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Publication Information
Release: SSA Warehouse Management 4000 Version 3.10 Publication Date: July 2005
Table of Contents
INTRODUCTION ............................................................................................................ 1 ORDER PROCESSING WORKFLOW .......................................................................... 3 RECEIVE NOTIFICATION OF ORDER AT WAREHOUSE ....................................................... 4 CREATE SHIPMENT ORDER ............................................................................................ 4 ALLOCATE INVENTORY AND SET UP PICK TASKS............................................................. 4 GIVE THE PAPERWORK TO THE WAREHOUSE .................................................................. 4 PICK THE ORDER AND UPDATE PAPERWORK .................................................................. 4 SHIP THE ORDER .......................................................................................................... 4 PREREQUISITE ORDER PROCESSING SETUP ........................................................ 5 SHIPMENT ORDER DATA IMPORT ................................................................................... 5 BILLING SERVICES......................................................................................................... 5 PICK LOCATIONS ........................................................................................................... 5 STRATEGIES ................................................................................................................. 5 KITTING ........................................................................................................................ 6 SUBSTITUTE COMMODITY .............................................................................................. 6 ORDER STATUS HISTORY .............................................................................................. 6 WAREHOUSE PLANNER ................................................................................................. 6 SHIPMENT ORDERS..................................................................................................... 7 CREATING A SHIPMENT ORDER ............................................................................... 8 VIEWING ORDER STATUS HISTORY ....................................................................... 11 PERSONALIZATION ................................................................................................... 13 USING PERSONALIZATION....................................................................................... 15 ALLOCATION .............................................................................................................. 17 PRE-ALLOCATION ........................................................................................................ 17 ALLOCATION ............................................................................................................... 17 ALLOCATING ORDERS ............................................................................................. 19 PRE-ALLOCATION ........................................................................................................ 19 ALLOCATION ............................................................................................................... 19 CARTONIZATION .......................................................................................................... 19 ALLOCATING A SINGLE ORDER.............................................................................. 20 ORDER SELECTION MODEL..................................................................................... 21 CREATING AN ORDER SELECTION MODEL..................................................................... 22 ALLOCATING MULTIPLE ORDERS .......................................................................... 25
ALLOCATION SUBSTITUTION .................................................................................. 26 ALLOCATING SUBSTITUTE ITEMS .................................................................................. 26 UN-ALLOCATING ORDERS ....................................................................................... 27 UN-ALLOCATING A SHIPMENT ORDER ........................................................................... 28 UN-ALLOCATE PICK DETAIL LINES ................................................................................ 29 UN-ALLOCATING ORDER DETAIL LINES ......................................................................... 30 WAREHOUSE PLANNER ALLOCATION................................................................... 33 WAREHOUSE PLANNER BATCH CREATION.......................................................... 34 ALLOCATING ORDERS USING WAREHOUSE PLANNER...................................... 36 WAVE PLANNING ....................................................................................................... 39 PRE-ALLOCATION ........................................................................................................ 40 BATCHING ................................................................................................................... 40 ALLOCATION ............................................................................................................... 40 RELEASE .................................................................................................................... 40 CREATING WORK ORDERS .......................................................................................... 40 CREATING AND ALLOCATING A WAVE.................................................................. 41 MANPOWER PLANNING FROM THE WAVE ............................................................ 43 DEFINING DEFAULT UNITS PER HOUR FOR MANPOWER PLANNING ................................. 44 VIEWING MANPOWER/TIME PLANNING ON A WAVE ........................................................ 45 WAVE ORDER CONSOLIDATION ............................................................................. 49 CONSOLIDATION PREREQUISITES ................................................................................. 49 CONSOLIDATING ORDERS BY WAVE ..................................................................... 50 CONSOLIDATION RELEASE PROCESS................................................................... 53 ALLOW COMMODITY CONSOLIDATION UN-CHECKED ...................................................... 53 ALLOW COMMODITY CONSOLIDATION CHECKED ........................................................... 53 MASS UPDATING WAVES ......................................................................................... 54 WAVE STATUS ........................................................................................................... 56 STATUS TYPES............................................................................................................ 56 NOT STARTED ......................................................................................................... 56 RELEASED TO TASK MANAGER ................................................................................. 56 COMPLETED ............................................................................................................ 56 VIEWING WAVE STATUSES........................................................................................... 56 ORDER STATUS ......................................................................................................... 57 STATUS TYPES............................................................................................................ 57 NOT STARTED ......................................................................................................... 57 CREATED EXTERNALLY ............................................................................................ 57 CREATED INTERNALLY ............................................................................................. 57 CONVERTED ............................................................................................................ 57 RELEASED FOR PICKING .......................................................................................... 57
