Bar Code Assisted Picking and Replenishment

Concepts and Options

Copyright I/O International, 2004

Preliminary specifications are for your information only and subject to change

I/O BCAPR

• RF hand held devices used to record picking of orders, reducing need for paper

• A single pass through the W/H may be for a single order or a batch of multiple orders

• Orders ready for picking may be assigned to a picker

• A single order (or a batch) may be broken down and assigned to multiple simultaneous pickers

I/O BCAPR

• New function places orders ready for picking into “Pick queue”

• Items allocated to respective bins when added to pick queue

• RF device used to pull up next order to pick (comes from pick queue)

• If no orders presently assigned to picker, next unassigned order ready to pick is dynamically assigned to requesting picker

I/O BCAPR

• RF device guides picker for what to pick, how many to pick, and from which bin

• Picker verifies pick by scanning item number, bin number and entering quantity (if necessary)

• During scan, item is removed from bin location quantity and allocated as picked stock

I/O BCAPR

• System recognizes when order picking is complete

• Upon order completion– Order is re-priced– Order step is advanced– Order is removed from pick queue

• Orders picked as a batch are staged in shipping area– Picked items broken down by order– Picking / packing lists may be printed to assist staging

• Orders packaged for shipping if necessary

Use bar code and RF technology with

to improve picking, replenishment and warehouse

efficiency and accuracy

I/O Bar Code Assisted Picking and Replenishment

Initiate Picking

New option places items to be picked on

pick queue

DMAS Work with Orders

• Take option to prepare order for picking

Order

Pick QueueMove to Pick

Queue

Scan

RF Picking

. . . and begins picking items as

directed on RF device

Order is assigned to picker (or picker

requests an order that is ready on RF

device) Pick Queue

Bin location

Item number

Scan

Assign to picker

Keys quantity if necessary

Staging Area

Picked items are then dropped off at

staging area and picking / packing lists

may be printed

Pick QueuePick Queue is

updated

Broken down to individual orders (if

necessary)

System recognizes when picking is completed and

updates pick queue

Packing List

Packing List

Allocate to bin

RF Replenishment

Replaces DMAS Replenishment

Report

DMAS order entry creates an entry in the replenishment queue when bins need replenishment

Order Entry

Repl QueuePut request in

Repl Queue

If bin below Minimum

Scan

RF Replenishment

. . . and begins replenishing items as directed on RF device

Replenishment request is assigned to RF user (or RF user requests next repl transaction that is waiting on RF device)

Repl Queue

FromBin location

Item number

Scan

Assign to picker Keys quantity

if necessaryToBin location

Item number

Immediately removed from contributing bin record . . .

. . . and added to receiving bin record

Item is in RF user’s put-away cart during transit to receiving bin

Management Tools

Work With Pick Queue• View orders available for

picking

• Approve order for picking (if tailored for this function)

• Aggregate orders into picking batch (optional)

• Assign order (or picking batch) to picker

• Picking batch (or order) may be assigned to more than one picker

• Monitor picking progress down to line item level

• Change picking assignments

Pick Queue

Ability to View:• Pick batches assigned to single picker

• Details of what single picker is presently picking

• Which pick batches a single order was broken into

• Which pickers are picking a single order

• Which pickers are picking a single pick batch

Click the display for more details

Stock Movement Log:• Picking transactions added to Stock

Movement Transaction Log

• Supported by pre-generated query

• May select transactions for single user

• May select only picking transactions or all transactions

Management Tools

Picking Status Inquiry• View picking status by

order sequence

• View picker and pick batch details of everything in a single order

• View picking status of single picking batch

• View list of orders whose picking has been completed

Pick Queue

Click the display for more details

Pick Queue Summary

• Pick batches are listed by batch number within assigned picker

• Pick batches not assigned to a picker are identified as *ANY

• Pick batches may be assigned to a picker but still be “unavailable” for picking (status of “U”)

• Each pick line is displayed with total bin stops for this line as well as total weight to be picked

Pick Queue Summary

• Pick batches are listed by picker within batch number

• Top priority pick batches are listed first (based on collating sequence of batch name)

• Manager can easily see which pickers are assigned to pick a particular pick batch

