Technology you can feel: how to improve picking with carts and light-guided systems

In every warehouse there comes a moment when the numbers stop adding up. Lines per hour stagnate, returns increase, and urgent orders disrupt the daily rhythm.

Sometimes the issue is blamed on staff or workload, but in reality the bottleneck is usually the method: too much walking, repetitive decisions, and confirmations that rely entirely on the operator’s attention.

The tools that truly improve picking are not the most complex ones, but those that address exactly this: walking less, thinking less, and confirming better. Multi-order picking carts and Pick-to-Light or Put-to-Light systems are two different—yet complementary—ways to achieve it.

Picking carts: efficiency on wheels

A well-designed cart can completely transform warehouse dynamics. It allows several orders to be grouped into a single route, reducing distance traveled and idle time between aisles.
Each compartment functions as an independent order, and with a simple tablet or hands-free scanner, the operator always knows which item belongs to which customer.

The result is not measured only in speed, but in stability. When routes are repeated less often, the flow becomes predictable and deliveries are met more consistently. In addition, visually separating orders minimizes transfer errors and mix-ups.
In environments with large catalogs, long routes, or demand peaks—such as seasonal campaigns or promotions—carts are an essential tool to maintain productivity without increasing headcount.

Pick-to-Light: precision without pauses

Light-guided picking takes the logic of picking to a new level of clarity. Each display shows the exact location where to act and the quantity to pick or place.
The operator does not need to search, read labels, or memorize locations: the system shows what to do, where, and how many times.

The impact is immediate. Errors caused by confusion between similar products disappear, work cadence accelerates, and training time for new staff is drastically reduced.

In sectors where speed and accuracy are critical—food, pharmaceuticals, cold storage, or e-commerce—a Pick-to-Light system turns every second into measurable performance. It is also especially useful in temperature-controlled environments, where reducing time spent in the zone means energy savings and better working conditions.

Two paths, one goal

Although both solutions act at different moments of the process, the goal is the same: improve efficiency without breaking what already works.
Picking carts optimize movement and order organization; Pick-to-Light perfects execution and confirmation. Combined, they turn picking into a continuous flow, without waiting or doubts, where every order is completed accurately and on time.

Companies that integrate both technologies often see KPIs change quickly: more lines per hour, fewer errors, better OTIF, and more consistent productivity across shifts.

Integrating without starting from scratch

Neither carts nor light-guided systems require replacing the WMS or rebuilding operations. They work as a lightweight layer that communicates with existing systems via tablets, scanners, or connected modules. This makes it possible to start a pilot in a single warehouse zone, measure results, and then scale with objective data.

Each project can be adapted to specific needs: from carts configured for small batches to networks of displays covering entire picking lines. What matters is that technology supports the process, not the other way around.

Electrotec: tailored precision, pace, and control

At Electrotec, we study each operation before recommending a solution. We analyze order volume, catalog type, layout structure, and current KPIs to define exactly where improvements will have the greatest impact. This may be a multi-order cart with scanner confirmation, a Pick-to-Light system adapted to critical zones, or a combination of both.

Our goal is not to add technology, but to turn it into visible results: greater accuracy, higher speed, and a warehouse that is once again fully under control.