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IN PICKING .............................................................................................................. 58 PARTIALLY PICKED .................................................................................................. 58 PART PICKED/PART SHIPPED ................................................................................... 58 PICKED COMPLETE .................................................................................................. 58 PICKED/PART SHIPPED ............................................................................................ 58 IN PACKING ............................................................................................................. 58 PACK COMPLETE ..................................................................................................... 58 STAGED .................................................................................................................. 58 MANIFESTED ........................................................................................................... 58 IN LOADING ............................................................................................................. 58 LOADED .................................................................................................................. 58 PARTIALLY SHIPPED ................................................................................................ 59 SHIPPED COMPLETE ................................................................................................ 59 DELIVERED ACCEPTED ............................................................................................ 59 DELIVERED REJECTED ............................................................................................. 59 CANCELLED EXTERNALLY ........................................................................................ 59 CANCELLED INTERNALLY .......................................................................................... 59 PART PRE-ALLOCATED............................................................................................. 59 PART ALLOCATED .................................................................................................... 59 PART ALLOCATED/PART PICKED .............................................................................. 59 PART ALLOCATED/PICKED ....................................................................................... 59 PART ALLOCATED/PART SHIPPED............................................................................. 60 ALLOCATED ............................................................................................................. 60 ALLOCATED/PART PICKED ....................................................................................... 60 ALLOCATED/PART SHIPPED...................................................................................... 60 PART PICKED/PART SHIPPED ................................................................................... 60 PICKED ................................................................................................................... 60 PICKED/PART SHIPPED ............................................................................................ 60 SHIPPED ................................................................................................................. 60 RELEASED TO WAREHOUSE PLANNER ...................................................................... 60 ERROR CONDITIONS .................................................................................................... 61 OUT OF SYNC .......................................................................................................... 61 UNKNOWN ............................................................................................................... 61 VIEWING ORDER STATUSES.................................................................................... 62 WAVE REPORTS ........................................................................................................ 63 VIEWING CONTAINER DETAILS ............................................................................... 64 ORDER PROCESSING REPORTS ............................................................................. 66 ORDER PROCESSING EVENTS ................................................................................ 68 COMMENT FORM ....................................................................................................... 69
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Revision History
Date 9/24/2003 12/2/2003 8/12/2004 8/16/2004 5/3/2005 6/9/2005 6/30/2005 Editor Jude Duniho Jude Duniho Steve Wale Jude Duniho Julie White Jude Duniho Stuart Manning Description of Change Reformat Edited. Decimal support added. Company address change.
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Introduction
Chapter
Introduction
Order Processing is the process in which orders for product in the warehouse are recorded and then later picked for shipment. The goal of order processing is to optimize order fulfillment and enhance inventory control.
Introduction
Chapter
Note
These steps can vary from facility to facility. If the facility is utilizing EDI or RF, most of the paper is eliminated from these steps. However, the information flow behind the scenes is still the same.
Billing Services
If the warehouse plans to personalize orders by using Value Added Services, such as engraving, gift-wrap, and so on, the Value Added Services (VAS) must be defined on the Billing Services window. This window is accessed through Billing Setup Billing Services.
Pick Locations
Pick locations are locations in the warehouse from which warehouse workers pick product for shipment. SSA Warehouse Management 4000 does not allocate a Commodity unless the Commodity pick location is set up. Before the warehouse can allocate and pick orders, pick locations must be assigned to the Commodity through Support Setup Commodity.
Strategies
A strategy is a list of rules related to a Commodity or user. A main strategy consists of two sub-strategies: allocation and pre-allocation. Based on the requested task, SSA Warehouse Management 4000 uses the strategies defined at the Commodity and user level to determine how items should be allocated, how tasks should be dispatched, and so on. To allocate and release tasks, strategies must be set up for allocation, pre-allocation, and task dispatch.
Kitting
Certain Commodities in the facility are composed of several components that must be shipped together. For example, a facility can ship computer systems where the single Commodity is composed of a CPU, monitor, keyboard, and mouse. SSA Warehouse Management 4000 allows you to kit this type of Commodity by creating a Bill of Material (BOM). To use Kitted products, a Bill of Material must be set up via Support Setup Bill of Material.
Substitute Commodity
To use the allocation substitution feature, items must be defined for substitution on the Support Setup Substitute Commodity window. When a substitute is defined, SSA Warehouse Management 4000 allocates the substitute item if a stock-out condition occurs for the original Commodity.
Warehouse Planner
To use the warehouse planner integration feature, The UseWarehousePlanner flag must be enabled (ON) in the System Administration Configure System Settings window. Also, the BatchInProcessingByWP on the System Administration Configure System Settings window must be disabled (OFF) for a new batch to process. This field is updated by the system; however, you can update this field only if the batch was stopped and the flag was not updated.
Shipment Orders
Chapter
Shipment Orders
This section describes the Shipment Order process and how to create a new Shipment Order. The following topics are covered: Creating a Shipment Order Viewing Order Status History
A Shipment Order is an outbound document in response to a customers request for product from the warehouse. It records the quantity of each Commodity ordered, as well as the destination of each shipment. Shipment Orders can be created manually, or transmitted electronically through Electronic Commerce or Data Exchange.
Shipment Orders
Note
A system-generated Shipment Order number is automatically created in the SO Number field. This number can be changed to a non-sequential value (for example, add a letter or name). If the number is changed to a sequential number that has not yet been used by the system, it can later cause duplication errors, resulting in system termination.
3. Type the name of the Seller in the Seller field. Or, right-click and select Lookup Values for Seller, and select the Seller. 4. The Order Type and Order Handling Type fields are pre-populated with values for a standard Shipment Order. If necessary, these fields can be changed by selecting another value from the corresponding drop-down list.
Note
The Order Status field is pre-populated and updated by SSA Warehouse Management 4000. This field cannot be changed.
