BUILD YOUR PICK TO LIGHT BUSINESS CASE
Pick-to-Light ROI Calculator
Calculate Savings, Payback Period & Productivity Gains
Explore the value of light-guided picking in your warehouse, stores or assembly workflow. Compare operating costs and estimated annual savings using your team’s inputs, then review the investment payback.
HOW THE ESTIMATE CONNECTS
Guided locationsModules & tasks
Operating inputsLabour & accuracy
Annual savingsScenario comparison
Payback estimateModule-based investmentYour inputs shape the estimate. Validate the assumptions with your team.
FROM OPERATION TO BUSINESS VALUE
See the opportunity.
Understand the assumptions.
Productive operator time.
Estimate the labour value associated with the improvement percentage you select.
Picking accuracy.
Evaluate the operating value of improved accuracy against your current picking activity and cost baseline.
A clear investment view.
Review module-based system cost, annual operating-cost comparison and estimated payback in months.
YOUR INPUTS. YOUR ESTIMATE.
Calculate your
Pick To Light payback.
Use a representative operating period. Select the region, enter your picking scope and review each assumption before calculating.
Pick-to-Light ROI Calculator
Estimate annual savings and payback period using indicative industry assumptions and your operational data.
The default values used in this calculator are based on industry-typical ranges observed across multiple Pick-to-Light and guided picking deployments globally. These values are intended to provide a reasonable starting point for evaluation.
Typical industry observations:
• Guided picking systems commonly deliver 25–40% productivity improvement by reducing search time and operator decision effort.
• Error reduction of 80–99% is frequently observed due to visual guidance and confirmation at the pick location.
• Manual picking environments often operate with 0.5–2% error rates, depending on SKU mix and order complexity.
Industry background reading:
• Interlake Mecalux – Pick-to-Light overview: https://www.interlakemecalux.com/blog/pick-to-light
• Honeywell – Guided picking solutions: https://sps.honeywell.com/us/en/products/productivity/voice
• DHL Logistics Trend Radar: https://www.dhl.com/global-en/home/insights-and-innovation/thought-leadership/trend-reports/logistics-trend-radar.html
Note: Actual results depend on process design, SKU characteristics, operator skill levels, and warehouse layout. Users are encouraged to modify inputs to reflect their real operational conditions.
THE GUIDED WORKFLOW
Visible instructions.
A measurable operating change.
Pick To Light presents the next instruction at the assigned location. The application supplies task context and records the operator’s acknowledgement. Evaluate the time spent locating, interpreting and completing each task using a representative process comparison.
A PRACTICAL INPUT GUIDE
Build the estimate
from your operating baseline.
Operating scope.
Enter the operator count, average monthly salary, daily pick lines and working days per year. The supplied calculator uses those inputs to form its annual labour and picking-accuracy cost baselines.
Enter the picking error rate and cost per event from your own records. Review productivity improvement and error-reduction assumptions against a pilot or measured process comparison.
Commercial context.
Choose India, USA or Europe for the calculator’s regional currency and starting values. These defaults remain adjustable through the calculator or its administrator settings as applicable.
The current plugin calculates system cost from the entered module count and configured module price. Include any separately quoted integration, commissioning or other project costs in your detailed investment review.
HOW TO READ THE RESULT
Annual savings.
Estimated payback. Clearly separated.
Annual operating comparison.
The calculator displays labour cost, accuracy-related cost and total annual cost for the manual and guided scenarios. Estimated annual savings are the difference between those two modeled totals.
Payback in months.
The plugin divides its module-based system cost by estimated annual savings and multiplies by twelve. A useful payback estimate requires positive savings and a representative baseline.
From estimate to decision.
Productivity value can mean capacity for more work, time reassigned to other activity or an agreed staffing benefit. Confirm how that value is realized in your operation.
Use the calculator’s report action to print or save the result for team discussion. Keep the input baseline and commercial scope alongside the report.
APPLICATIONS TO EXPLORE
Find the workflow
behind the business case.
Warehouse order picking
Location instructions and acknowledged order-line progress.
Assembly and kitting
Component guidance, task sequence and defined completion rules.
Line-side material supply
Point-of-use stock and the next replenishment response.
REFERENCE INPUTS AND VALIDATION
Start with an estimate.
Validate it in your operation.
The supplied plugin includes reference improvement inputs and background reading. Treat them as a starting point for scenario evaluation. Confirm task complexity, picking layout, operator activity and integration scope through your own measurements.
The result is an indicative business-case estimate. Review inputs with your operations and finance teams before approving an investment.
COMMON CALCULATOR QUESTIONS
A clear estimate.
A confident next conversation.
Is there a charge to use this calculator?
The public tool can be used without a calculator fee.
What determines the number of modules?
Enter the intended guided locations for this estimate. Confirm device placement and workflow coverage in the application design.
Does it cover both warehouse and assembly work?
Yes. Use the baseline for the selected picking or assembly activity, and keep distinct activities separate when preparing the detailed business case.
Are the estimated savings assured?
They depend on the entered baseline and improvement assumptions. A representative pilot can establish the results your team should use.
Can I change the currency and cost assumptions?
The supplied calculator has India, USA and Europe region settings. Its administrator can configure exchange-rate and module-price defaults.
Is continuous public internet needed for the application?
On-premise and cloud arrangements are available. The network requirements follow the selected deployment and integration architecture.
YOUR APPLICATION. YOUR INVESTMENT CASE.
Turn the estimate into
a practical Pick To Light plan.
Share your picking locations, task volumes and operating baseline. We’ll map the relevant configuration and a representative pilot.