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SOLVED Supply Chain Challenge?
Light the Way: Training Made Simple With LightSort ® Pick-and-Put Solution When a consolidator needed a fast, simple way to onboard warehouse workers, Engineering Innovation’s LightSort provided an intuitive solution that worked from day one.
training sessions, employees were onboarded during active shifts without disruption. The LightSort pick-and-put to light solution didn’t require a full system overhaul. It t naturally into their existing work ow and made smart use of limited— and valuable—warehouse space. Seamless WMS integration was made possible through our exible API.
THE LABOR PROBLEM NO ONE COULD IGNORE
A major parcel consolidator faced constant disruption due to an unstable labor pool. Daily no-shows, high turnover, and a revolving door of temporary workers created major inef ciencies on the sortation line. Throughput was inconsistent. Training took too long. Supervisors couldn’t keep up. Language and literacy
The solution was also built to scale. LightSort systems can be easily expanded by linking racks together into what we call “Cells.” Each Cell supports up to three operators working simultaneously, creating a modular and scalable structure that can grow, or shrink, with volume. Expanding the system into new zones took hours as opposed to weeks. Most importantly, it worked from day one. The team hit their targets with fewer people, even when shifts were short-staffed. They nally had a process that could ex with labor uctuations—a problem we see continuing as we head into the new year.
barriers made matters worse. Most workers spoke little English, and some couldn’t read numbers. That meant even basic tasks—like reading shipping labels— were error-prone. Training new hires took hours, only to yield spotty results. These challenges were frustrating and expensive. High error rates led to rework and delays. Labor budgets ballooned as the team overcompensated with additional staf ng. Even then, meeting outbound shipment deadlines was hit- or-miss. The operational model wasn’t sustainable, especially heading into peak season. While the team overstaffed shifts, hoping to offset unpredictability, it just drove up labor costs and still didn’t guarantee performance. They needed a faster, simpler way to onboard workers, and a system that anyone could use con dently, regardless of experience or skill level.
THE FASTER WAY TO TRAIN? MAKE ONBOARDING EFFORTLESS. We installed the LightSort Gaylord Rack, our light-guided sortation solution, at their key facilities. The concept is simple: workers wear a wireless ring scanner. They scan a parcel, and LightSort illuminates exactly where it should go. No label reading. No codes. No hesitation. Anyone could walk in, pick up a scanner, and be productive in minutes. Training time dropped from hours to minutes. As accuracy improved and mis- sorts decreased, supervisors were nally freed up to focus on optimizing ow instead of correcting errors. The system was so intuitive, even workers with zero warehouse experience could grasp it instantly. “Like teaching someone to follow a ashlight—that simple” is how one user described it. Instead of lengthy
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24 Inbound Logistics • November 2025
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