Shipment Orders
5. Select the Order Handling Type from the drop-down list in the Order Handling Type field. 6. If applicable, populate the remaining (optional) Shipment Order header fields. These fields are not required to save the record, but depend on the warehouse business operation. Refer to Shipment Order Field Definitions for more information on these fields. 7. In the Detail List, type the Commodity code for the first detail line in the Commodity field and then press Tab. Or, right-click and select Lookup Values for Commodity, and select the Commodity. 8. To modify the pack code that SSA Warehouse Management 4000 displays for the Commodity, select it from the Packkey list. 9. To use a different UOM, select it from the UOM list. 10. Based on the UOM selected, enter the quantity of the Commodity ordered in the Open Qty field.
Note
To view the quantities available for the Commodity, right-click and select View Balances Lot by Loc by Movable Unit.
The following fields are pre-populated based on the Commodity (product) ordered. These fields can be changed if necessary: Lottable01-Lottable10 - Applicable lot requirements for the order. If the ExternalLot field is populatedwhich can only happen through an APIthese fields cannot be modified. Tariff - Pricing model assigned to the product that defines the rates and method of billing for storage and associated charges. Rotation - The rotation assigned to the product that defines whether the Commodity is allocated from FIFO (First in-First out) or LIFO (Last in-First Out). Shelf Life - Indicates the amount of shelf life time for the Commodity. Allow Substitute Commodity - Flag that indicates whether the Commodity allows Auto Substitution if the original Commodity is not in stock. Ship Group 1-3 - If set to Yes, it prevents products that fail the validation parameters set up by the warehouse from being shipped. 1. Enter any special picking instructions related to the order line in the Picking Instructions field. 2. Enter any special user-defined data in the User Defined 1-5 fields. 3. Enter special notes pertaining to the order in the Notes field.
Shipment Orders
4. If necessary, in the Carton Break field for each detail line, enter a code to identify items that must be in a separate carton. For example, if a Shipment Order with five detail lines has two details with a P1 Carton Break Code, these products are put in the same carton. If the other three details lines have a different Carton Break Code, such as P2, those products are put in a separate carton. If there are no special cartonization requirements, leave the field blank. 5. If using the Carton Break functionality, enter a quantity in the Break Quantity field. Multiples of this number is packed into a single carton until only leftover quantities remain. For example, if a Shipment Order detail is for a quantity of 12 each with a break quantity of 5, either 5 or 10 each can be packed into a single carton (depending on available space) and the balance of 2 is placed in a separate carton. 6. To enter additional detail lines, right-click the Detail List, select Add, and then repeat steps 4 through 6. 7. Right-click and select Save.
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Shipment Orders
Note
If only one record meets the search criteria, the record displays in Form view. Right-click and select View Items, to view the order details. (Continue with step 4).
3. Click the blue book in front of the Shipment Order. The Detail List tab displays. 4. Right-click in either the header or detail list area and select View Status History. The Status History tab displays.
Note
For additional information on setting up Order Statuses, refer to the SSA Warehouse Management 4000 User Reference Guide, Chapter 3 Setup, Setting Up an Order Status.
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Shipment Orders
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Personalization
Chapter
Personalization
The topics below provide an overview of Personalization, and discuss the steps to perform Value Added Services (VAS) on Shipment Orders. Personalization is the process of customizing orders based on customer need. The term personalization consists of Value Added Services (VAS), as well as the ability to turn Shipment Order demand into work orders. The following are some examples of Value Added Services that can be requested by a customer. Each of the services listed below have an instruction indicating the actual text that should be put on the Commodity. Engraving Monogram Laser Gift wrap
Personalization allows the warehouses to download up to three VAS processes, along with support for an 80-character field for each of the three VAS processes. An unlimited number of VAS processes can be manually input and printed on pick tickets. The VAS processes and Notes fields are printed from the Shipment Order onto the pick ticket to ensure that the pickers know where to direct the products once they are picked. The VAS information displays on the pick tickets or on the workstation window, but not on the RF window. If a warehouse is supporting VAS processing, pick tickets are used. Currently, that is the only way SSA Warehouse Management 4000 supports display of this data. The picking process can be done in any manner the warehouse chooses, but the VAS process support is on the pick list. The 80-character Notes field is used to define the details of the service to be performed. For example, if a gift card was to be included with the Commodity, the VAS would be GIFTCARD, and the 80-character field would contain your message. There is also a VAS User-defined field that prints following the Notes, which provides specific information required by the VAS workers. For example, if an engraving VAS needed to display which typeface should be used, it can be placed in the VAS Userdefined field. The VAS User-defined field name can be changed in the language.ini file to any name the operations need. If this field is used for multiple data elements, the name should remain generic, such as VAS TYPE.
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Personalization
To use Personalization, VAS processes must first be defined on the Billing Services window (accessed through Billing Setup Billing Services), as shown in the following example.
Billing Service
These billing services must be in place because they are utilized during the import process. They display as a drop-down option (VAS Description) when manually adding services to a Shipment Order. Currently, SSA Warehouse Management 4000 does not automatically bill for these services.
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Personalization
Using Personalization
First, you must either import orders with VAS processes attached, or manually create the Shipment Orders and add the VAS services. Electronic Commerce can be used to help define the file layout and then import orders into SSA Warehouse Management 4000. Refer to the SSA Warehouse Management 4000 Integration Guide for additional information. The steps below describe how to manually add VAS services. 1. Follow Steps 1-9 in Creating Shipment Orders. 2. Right-click and select Show VAS Detail from the drop-down menu. 3. Right-click and select Add. The VAS Detail tab displays.
