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How to monitor pick/pack waves

After you have created the pack plan, the bills of lading, the pick plan, and at least some of the pick tickets, you can start to monitor the progress of the wave.

You can monitor:

  • the pack plan
  • each of the bills of lading
  • all of the BOL items in your wave
  • the pick plan
  • each of the pick tickets
  • all of the pick ticket items in you wave
  • the progress of a specific sales order item
  • inventory as it is being picked and packed
  • any exceptions to the process

To montior the pack plan:

Monitoring the pack plan allows you to view the overall progress of the packing for this wave.

  1. Select Wave Fulfillment>Pack Plans. A list of pack plans appears. You can find your pack plan based PaP #, Wave #, or other fields.
  2. The pack plan has a Status of:
    • In Progress when it is first created
    • Closed when all of the goods have been packed and shipped out of the warehouse on a Closed bill of lading
  3. From the Wave Fulfillment>Pack Plans list view, highlight the pack plan and select View iconView. The details of the pack plan display.
  4. In the Pack Plan Items table:
    • The Full View displays all of the pack plan items
    • The Unplanned View displays only the pack plan items that have an Unplanned Qty greater than zero.

      Pack plan items have an Unplanned Qty greater than zero if the packer working on the bill of lading has rejected some of the items initially picked. A new pick plan must be created before these items can be put onto bills of lading and shipped out of the warehouse.

    • Each pack plan item has a Status of:
      • In Progress when it is in the process of being picked and packed
      • Ready when it has been completely packed
      • Closed when it has been shipped out of the warehouse on a Closed bill of lading

To monitor each bill of lading:

Monitoring the bill of lading allows you to track what has been delivered to the dock or packing station and what has been packed. You can look at the details of each bill of lading.

  1. Select Wave Fulfillment>Bills of Lading. A list of bills of lading appears. You can find your bills of lading based on BOL #, Wave #, or other fields.
  2. The bill of lading has a Status of:
    • In Progress when it is first created
    • Closed when all of the packages are Closed and the goods have been packed and shipped out of the warehouse
  3. From the Wave Fulfillment>Bills of Lading list view, highlight one of the bills of lading in your wave and select View iconView. The details of the bill of lading display.
  4. In the Pack Items table:
    • The Pack View displays one line for every Item # and unit of measure on this bill of lading.
    • The Demand View displays one line for every sales order line being fulfilled.
    • The Fulfillment View displays one line for every inventory item being picked (regardless of original location) and pick plan or pick ticket status.
    • Each BOL item has a Status of:
      • In Progress while the goods requested (Qty to Pack) are being picked
      • Ready when all the goods (Qty Avail to Pack) have been picked and delivered to the packing station
      • Closed when all of the goods (Qty Packed) have been packed and shipped out of the warehouse
  5. In the Packages table:
    • Each package has a Status of:
      • In Progress while the goods are being picked and packed
      • Ready when all of the items in the package are Ready
      • Closed when the user seals the package

To monitor all of the packed items in your wave at once:

Monitoring the bill of lading allows you to track what has been delivered to the dock or packing station and what has been packed. You can view all of the items across all of the bills of lading for the wave at one time.

  1. Create an activity line manager that has a Filtering for Document Type of Bill of Lading. (Remember that activity lines are line items on SmartTurn documents that reflect the warehouse transaction being carried out on the document. Activity line managers allow you to sort, filter, and report on sets of these lines.)
  2. View the activity line manager.
  3. Search for the Wave #. All of the pack items in your wave are displayed, including their Status and Qty.

See also Using the activity line manager to view details for a wave of work.

To monitor the pick plan:

Monitoring the pick plan allows you to view the overall progress of the picking for this wave.

