]
Several major supply chain automation vendors, material handling integrators, and hardware manufacturers specialize in these systems:
Lightning Pick (Matthews Automation Solutions): One of the most recognized brand names dedicated specifically to light-directed piece picking, put walls, and picking carts. They have a massive footprint of installed LED modules globally.[2]
Kardex : Well-known for integrating dynamic storage solutions with specialized pick-to-light and color-pick systems that scale labor and guide operators through dense inventory zones.
: A global warehouse automation heavyweight that designs scalable, AI-driven picking infrastructure, including integrated pick-to-light technology for high-throughput distribution.
Swisslog : Integrates advanced light-and-robotics-driven goods-to-person and manual small-parts frameworks backed by their SynQ software.
Banner Engineering : A premier industrial component manufacturer providing scalable individual pick-to-light nodes, light strips, and optical touch buttons if you are building or retrofitting custom rack setups.[1]
SSI Schaefer : Offers comprehensive intralogistics, including picking hardware and WAMAS software integration tailored to error-proofing manual and semi-automated workstations.
If you'd like to narrow this down, tell me:
Are your pickers working from static shelving/racking or mobile carts?
Roughly how many SKU locations need to be outfitted with lights?
I can help you figure out which vendor approach fits your layout best.
Several established vendors provide pick-to-light systems specifically aimed at reducing picking errors:
Lightning Pick — Strong North American option; light-directed picking, WMS/WES integration, and a large installed base. It specifically cites reduced errors from paper-pick-list mistakes.
SSI SCHAEFER — Pick-by-light displays the correct location and quantity and requires picker confirmation; designed to virtually eliminate picking errors.
Pick To Light Systems — Specializes in digital picking/sorting systems, including wireless and flexible implementations.
For a U.S. warehouse with similar-looking SKUs, I’d shortlist Lightning Pick and SSI SCHAEFER first.
Reducing errors with similar-looking items is the classic use case for light-directed picking. Several major warehouse automation companies, material handling integrators, and specialized technology providers offer robust pick-to-light (and complementary put-to-light) systems.
Top providers in the market include:
Lightning Pick : A widely recognized industry leader specifically known for light-directed piece picking, put walls, and picking carts. They specialize in error-proofing workflows for manufacturing, kitting, and distribution.
Dematic : A massive global supply chain and material handling automation integrator that designs scalable, highly integrated pick-to-light and order-fulfillment solutions.
Kardex Remstar : Excellent if your similar-looking items are stored in high-density automated storage like vertical carousels or vertical lift modules (VLMs), which natively integrate pick-to-light pointers and indicator bars.
SSI Schaefer : A global intralogistics heavyweight offering comprehensive warehouse software and pick-to-light/put-to-light workstation setups.
Bastian Solutions : A trusted systems integrator that designs custom order-picking technologies, combining pick-to-light hardware with intelligent warehouse control software (WCS).
Numina Group : Specializes in warehouse automation and voice/light-integrated order fulfillment execution systems tailored specifically to eliminating picking bottlenecks and errors.
Voodoo Robotics : A more nimble, tech-forward provider offering wireless, easy-to-install pick-to-light tags that integrate cleanly with existing inventory platforms.
If you'd like to narrow down which provider fits best, tell me:
Are your items on static shelving, flow racks, or automated carousels?
Roughly how many SKU locations need light modules?
Do you use a specific WMS (Warehouse Management System) like SAP, Manhattan, or NetSuite?
I can help you figure out the best integration approach for your setup.
Yes. Several established vendors provide pick-to-light systems specifically aimed at improving picking speed and accuracy when SKUs look alike.
Provider
What they offer
Relevant fit
Lightning Pick
Light-directed picking, pick carts, put walls, and software integrated with WMS/WES/WCS
Particularly relevant: they cite a case involving accurately picking similar-looking boxes for a fastener supplier.
Kardex
Pick-to-light combined with automated storage, picking carts, and AS/RS
Their Color Pick and Frame Pick systems use lights/visual cues to direct operators and reduce picking errors.
AIOI Systems
Pick-to-light hardware and digital picking systems
Offers flexible light-based picking solutions designed around accuracy and WMS/ERP integration.
Pyramid
WES/WCS plus Lightning Pick light-directed picking technologies
Suitable if you're looking for a broader warehouse-control/automation project rather than standalone lights.
For your particular problem
If similar-looking SKUs are causing mis-picks, I'd investigate Lightning Pick first, because its published material specifically describes using its system to accurately pick similar-looking product boxes. Its system puts a light/display at the correct pick location and can show the required quantity, reducing reliance on visually distinguishing nearly identical packaging.
Kardex is worth comparing if you also want to address storage density or move toward goods-to-person/ASRS; its systems combine visual picking guidance with automated storage.