4. Select the VAS description from the drop-down list in the VAS Description field, and add the VAS text information to be performed on the Commodity in the VAS Notes field. 5. To add information for the VAS, such as which font type to use, colors, and so on, scroll to the right and enter the information in the VAS User-defined Field.
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Personalization
Notes
The services added to the Billing Services now displays as the drop-down list. These services only need to be added if you want them to be performed. This functionality does not alter the way in which the standard Shipment Order or the standard allocation processes work. Once the order is allocated, the pick list displays the data to ensure the services are performed on the Commodity. It is then up to the order picker to deliver the order to wherever the order specifies. The actual picking of Commodities can be done by any method supported by the SSA Warehouse Management 4000 system. To generate a pick list, right-click in the Shipment Order header and choose Generate Pick List. A sample pick list displays below:
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Allocation
Chapter
Allocation
The topics in this section describe the allocation process for Shipment Orders, and the steps to allocate and un-allocate inventory for orders. The following topics are covered: Allocating Orders Allocating Multiple Orders Allocation Substitution Un-allocating Shipment Orders Un-allocating Pick Detail Lines Un-allocating Order Detail Lines
After orders are created, the warehouse must be searched for available product. When found, the product is reserved for that order. This reservation process is known as allocation. Allocation consists of two components: pre-allocation (soft) and allocation (hard).
Pre-allocation
Soft hold on inventory, based on lot information. If a user only pre-allocates, the preallocated inventory can still be moved. Pre-allocation is used to check for sufficient stock to fill an order; however, the product does not need to be in the primary pick location.
Allocation
Hard hold on inventory. A hard hold means that allocated product has been reserved for one order only and cannot be picked for a different order. Inventory is reserved by location, lot, and if necessary, an ID. Orders can be allocated one at a time (from the Shipment Order window) or in groups using the Order Processing or Wave modules.
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Allocation
Pre-allocation and allocation work together to create candidates and reserve inventory based on certain criteria, like task dispatch, pre-allocation, and allocation are somewhat user configurable. The steps used for each are based on the unit of measure.
Notes
Inventory that has been put on hold cannot be allocated. It is possible to over-allocate by activating a system setting (System Administration Configure System Settings.) If the AllowOverAllocations flag is enabled, you can allocate more of the product than is available in the pick location when using the standard (STD) allocation strategy. Replenishment tasks are created to move the inventory to the correct locations for picking. However, there must still be sufficient product in the warehouse.
SSA Warehouse Management 4000 allocates orders based on location and lottable combinations for an order. The system looks at each of the ten lottable fields stored on the Shipment Order, and attempts to find candidate lots with those attributes. If one candidate lot is found, then that lot is selected for allocation. If multiple candidate lots are found, the system looks at the Rotate By and Default Rotation fields on the SKU table, and selects the lot that meets those requirements. If the system finds one candidate lot that meets the Rotate By and Default Rotation requirements, the lot is selected for allocation. If the system finds multiple candidate lots that meet the Rotate By and Default Rotation criteria, the lot is allocated based on FIFO.
Refer to the SSA Warehouse Management 4000 User Reference Guide Chapter 3 SSA Warehouse Management 4000 Setup for additional information on setting up lottables.
18
Allocation
Allocating Orders
SSA Warehouse Management 4000 provides three ways to allocate products to fill orders. Individual orders can be allocated from the Shipment Order window by rightclicking and selecting Allocate after entering the Shipment Order. Multiple orders can be allocated using an Order Selection Model. This process enables the batch allocation function, which is discussed later in this section. Finally, orders can be allocated from the wave window. Refer to Wave Planning for additional information on creating and allocating waves.
The allocation process is strongly affected by the application configuration upon installation. In general, SSA Warehouse Management 4000 goes through the following steps for allocation:
Pre-allocation
Pre-allocation uses an Order Selection Model to determine the lots from which to allocate the order, based on the lottable criteria you enter on the Shipment Order window. Pre-allocation also determines how many pallets, cases, innerpacks, and so on, are needed.
Allocation
Allocation takes the results of pre-allocation and assigns the locations from which to pick the order.
Cartonization
Cartonization uses the results of allocation to determine how to package incomplete pallets, cases, innerpacks, and so on. After an order is allocated, SSA Warehouse Management 4000 cartonizes the order by assigning case IDs to each line item that fits in a single carton, based on the carton group assigned to that Commodity.
19
Allocation
3. Click on the blue book for the Shipment Order. The Detail List tab displays. 4. Right-click and select Form View. The Form tab displays. 5. Right-click on the order in the header and select Allocate. Click Yes to confirm. 6. After allocation has completed, right-click and select Show Pre-allocated Picks. 7. Right-click and select Show Picks. Review the allocation and pre-allocation strategies used to search the warehouse for products.
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Allocation
21
Allocation
4. Enter the name of the new model in the Parameter Code field.
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Allocation
5. If the new record is the facilitys default Order Selection Model, select the Is Default? option.
Note
There can only be one parameter code with Is Default? selected. The system default parameter code (STD) has the check box selected; if another parameter code is to be used as the default, the Is Default? option in the STD parameter must be deselected.
6. Define the range of orders affected by the model. Populate the appropriate fields, placing the lower end of each range in the left column and upper end of each range in the column on the right. Refer to Order Selection Model Field Definitions for additional information on these fields.
Note
If a field is left blank, it defaults to all orders affected by that field. For example, if the Delivery Date Range field is blank, orders with every delivery date are included.
