Optimising B2B Order fulfilment with pre-pack staging and pick-order-groups

Prerequisites

Increff wms sprint 67 deployment

Initial setup

Creating pre pack staging locations in system. One pre-pack staging location means area for putting boxes of one order.

Please keep your locations space according to your average order size.

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

Suggested is one Aisle should have upto 100 locations.

Open

Create, Enable / Disable Pre-pack staging 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.

Pick Order Group screen

Open

Create Tab - Search Orders via filters

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

Releasing pick list for pick order group

Supervisor will release the pick list for a pick order group.

Generating Pack Box IDs for orders

Bulk packing screen to be used to print Pack Box ID stickers for all orders in a pick order group.

As Is process.

Here we are generating Pack Box IDs before-hand only so we can use these Pack Boxes for pigeonholing and consolidation after picking via pick-order-group.

Supervisor can use Outwards: Order Status Report - OMS → to search the orders for the external pick order group code, and select the filter for the orders not associated with pre-pack staging locations.

They will get the orders which are added in pick order group and no boxes are not put-awayed in the location.

Placing boxes for orders on pre-pack staging area

Once the boxes are stickered, the operator will put the empty boxes on pre-pack staging locations.

Seeing the pick pendency and deciding where to start from

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

Picking using pick order groups

Select batch picking from top right for batch picking.

Input the pick order group code in the Bulk Pick Item screen, then scan the any location 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 item code.

Physically there will be one box for one 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 Pack 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 placed. The operator can scan the Pack 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 pack 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 pack box.

As there could be delay in adding items to pack boxes and closing the box, operator will have to scan all the items to confirm that all items are preset.

Viewing pre-pack staging locations status

Operators can use this screen to see what all pack boxes are there on pre-pack staging locations which are eligible for making the invoices

Weight capturing

Invoicing

Scan all the boxes to generate the system invoice and mark boxes as invoiced.