  1. Select Wave Fulfillment>Pick Plans. A list of pick plans appears. You can find your pick plan based on PiP #, Wave #, or other fields.
  2. The pick plan has a Status of:
    • Saved when it is first created; inventory is soft allocated at this point
    • In Progress once pick tickets are created (however, not all of the pick plan items may be on pick tickets yet)
    • Closed when all pick tickets are either closed or cancelled
  3. From the Wave Fulfillment>Pick Plans list view, highlight the pick plan and select View iconView. The details of the pick plan display.
  4. In the Pick Plan Items table:
    • the Full View displays all of the pick plan items
    • the Unplanned View displays all of the pick plan items for which all or part of the item has not yet been put onto pick tickets. The Unplanned Qty lists the amount of goods not yet put onto pick tickets.

To monitor the pick tickets:

Monitoring the pick tickets allows you to track what has been picked and delivered to the dock or packing station. You can look at the details of each pick ticket.

  1. Select Wave Fulfillment>Pick Tickets. A list of pick tickets appears. You can find your pick tickets based on PT#, Wave #, or other fields.
  2. The pick ticket has a Status of:
    • Saved when it is first created
    • In Progress while the goods are being picked
    • Closed when all of the goods have been picked and delivered to the destination location (packing station)
  3. From the Wave Fulfillment>Pick Tickets list view, highlight one of the pick tickets in your wave and select View iconView. The details of the pick ticket display.
  4. In the Pick Ticket Items table:
    • The Full View displays all of the pick ticket items
    • The Pick View displays all of the inventory items still in their original location
    • The Put View displays all of the inventory items in transit locations (that is, items that have been picked from their original location but not yet delivered to the destination location)
    • Each pick ticket item has a Status of:
      • Saved when it is still in its original location
      • Started when it is picked from its original location
      • Closed when it is delivered to the destination location (packing station)
      • Cancelled if the user cancels the pick

To monitor all of the pick ticket items in your wave at once:

Monitoring the pick tickets allows you to track what has been picked and delivered to the dock or packing station. You can view all of the items across all of the pick tickets for the wave at one time.

  1. Create an activity line manager that has a Filtering for Document Type of Pick Ticket. (Remember that activity lines are line items on SmartTurn documents that reflect the warehouse transaction being carried out on the document. Activity line managers allow you to sort, filter, and report on sets of these lines.)
  2. View the activity line manager.
  3. Search for the Wave #. All of the pick ticket items in your wave are displayed, including their Status and Qty Picked.

See also Using the activity line manager to view details for a wave of work.

To monitor the progress of a specific sales order item:

You can trace a specific sales order item's progress through the wave:

  1. Find the sales order line item:
    • Select Ordering>Sales Orders. Highlight the sales order and select View iconView. In the Items table, locate the sales order line item.

      OR

    • Select Ordering>Sales Order Items List. Highlight the sales order item and select View iconView. In the Items table, locate the sales order line item.
  2. In the Items table, check the checkbox next to the item.
  3. Select Explore from the toolbar of the table.
  4. In the Explore page, select Show all lines. The tables on the Explore page display all of the line items that are related to the selected item, across all of the documents in the system.

    For example, if this sales order item is being fulfilled on one bill of lading, but being picked on two different pick tickets, then there is one sales order item, one bill of lading item, and two pick ticket items (there is also one pack plan item and one pick plan item). The Explore page allows you to view at a glance all of the warehouse activity, including Status values, related to one line item. See more information on Using the Explore screen.

To monitor the inventory that is being picked and packed in your wave:

You can monitor the inventory that is being picked and packed in your wave by running reports against inventory:

  • Inventory that is in your Transit Locations has been picked from its original location but not yet delivered to its destination location (the dock or packing station).
  • Inventory that is in the dock or packing station has been picked and delivered to its destination location.
  • Some inventory may remain at the dock or packing station after the wave has been completed. Inventory may be left at the packing station because it was rejected by the packer during the packing process, or because the sales order was removed from the wave after the inventory was picked and delivered to the packing station. Inventory left at the packing station after wave has been completed must be processed appropriately, for example it may be bin transferred back to a bulk storage location.

To run reports against inventory:

  • Select Reports>Quantity by Location. SmartTurn displays a single line item for each Location. Locate the dock or packing station for this wave. Highlight the location and select View to see detailed information about the individual inventory items in this location.