7. Click the Pick Options tab. The Pick Options tab displays.
8. Select the appropriate option from the Order Picking Procedure list. If Batch Picking is selected, populate the additional fields on the window. Refer to the SSA Warehouse Management 4000 Batch Picking User Guide for additional information.
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Allocation
10. Fill in the appropriate fields to specify the models carton and carrier defaults. 11. Click the Pre-allocation Options tab. The Pre-allocation Options tab displays.
12. Choose an option from each of the lists on the tab to specify how orders are to be allocated under this model. 13. Click the Save icon. Refer to Order Selection Model Field Definitions for additional information.
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Allocation
25
Allocation
Allocation Substitution
Once an order has completed the initial allocation routine, SSA Warehouse Management 4000 verifies whether a stock out condition exists on an order. A stockout condition is defined as any point during the allocation routine when inventory is no longer available. If a stock-out condition exists, the system automatically re-allocates the order using the substitute items. The list of acceptable substitutes must include a quantity. For example, a warehouse operation can use two six-packs of soda as a substitute for one twelve-pack. Conversely, a warehouse operation can use one twelve-pack as a substitute for two six-packs. To use the allocation substitution feature, items must be defined for substitution on the Support Setup Substitute Commodity window. When a substitute has been defined, SSA Warehouse Management 4000 allocates the substitute item if a stockout condition occurs for the original Commodity. Refer to the SSA Warehouse Management 4000 User Reference Guide, Chapter 3 Setup, Setting Up a Commodity for additional information on setting up Substitute Commodities.
If a Substitute Commodity has been defined, the Allow Substitute check box is automatically checked. This box can be unchecked, if you do not want to allow the substitution. If the field is checked and a stock-out condition exists for the order; the substitutes are applied against the order line, following the sequence defined for the substitute until the balance of all allocations are complete, or all substitutes have been used. If this field is not checked and a stock-out condition occurs, the substitutes are not applied against the order line, even if substitutes have been defined for the original Commodity.
When the substitute has been applied to the Shipment Order, a new detail line for each substitute item is added to the Shipment Order directly under the original Commodity. Each substitute has the Is Substitute check box selected.
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Allocation
Un-allocating Orders
During picking operations, certain conditions can arise, such as cancellations that make it necessary to reverse the effects of allocation for an entire shipment order. The use of un-allocation at the order level indicates that no portion of the order is to be shipped. Un-allocation removes the systems reservation of stock for a customers order. It also removes any associated task manager pick tasks. If you need to un-allocate an entire Shipment Order, Un-allocate Orders should be used. An order can be un-allocated (clearing the quantity allocated and quantity picked columns) until it is shipped. Shipping product is the point of no return and orders cannot be un-allocated at this point. Below are some common examples why Un-allocate Orders would be required: Accounts receivable has informed the warehouse that an order, which has already been released to the floor, must be cancelled due to the customers non-payment of bills. A customer has called and cancelled their order, which has been allocated, and you must remove the entire order from picking. Certain orders cannot be picked in time for the overnight service. The warehouse needs to un-allocate the orders today, and re-allocate them tomorrow.
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Allocation
2. To narrow the search before retrieving orders, enter information into the appropriate fields. 3. Right-click and select Retrieve Candidate Orders. The List tab displays with a list of all Shipment Orders that match the search criteria.
Note
Only orders marked with the un-allocate bitmap can be un-allocated. To view a key to the status bitmap, right-click the window, select Options, and then Show Legend.
4. To un-allocate individual line items from an order, right-click the window, select Mark/Un-allocate Items for Order, and then click the order to select it. The Detail List for the selected order displays and all menu controls toggle to the detail level. To return control to the order level, right-click and select Return to Marking/Un-allocate Orders. 5. To keep an eligible allocated order or detail line from being unallocated, click on the status bitmap to mark it. A red not () symbol displays over it, indicating that it is not un-allocated.
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Allocation
6. After all of the orders or lines have been marked that are not un-allocated, right-click the window, select Un-allocate Orders, and then click Yes to confirm.
To un-allocate pick detail lines: 1. Navigate to Order Processing Tasks Unallocate Pick Detail Lines. The Un-allocate Pick Detail Line window displays. 2. To narrow the search before retrieving pick detail lines, enter information into the appropriate fields.
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Allocation
3. Right-click the window and select Retrieve Candidate Pick Line Items. The List tab displays a list of all pick detail lines that match the search criteria. Each line shows an icon just to the left of the pick detail number indicating the lines allocation status.
Note
Only lines marked with the Un-allocate bitmap can be un-allocated. To view a key to the status bitmap, right-click the window, select Options, and then Show Legend.
4. To keep an eligible allocated pick detail line from being un-allocated, click the status bitmap to mark it. A red not () symbol displays over it, indicating that it is not to be un-allocated. 5. After all of the lines have been marked that are not to be un-allocated, rightclick the window, choose Un-allocate Pick Line Items, and then click Yes to confirm.
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Allocation
1. Access Order Processing Tasks Un-allocate Order Detail Lines. The Un-allocate Order Detail Line window displays. 2. To narrow the search before retrieving order detail lines, enter information into the appropriate fields. 3. Right-click and select Retrieve Candidate Order Line Items. The List tab displays a list of all order detail lines that match the search criteria. Each line shows an icon to the left of the order detail number indicating the lines allocation status.