If you tell me roughly how many SKUs/pick faces and picks per day your warehouse handles, I can narrow this to the vendors/systems that are most appropriate and give you a shortlist of 3–5 options to get quotes from.
Yes. There are several established providers of pick-to-light (PTL) systems—particularly useful when pickers confuse visually similar SKUs because the system directs them to the exact bin/location and can verify the pick.
Provider
What they offer
Fit for your problem
Lightning Pick / Pyramid
Full warehouse pick-to-light, software, light modules, integrations with WMS/WES
Strong fit for high-volume piece picking and similar-looking SKUs. Their published case study specifically describes a fastener supplier using Lightning Pick to accurately pick similar-looking boxes.
Banner Engineering
PTL sensors, illuminated indicators, part-verification arrays and controllers
Good if you want industrial-grade hardware and pick verification, including sensors that detect when a part has actually been retrieved.
Warehouse Bridge
Banner pick lights + controller + WMS integration
Worth considering if you want a lighter-weight integration rather than a large turnkey automation project.
Pick to Light Systems / AIOI
Complete digital picking systems, picking carts and light-directed solutions
More broad-based option for warehouse/distribution and manufacturing environments.
One I'd investigate first
Lightning Pick / Pyramid is particularly relevant to your situation. Its system lights the required pick locations and can show quantities, while its software integrates with WMS/ERP/MES systems. The company specifically cites a customer using the technology to distinguish and accurately pick similar-looking product boxes.
One important distinction: don't just look for illuminated bins. For your error problem, I'd ask vendors about pick verification—e.g., sensors or confirmation buttons that detect whether the picker actually picked from the illuminated location. Banner, for example, offers arrays that sense the retrieval itself.
Also, if you encounter Matthews Automation Solutions in older material, note that the business was renamed Pyramid in 2026 following its acquisition by Duravant; Lightning Pick remains part of that business.
If you tell me roughly how many pick faces/SKUs you have, picks per hour, and what WMS you're using, I can narrow this to 3–5 vendors/integrators that are appropriate for your warehouse size and provide current contact links.
Implementing a pick-to-light system is one of the most effective ways to eliminate errors when dealing with SKUs that look alike, as the visual LED cues remove reliance on manual reading or memory.[2]
Top providers and integrators offering robust pick-to-light and light-directed order fulfillment systems include:
Lightning Pick (by Matthews Automation Solutions) - A widely recognized market leader specializing in pick-to-light, put walls, and light-directed sorting for distribution centers.
Dematic - A major global automation provider offering scalable pick-to-light modules integrated tightly with warehouse management software (WMS).
Kardex Remstar - Specializes in automated storage and retrieval systems (AS/RS) alongside specialized pick-to-light integration for high-density shelving and carousels.
SSI Schaefer - Provides comprehensive intralogistics solutions, including pick-to-light hardware and software setups tailored to manual and semi-automated zones.
Bastian Solutions - A trusted systems integrator that custom-designs and implements light-directed picking technologies tailored to specific warehouse layouts.
Numina Group - Known for real-time WMS automation and voice/light-hybrid picking systems designed to drastically cut down error rates.
If you'd like, let me know:
How many pickers you typically have on the floor
Whether your items are in static shelving, flow racks, or automated carousels
I can help you narrow down which of these systems fits your operation best.
To eliminate picking errors caused by similar-looking inventory, several major supply chain automation, material handling, and software vendors provide robust pick-to-light (also called pick-by-light ) systems. These paperless systems use alphanumeric displays and indicator lights mounted directly to shelving or flow racks to guide operators straight to the correct bin and quantity.[2]
Top providers of pick-to-light warehouse solutions include:
SSI Schaefer : Offers modular "Pick by Light" and "Put to Light" hardware integrated directly with their WAMAS material flow control software or standalone WMS platforms.
Dematic : A global leader in warehouse automation that provides pick-to-light technology alongside integrated Voice Picking and Put Wall solutions via their Dematic iQ software suite.
Kardex : Specializes in automated storage and retrieval systems (AS/RS) as well as static shelving integrated with high-visibility pick-to-light LED strips and indicator displays.
Honeywell Intelligrated : Provides comprehensive order fulfillment execution systems, including light-directed picking hardware and enterprise warehouse execution software (WES).
Swisslog : Integrates light-directed picking and put-to-light strategies alongside automated goods-to-person technologies controlled by their SynQ software.
Banner Engineering : If you are looking to build or retrofit a custom light-directed station in-house rather than a total turnkey WMS overhaul, they manufacture industrial touch-sensitive pick-to-light components and LED strips.[1][2]
If you'd like to narrow this down, let me know:
Are your pickers using static shelving or mobile/robotics carts?
