Blackberry operation workflow with pre-pack staging and pick-order group

Orders per day

3000 to 4000 orders per day

SKUS and Items per order

Initial setup

Creating pre pack staging locations in system.

We allow creating Aisles and Locations for pre-pack staging area.

suggested is one Aisle should have upto 300 locations.

Workflow

Creating pick order groups

One pick order group can have upto 600 line item.

Considering a sample size that orders have about 10 SKUs each, we would recommend creating pick groups of upto 50 orders.

Supervisor can search order based on customer/suppliers, customer priority, Delivery city.

All these options are made keeping in mind that mostly what is going to be shipped together will also be picked together so it can stay closer in pre-pack staging area.

supervisor can also jasper reports to select the orders and then upload here to create the pick order group.

Releasing picklist for pick order group

Supervisor will release the picklist for a pick order group.

Generating box Ids for orders

Bulk packing screen to be used to print box id stickers for all orders in a pick group.

As Is process.

Here we are generating box Ids before hand only so we can use these pack boxes for pigeonholing and consolidation after picking via pick-order-group.

Placing boxes for orders on pre-pack staging area

Once the boxes are stickers, operators will put the empty boxes on pre-pack staging locations.

Seeing the pick pendency and deciding where to start from

Pickers will use the pick pending screen to see where all picking is there for assigned pick-order-group

Picking using pick order groups

Operators will input the pick-order-group id in picking screen to start the picking.

Sorting

For sorting we have given option to do single level sorting or a multi level sorting.

Multi level sorting is more efficient is there are more number of orders to be sorted which are placed in multiple aisles.

If all boxes of a pick order group are nearby places only then no need of multi sorting.

Assuming all items coming for sorting are pick order group wise.

Multi level sorting (first sort)

Operator can enable a toggle from top right corner to enable multi level sorting option where only input is itemCode.

Physically there will be one box for 1 aisle.

Operators can scan the item code and see the in which Aisle the order is placed.

they can put the item in box for relevant aisle. (no need to scan box id)

Single sort or second sort for multi level.

Operator will scan the item code system will show the order Id, and if the any location where the order’s box is places. operator can scan the box id in that location to confirm.

If doing multi level sorting then, items segregated from previous step can now be sorted to put into respective locations.

Closing boxes

operator will use bulk packing screen to close the box once they see the box is full. or they will see a popup in sorting if all items of the order have reached the box.

Weight capturing

As is.

Invoicing

As is.