Note
Only lines marked with the Un-allocate bitmap can be un-allocated. To view a key to the status bitmap, right-click the window, select Options, and then Show Legend.
4. To specify which detail lines to un-allocate, right-click and select one of the following options: Un-allocate All Orders - This option un-allocates all order lines for all Shipment Orders. Un-allocate All Lines for Order # XXXX - This option un-allocates all order lines for a selected Shipment Order. Un-allocate Line XXXX for Order XXXX - This option un-allocates a selected Shipment Order Detail Line.
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Allocation
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Chapter
Warehouse Planner is a specialized module, which runs independently from SSA Warehouse Management 4000. With this integration, between SSA Warehouse Management 4000 and Warehouse Planner, customers can allocate product in Warehouse Planner by passing pre-allocated orders, item master, and inventory information. Warehouse Planner can assign specific resources to complete picks based on the zones they are working within the facility. The SSA Warehouse Management 4000 Task Manager is used to direct a selector to the next available task, based on the sequence provided by Warehouse Planner. This allows the operation to take advantage of the prioritization and planning logic in Warehouse Planner and the flexibility of SSA Warehouse Management 4000 to process and pick orders.
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1. Type the name of the Order Selection in the Parameter Code field. 2. If necessary, populate the following field to specify special order selection: No. of Orders to be Retrieved - Indicates the maximum number of orders to be assigned to the wave.
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3. Populate the From and To fields to define the parameters for the Warehouse Planner. Refer to Warehouse Planner Field Definitions for more information on these fields.
Note
Be careful when setting up parameters. If any through fields are left at the default setting, the system pulls up all data for that selection parameter field. For example, if Storer contains the ZZZZZ default, it pulls up orders for multiple Storers.
4. Right-click in the record and select Create WP Batch. Click Yes to Save. A new Planner Order Batch tab is created with all the eligible orders that match the order selection criteria. 5. Using the right-click Add and Delete action, the list of eligible orders can be modified. To delete an order, highlight the order and right-click Delete. To add an order, right-click on Add. The right-click Add causes a popup window to display that contains orders that are eligible to be processed by Warehouse Planner. You can then select one or more orders to add to the batch.
6. The orders are now ready to be processed by Warehouse Planner. Right-click the Planner Order Batch tab, and then select Release to Warehouse Planner.
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4. Since only SKUs that use the standard strategy are sent to Warehouse Planner, detail lines for other allocation strategies must be allocated at this time.
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5. The wave can now be released to generate the pick tasks. Any picks that were not allocated by Warehouse Planner have a pick sequence of 99999.
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7
Wave Planning
Creating and Allocating a Wave Manpower Planning Wave Order Consolidation Consolidating Orders Mass Updating Waves Viewing Wave Statuses Viewing Order Processing Statuses Wave Reports
Chapter
The topics below describe wave processing and the steps to create, allocate, and view waves. The following topics are covered:
A wave is simply a group of orders. Orders with the same criteria can be batched into a wave to simplify the picking process. Waves are manually released and allocated based on the criteria you select. The wave window allows the retrieval of a limited number of orders per wave. In addition, the wave window restricts orders to a single wave unless you specifically request duplication. Wave processing includes the following functionality:
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Pre-allocation
Pre-allocation is the process used to verify and reserve quantities of products.
Batching
Batching is the process that allows picking Commodities in bulk, followed by sortation of final customer orders.
Allocation
Allocation is the process where SSA Warehouse Management 4000 determines where and how Shipment Orders should be picked. SSA Warehouse Management 4000 then cartonizes the order to ensure the most efficient use of multiple sized shipment containers.
Release
Release is the process in which work tasks associated to a wave of Shipment Orders is released to the warehouse floor.
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5. Type the name of the wave in the Parameter Code field. 6. If necessary, populate the following fields to indicate special order selection: Include Orders From Existing Wave - If this box is checked, the Wave planner can place the same order on more than 1 wave. No. of Orders to be Retrieved - Indicates the maximum number of orders to be assigned to the wave.
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Status Group - The order Status Group that should be considered for inclusion on the wave. Order Handling Type - Order Handling method assigned to orders that should be considered for inclusion on the wave. RF ID Orders - A drop-down menu that determines if only RFID orders should be included on the wave. The three options are: Include RFID order, Exclude RFID orders, and Include Both.
7. Populate the From and To fields to define the parameters for the wave. Refer to Wave Field Definitions for more information on these fields.
Note
Be careful when setting up parameters. If any through fields are left at the default setting, the system pulls up all data for that selection parameter field. For example, if Storer is left at the ZZZZZ default, it pulls up orders for multiple Storers.
8. Right-click in the record and select Build Wave From Order Selection Criteria. Click Yes to Save. 9. Right-click the detail (Under Wave Orders, lower left), and select Pre-allocate Order to see what is available. Click Yes. To ensure the products preallocated, access the Not Fully Pre-allocated Order Details tab. 10. If it is necessary to consolidate orders, right-click and select Consolidate.
Note
Refer to Consolidating Waves for additional information.
11. Right-click and select Allocate Orders. Click Yes. Multiple detail tabs display. 12. Right-click and select Release Wave. Click Yes. This releases the tasks to Task Manager and saves the wave.
Note
To delete pick details, click the Allocated Pick Details tab, click the record, then right-click and select Delete Pick Details by Order #.
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4. When you select Manpower/Time Planning, the following screen displays. This
screen displays the Wave Summary as well as the individual summaries of orders on the wave.