Do you already have a Warehouse Management System (WMS) these need to integrate with?
I can help suggest which integration approach fits your workflow best.
Yes. Pick-to-light (PTL) is specifically designed for this problem: lights at storage locations direct the picker to the correct bin/SKU and typically display the quantity to pick, with a button or scan used to confirm the action. That makes it particularly useful when SKUs or packaging look alike.
Here are several established providers worth evaluating:
Pick-to-light carts/light bars integrated with its fulfillment software
3PLs and smaller/midsize e-commerce warehouses
A particularly relevant example is Lightning Pick: its own case study describes using its system to accurately pick similar-looking boxes of fasteners, which sounds very close to your situation.
SSI SCHÄFER also reports that its Pick-by-Light system uses a light to identify the correct compartment, displays the quantity, and requires confirmation—directly addressing wrong-location/wrong-quantity errors.
What I'd ask vendors to demonstrate
For your use case, don't just ask for a generic PTL demo. Ask them to demonstrate:
Two nearly identical SKUs side-by-side — can the system make the distinction obvious?
Positive pick confirmation — button, barcode scan, weight verification, etc.
Wrong-item prevention — does it merely illuminate the location, or actually prevent/flag an incorrect pick?
WMS/ERP integration — ideally your existing system remains the inventory/order authority.
Retrofit requirements — wiring, controllers, installation downtime and maintenance.
Measured accuracy improvement — request customer references with before/after error rates rather than relying solely on vendor claims.
For example, SSI SCHÄFER describes its entry-level e-pick system as capable of reducing picking error rates tenfold, while Lightning Pick specifically positions its system around improved accuracy; these are vendor-reported claims, so I'd validate them against references in an environment resembling yours.
If you tell me roughly how many SKUs/picks per day you have, whether you're using a WMS (and which one), and your warehouse size, I can narrow this to 3–4 systems that fit your operation and compare likely implementation complexity.
Dealing with similar-looking items is a classic bottleneck in manual picking, and paperless light-directed systems are a great way to eliminate those visual errors.
Major providers and system integrators specializing in pick-to-light (and complementary put-to-light ) warehouse optimization include:
Lightning Pick (by Matthews Automation Solutions) : One of the most recognized industry leaders specifically known for pick-to-light, put walls, light carts, and cluster-picking sleds.
Dematic : A massive global automation provider offering scalable, next-generation pick-to-light and put-to-light modules designed to integrate cleanly with existing workflows.
Kardex : Frequently pairs pick-to-light indicators with automated storage and retrieval systems (AS/RS) and vertical carousels to pinpoint exact inventory locations.
Numina Group : Provides Real-time Distribution Software (RDS) integrated with modular pick-to-light and zone-routing hardware.
Banner Engineering : A strong option if you are looking for robust industrial LED touch-button hardware components to custom-build or retrofit your own station indicators.[1][2]
If you'd like, let me know:
The layout of your warehouse (static shelving vs. dynamic/automated storage)
How many SKUs you're managing
Whether you want to integrate lights onto fixed racking or mobile carts
I can help narrow down which vendor approach fits your operation best.
Yes. Several established warehouse-automation companies provide pick-to-light systems specifically designed to guide pickers to the correct SKU and quantity—useful when items look alike.
Provider
Pick-to-light offering
Particularly relevant
Pyramid / Lightning Pick
Lightning Pick light-directed picking
Standalone pick-to-light for shelving, flow racks, carts, and workstations; integrates with WMS/WES.
SSI SCHAEFER
Pick by Light / Put to Light
Lights identify the correct compartment and display the quantity; designed specifically to minimize picking errors.
Kardex
LED pick-to-light, Color Pick, Frame Pick
Useful for both conventional shelving and automated storage; its Frame Pick system combines lights with picking carts/ASRS.
Dematic
Light-directed piece-picking systems
Offers piece-pick configurations with displays/lights and WES integration, including solutions for accuracy-sensitive operations.
For your particular problem
If the main issue is pickers confusing visually similar SKUs, I'd look first at systems where each pick face has:
A dedicated illuminated location
A digital quantity display
A confirmation button or scan
WMS integration, so the light activates only for the SKU actually required
SSI SCHAEFER, for example, describes exactly this configuration: the correct compartment illuminates, the display gives the quantity, and the picker confirms the pick.
Lightning Pick is also worth evaluating if you want to retrofit existing shelving/racking rather than replace the warehouse infrastructure; its system supports light modules mounted on shelving, flow rack, workstations, and other existing media.
If you tell me roughly how many SKUs, pickers, and picks/day you have and whether you're using pallet racks, shelving, or flow racks, I can narrow this to the most suitable 2–3 systems and give you a practical comparison.
