Is the light itself the error-proofing?

No, and this is the common misconception. A light is guidance. The error-proofing is the interlock: the station will not advance until a sensor confirms the correct bin was actually reached. Without confirmation you have a faster way to make the same mistakes.

How is this different from scan-to-verify?

Scan-to-verify confirms after the fact and depends on the operator scanning what they actually took. A sensor-confirmed light system verifies the reach itself, so a substitution cannot be recorded as correct.

How quickly do operators reach full productivity?

Usually within a shift or two, because the system directs the sequence rather than requiring it to be memorised. The larger gain is on variant-heavy lines, where the cost of learning a new kit configuration drops to near zero.

Can it drive from ERP work orders?

Yes. Kits are built from the released work order, so a BOM revision reaches the line without anyone re-teaching a station. Integration follows the same ISA-95 boundary used by MileSoft ERP.

What happens when an operator deviates?

The station holds and records the deviation with its reason rather than silently allowing it. That record is what turns a recurring interlock trip into a fixable process problem instead of an operator complaint.

Manufacturing Pokayoke

Pick-to-Light Software for Faster, Error-Free Picking

Light-directed picking system that guides operators to the exact location and quantity. Eliminates picking errors and dramatically increases throughput.

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Features

Key Features

Built-in capabilities that set our software apart

Light-Directed Picking

Only the correct bin illuminates for the active kit, with quantity shown at the pick face

Bin Interlocks

Adjacent bins stay locked until the right pick is confirmed, so a wrong pick is prevented rather than flagged

Sensor-Confirmed Picks

Confirmation comes from a bin sensor, not a button press, so the record reflects what was taken

Full Pick Logging

Every pick captured with operator, bin, kit, and timestamp for audit playback

Work-Order Integration

Kits resolve from ERP and MES work orders, so the operator never selects the variant

Multi-Variant Handling

Close-cousin variants are distinguished by the system rather than by operator memory

Benefits

Key Benefits

What your team gains from adopting our platform

Removes 90%+ of wrong-part picks by making the wrong pick physically impossible

Cuts operator ramp-up from 4-6 weeks to 3-5 days by removing variant memorisation

Speeds up picking operations without adding a verification step

Produces a complete, audit-ready record of every pick

Scales across kitting bays without retraining on each new variant

Why Us

Why Choose Our Systems

Built for Picking Excellence

Purpose-built for pick-to-light systems, covering every step from configuration to operation.

One Platform, Complete Control

Integrates configuration, monitoring, and reporting into one unified system.

Speed Up Picking

Light-directed workflows and real-time dashboards boost throughput and reduce errors.

Trusted by Industry Leaders

Trusted by top manufacturers and warehouses to optimize their picking operations.

Testimonials

What Our Clients Say

Trusted by industry leaders across manufacturing, HVAC, and logistics.

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"The software features, such as real-time monitoring and alerts, have proved invaluable in optimizing machine operations. MileSoft team's professionalism, technical expertise, and dedication to meeting our requirements have been impressive."

PAM Systems Pvt. Ltd.Industrial Systems Integrator

"Our “Part-Process Matrix” as a concept and Software received 1st runner-up award in MVML Innovation fair 2014. As a customer we appreciate your support and efforts to deliver it on time and most importantly as per customer requirement."

Mahindra Vehicle Manufacturers Ltd.Automotive Manufacturing

"MileSoft's product excellence and implementation are top-tier, consistently exceeding expectations. We value their dedication to solving challenges and delivering long-term solutions. After-sales support is exceptionally reliable."

CU Air Conditioning Industries LLCHVAC Manufacturer, Dubai

"MileSoft has been an integral part of Rheem's journey for the past two decades as a trusted solution provider. Support is consistently prompt, reliable, and proactive."

Rheem ManufacturingClimate Solutions

"The software features, such as real-time monitoring and alerts, have proved invaluable in optimizing machine operations. MileSoft team's professionalism, technical expertise, and dedication to meeting our requirements have been impressive."

PAM Systems Pvt. Ltd.Industrial Systems Integrator