Manpower/Time Planning Screen Wave and Order Detail Summary The Rate Information is the average number of eaches, cases and pallets that can be picked in one hour in the warehouse. The Rate Information is required in the calculations for Workers and Hours. The Rate Information is defaulted from the Tools Client Options screen, but this information can be edited on the Wave screen.
1. Enter the data for at least one Each, Case or Pallet Hours field. 2. Right-click and select Calculate Results.
NOTE: The calculations for Number of Workers to complete the picks on a Wave is Planning Units / (Planning Hours*Rate of Picking).
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Manpower/Time Planning (Number of Workers) To Calculate Number of Hours necessary to complete the picks for a wave:
1. Enter the data for at least one Eaches, Cases or Pallets Workers field. 2. Right-click and select Calculate Results.
NOTE: The calculation for the Number of Hours to complete the picks for the Wave is Planning Units / (Rate of Picking* Planning Workers).
To clear the results: Right-click and select Clear All. This clears all data in the Hours and Workers fields.
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Consolidation Prerequisites
To use the Consolidate Orders feature, the following prerequisites are required: Eligible commodities must have the Allow Commodity Consolidation check box activated (checked) on the Commodity General Tab within the Commodity window (accessed through Support Setup Commodity). For additional information, refer to the SSA Warehouse Management 4000 User Reference Guide, Chapter 3 Setup, Setting Up a Commodity. Speed locations must be set up on the Location window. For additional information, refer to the SSA Warehouse Management 4000 User Reference Guide, Chapter 3 Setup, Setting Up a Location.
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Note
The following scenarios disqualify commodities from consolidation:
Soft allocation strategy is used for the commodity. The Allow Consolidation option is deselected on the Commodity Control tab. The total wave demand is less than the minimum wave quantity. The Incl option that was originally checked by the system (the default) is deselected. The commodity is for a batched order.
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3. Select the Speed Location from the drop-down list in the Consol. Loc field, or clears the Incl check box to indicate that a commodity should not be included.
Notes
The Eligible Consolidated Commodities List displays even if there are no commodities to consolidate. Click Exit to abort the wave processing, or Continue Processing to continue. If there are missing speed line locations, the system returns the following error message:
4. In the Max Loc Qty field, enter the maximum quantity for a commodity that can be replenished to a speed location at any one time.
Notes
If left blank, the system replenishes the entire wave demand to the speed location. If populated, the system respects the total and only replenishes when the next Replenishment UOM fits. The system uses the PickCase Replenishment UOM if available, and the Pick-Piece UOM if no case pick is assigned.
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6. Click OK. The Consolidated Commodities List tab displays, indicating which commodities were consolidated.
7. Right-click and select Allocate Orders. Click Yes to accept. Multiple detail tabs display. 8. Right-click and select Release Wave. Click Yes.
Notes
The allocation process for consolidated commodities over-allocates the speed line locations used for regular orders based on the most efficient UOMs. All picks, regardless of UOM, are over-allocated from the speed line location. The system then replenishes the speed locations, respecting the maximum, with a quantity equal to the demand. The system does not replenish quantities greater than the wave demand. You cannot Consolidate Orders more than once per wave. If Consolidate Orders is selected a second time, an error message is generated indicating the wave has already been consolidated.
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6. Click the field to be updated (Route, Stop, Door or Carrier) and populate the appropriate information.
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7. Based on the field change, right-click and select the corresponding menu option (options are Mass Update Route, Stop, Door and Carrier). The following two options are available: Update All (Routes, Stops, Doors or Carriers) - This functionality enables you to select a specific Shipment Order, and have the corresponding field for all Shipment Orders on the wave updated with the same information. For example, if you change the route to 101 on a selected Shipment Order, and select Update All Routes, all orders on the wave are updated with the same route number. Update Only Blank (Routes, Stops, Doors or Carriers) - This functionality allows you to select a specific Shipment Order; and have the corresponding field for all Shipment Orders, with a blank field, updated with the same information. For example, if you change the route to 101 on a selected Shipment Order, and selects Update Only Blank Routes, only the Shipment Orders with blank (empty) route information are updated. Any other Shipment Orders with a route already defined are not updated.
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Wave Status
After waves are created, you can view the status of the wave and the associated order details. The Wave window is used to track the progress of the wave as it goes through the picking and shipping process. The list below describes the different statuses for a wave.
Status Types
Not Started
The wave has not been allocated and picking has not started.
Completed
All wave tasks have been completed.
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Order Status
The Order Status window provides the status of each Shipment Order within a wave. This window is vital in helping you to determine the progress that has been made on an order. Management decisions for timing and workflows are made from the data seen on this window. Operations that use sortation equipment must have clear visibility to wave statuses to know when to release the next wave. Below are some common examples why the Order Status window is helpful: A customers order has been placed in a wave. The customer is requesting changes to the order. By checking the status of the order, you can determine if those changes can be made. The warehouse has scheduled overtime. A status check of the last wave determines how far the tasks have progressed, so accurate predictions can be made for the schedule. The shipping shift is ending and the manager needs to determine that all work has been completed.
Status Types
Not Started
The order has been added to the wave but no processing has been done.
Created Externally
Order is initially added into the system. The customer order and order details are created via an interface with an outside application.
Created Internally
Order is initially added into SSA Warehouse Management 4000. The customer order and order details are created within the application.