• Manager can display Work with Picking Queue display by using an option of 1

Work with Picking Queue (L2610) Type options, press Enter. View: 1 of 2 Subsetted List Top A=Batch avail, U=Batch unavail, M=Manual pick order, S=Picking status B=Browse order, I=Item inq Batch WH Picker Sts Bin loc Typ Item Quantity CO Order B 10204_____ __ __________ _ __________ _____________ __ _____ _ B 10204 01 HAL A C-08-5 S 1001 8 CS 01 10204 _ B 10204 01 HAL A D-14-4 S 1015 5 EA 01 10204 _ B 10204 01 HAL A T-04-2 S 1018 2 CS 01 10204 _ 01-10201 01 RIC A D-14-4 S 1015 3 CS 01 10201 _ 01-10201 01 RIC A R-11-5 S 1019 5 EA 01 10201 _ 01-10201 01 RIC A T-04-2 S 1018 2 CS 01 10201 _ 01-10202 01 HAL A A-14-2 S 1006 1 CS 01 10202 _ 01-10202 01 HAL A C-08-5 S 1001 6 CS 01 10202 _ 01-10202 01 JOEL A D-14-4 S 1015 11 CS 01 10202 _ 01-10202 01 JOEL A E-08-6 S 1013 24 CS 01 10202 _ 01-10203 01 JOEL A C-08-5 S 1001 7 EA 01 10203 _ 01-10203 01 JOEL A R-11-5 S 1019 10 BX 01 10203 More... F3=Exit F5=Refresh F11=Alt view F12=Replenishment queue F14=Subset F16=Mass update F21=Pick Queue Summary F22=Picking status Help avail

Work with Picking Queue

• Work with Picking Queue display starts with pick batch selected on previous screen

• Each pick line in pick batch is displayed showing item number, bin location, picker, quantity and U/M to pick, etc.

• Using options A and U, Individual pick line status may by changed to available or unavailable for picking

• Use F14=Subset to use advanced method of selecting Pick Queue records

• Use F16=Mass update to make mass changes to all displayed records

F16=Mass updateF14=Subset

Picking Status

• The initial Picking Status display shows orders in order number sequence

• An order in multiple pick batches will display on multiple lines

• The status columns can be used to establish where in the picking process an order stands

• Details about a specific order may be viewed by using option B=Browse pick details

• A packing list may be printed using option K=Print packing list

Picking Status (L2610) Company ..: 01 Type options, press Enter. View: 1 of 2 Subsetted List Top K=Print packing list, P=Reprint pick list, B=Browse pick details Order WH Status Batch Cust Brn Ship Rte/Grp Day Ship Req _____ __ _ __ _ _____________ _______ ___ ____ ________ ____ _ 10201 O1 C 5 01-10201 230 040 40 *ORDER 02/28/2004 _ 10202 O1 I 5 01-10202 410 010 9999 *ORDER 02/23/2004 _ 10203 O1 M 4 01-10203 300 20 WEBER WED 02/16/2004 _ 10204 O1 C CC 5 B 10204 105 9999 *ORDER _ 10205 O1 C 5 01-10205 110 9999 *ORDER _ 10206 O1 B 3 01-10206 520 MORGAN TUE 03/12/2004 _ 10207 O1 B 3 4105 100 9999 *ORDER _ 10208 01 A 3 01-10208 605 20 *ORDER _ 10209 O1 B 3 4105 101 9999 *ORDER _ 10210 O1 A 3 4105 201 010 9999 *ORDER 02/17/2004 _ 10211 01 U 3 01-10211 550 9999 *ORDER _ 10212 O1 A 3 4105 202 3 *ORDER More... F3=Exit F5=Refresh F12=Return Help avail

Order Picking Details

• Each pick line within the order is displayed

• If an item is to be picked from multiple bins, one line will display for each bin

• For lines not yet picked, date and time indicated date and time of assignment to picker

• For lines already picked, date and time indicate date and time picked

• Column Dev indicates the quantity deviation of picked to ordered (Pick = Quantity to pick or ordered)

Order Picking Details (L2640) Co, Order, W/H . . : 01 10202 01 Request date : 02/23/2004 Cust, Brn, shipto .: 410 010 9999 Route/Group .: *ORDER Status, Hold, Step : I 5 Type options, press Enter. View: 1 of 2 Subsetted List Top K=Print packing list, P=Reprint pick list, B=Browse order Item Date/Time picked Sts User Batch Pick Qty Dev _____________ _ __________ _____________ _ 1001 02/12/2004 16:20:12 C HAL 01-10202 6 CS _ 1006 02/12/2004 16:25:33 C HAL 01-10202 1 CS _ 1013 02/13/2004 09:33:22 I JOEL 01-10202 24 CS 8 _ 1015 02/11/2004 14:18:50 B JOEL 01-10202 11 CS 11 F3=Exit F5=Refresh F12=Return Help avail

• What are your objectives?– Real-time data– Speed in picking– Speed in bin replenishment– Warehouse efficiency– Picking and replenishment accuracy– Picker productivity and statistics– Ease of use– Tight integration to DMAS

I/O Bar Code Assisted Picking and Replenishment

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