Converted
Order has been converted from a Flowthru Order to a Shipment Order.
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In Picking
The Order Detail has some pick details In Process.
Partially Picked
Some of the order detail lines for the order have been picked.
Picked Complete
All detail lines for the order have been picked.
Picked/Part Shipped
Detail line has been picked and partially shipped.
In Packing
The order line has at least one detail with a Drop ID assigned to it.
Pack Complete
All details for the order line have a Drop ID assigned to them.
Staged
All details for the order line are moved to a Location of Type = Staged.
Manifested
This status is triggered when the order detail has been updated by an interface with an outside manifesting system.
In Loading
At least one RF Loading task has been completed.
Loaded
All RF Loading tasks have been completed for an order.
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Partially Shipped
If the total of the Open Quantity is greater than zero, the total of the Shipped Quantity is greater than zero, and the Open Quantity minus the Allocated Quantity is equal to zero; this status is triggered.
Shipped Complete
All order detail lines have been picked and shipped.
Delivered Accepted
Status comes from an interface indicating delivery has been accepted.
Delivered Rejected
Status comes from an interface indicating delivery has been rejected.
Cancelled Externally
Status comes from an outside interface calling for the cancellation of the order.
Cancelled Internally
Status reflects the deletion of orders within SSA Warehouse Management 4000. Cancelled Internally = Deleted.
Part Pre-allocated
Partial stock has been reserved for this order, but some items were not in stock.
Part Allocated
Stock has been fully reserved for the order.
Part Allocated/Picked
The order has been allocated, not all items were available (not in stock, wrong location, and so on), and the order has been completely picked.
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Allocated
The order has been allocated and all items were in stock.
Allocated/Part Picked
The order has been allocated, all items were in stock, and the order has been partially picked.
Allocated/Part Shipped
The order has been allocated, all items were in stock, and the order has been partially shipped.
Picked
The order has been allocated, all items were in stock, and it has been completely picked.
Picked/Part Shipped
The order has been completely picked and some of the items have already been shipped.
Shipped
The order has been allocated, all items were in stock, and the order has been completely shipped.
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Error Conditions
Empty Order An order has been included for a wave, but there are no items for the order.
Out of Sync
A system error was detected while performing calculations to report the status. (Notify a supervisor if this status displays).
Unknown
Miscalculation in quantity available.
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Notes
You can view additional information for the order (such as task details, allocated pick details, and so on) by selecting the corresponding menu options under Wave Information. Select All Wave Information to view all the details at once. You can also view Order Status information from the Shipment Order window.
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Wave Reports
SSA Warehouse Management 4000 provides multiple wave reports to help manage daily wave activities. To access these reports, right-click the wave window and select Wave Reports. The following reports are offered: Bill of Lading RF-Assisted Pick Ticket RF-Directed Pick Ticket Pick List Pack Slip Commercial Invoice Catch Weight/Data List Catch Weight/Data Packing Slip
Note
To view all wave reports right-click and select All Wave Reports. Please refer to the next section for a description of these reports.
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Note
This can also be done from the Shipment Order screen. Right-click the Shipment Order header and select Show Picks. From the Show Picks tab, right-click and select Container Details.
3. To print container detail labels, check the box of the case IDs that need to be printed. To Select All Case IDs, right-click and select Select All. To Deselect all Case IDs, right-click and select Deselect All. 4. Right-click and select Print Container Details. Depending on the type of label being printed Standard or RF ID, the system presents the following screen to select which printer to which to print the labels. If one of the labels is an RF ID label the system presents the same screen but allows the user to select an RF ID printer.
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5. To assign a new case id, place the blue arrow next to the case id to update and right-click and select Assign New Case Id. The following screen appears to allow the user to assign a new Case Id.
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Current Stock Detailby Location Current Stock Detailby Product Current Stock Summary Drop ID Contents Empty Location Report High-Low Inventory Labor Detail Report Labor Summary Report Multiple Commodity in Location Report
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Report Name Multiple Locations Assigned to Commodity Report Pack Slip Pick List Product Near Expiration Report Re-order Forecast
Description Displays all Commodities that have been assigned to multiple locations. The report is sorted by Commodity and then location. Provides packing information for an order or group of orders. This document can be generated from the Shipment Order or the Wave. Contains all Shipment Order Pick Detail Line information necessary to perform picking activity in a paper environment. Displays products that are due to expire within a designated number of days from the system date. Displays information about the current inventory situation for a Commodity (On-hand and On-order) and the associated reorder point for that Commodity. Contains RF Assisted Picking information for an order. This report can be generated from the Wave. Contains RF Directed Picking information for an order, including barcode information. This report can be generated from the Wave. Provides details of system activity against a Commodity for a designated period. The transaction types associated with this activity also display. Provides detail on Shipment Order shortages where there is not sufficient product available to fulfill the requested quantity in full. Provides summary information on Shipment Order shortages where there is not sufficient product available to fulfill the requested quantity in full.
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Comment Form
SSA Warehouse Management 4000 Order Processing Guide
Every effort has been made to write this manual in as concise and accurate a manner as possible. Nevertheless, errors do occur. If you find any errors in this documentation, have difficulty with the wording, or just have comments or suggestions, please fill out a copy of this form and send it to: SSA Global Technologies, Inc. Technical Publications Department 8777 Stemmons Freeway Dallas, TX 75247 Please reference all errors, comments, etc., by chapter and page number. Thank you.
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