    OR

  • Create an inventory manager that has a Filtering for Location of the location you are interested in. (Remember that inventory managers allow you to sort, filter, and report on subsets of on hand inventory.) View the inventory manager to see detailed information about the individual inventory items in this location.

See also Inventory reporting for wave fulfillment.

To monitor what has gone wrong in your wave:

Sometimes, something out of the ordinary occurs during your picking and packing process.

  • If the picker picks short:
    • On the pick ticket: On the pick ticket line item, the Qty to Pick decreases to be equal to the Qty Picked entered by the user. The pick ticket item Status is Started or Closed.
    • On the pick plan: If the entire amount of the pick plan item was being picked by this pick ticket item, the pick plan item Status is In Progress (if the pick ticket item is Pick Started) or Closed (if the pick ticket item is Pick Finished). However, if the pick plan item was being picked on more than one pick ticket (for example, if it was split onto two pick tickets because of pick ticket capacity constraints), then the pick plan item Status remains In Progress. It becomes Closed when the rest of the pick ticket items for this pick plan item are Closed, and the Qty to Pick decreases to be equal to the total Qty Picked.
    • On the bill of lading: On the BOL item, the Qty Avail to Pack increases by the Qty Picked. This means that the Qty Avail to Pack may be less than the Qty to Pack even though all of the pick tickets have been completed. The packer can choose to ship the bill of lading anyway, or to re-plan the picks.
    • On the pack plan: The amount short (that is, the difference between the Qty to Pack and the Qty Avail to Pack) is listed as Unplanned Qty. The user can re-plan the picks.
  • If the picker cancels a pick:
    • On the pick ticket: On the pick ticket line item, the Qty Picked is 0. The pick ticket item Status is Cancelled.
    • On the pick plan: The pick plan item remains in Status of In Progress. The original Qty to Pick from the cancelled pick ticket item is listed as Unplanned Qty on the pick plan item. Select Create Pick Tickets to create additional pick tickets that include this amount.
    • On the bill of lading: There is no change.
    • On the pack plan: There is no change.
  • If the picker cancels an entire pick ticket:
    • On the pick ticket: The Status of the pick ticket and of all of the pick ticket items is Cancelled.
    • On the pick plan: The pick plan items remain in Status of In Progress. The original Qty to Pick from the cancelled pick ticket items is listed as Unplanned Qty on the pick plan items. Select Create Pick Tickets to create additional pick tickets that include these amounts.
    • On the bill of lading: There is no change.
    • On the pack plan: There is no change.
  • If not all of the pick plan items have been put onto pick tickets:
    • Any pick plan items that have not been put onto pick tickets are listed in the Unplanned View of the Pick Plan Items table. Select Wave Fulfillment>Pick Plans>View Pick Plan #: PiP-nnnn to view them.
    • See also Finding unplanned items.
  • If the packer rejects some of the goods picked:
    • On the pick ticket: The rejected picks appear in the Rejected Picks tab, with the Qty Rejected and whether or not the inventory was Returned to Inventory.
    • On the pick plan: The pick plan item Unplanned Qty increases by the Qty Rejected.
    • On the bill of lading: The rejected picks appear in the Rejected Picks view, with the Qty Rejected and whether or not the inventory was Returned to Inventory. On the BOL item for which the pick was rejected, the Qty Avail to Pack is decreased by the Qty Rejected.
    • On the pack plan: There is no change.
  • If the packer wants the rejected goods re-picked:
    • When the packer rejects a pick on the bill of lading, the Unplanned Qty on the pick plan item increases by the Qty Rejected. Select Create Pick Tickets to create additional pick tickets that include these amounts.
    • See also Finding unplanned items.
  • If the packer wants to send out the bill of lading without re-picking the rejected goods:
    • When packer rejects a pick on the bill of lading, the packer can then Force Ready the pack item. Choosing to Force Ready the pack item on the bill of lading has the following effects:
      • On the bill of lading: The item Qty to Pack is set to the Qty Avail to Pack, that is, the bill of lading now says that fewer items are supposed to be packed and shipped out of the warehouse.
      • On the bill of lading: The item Status changes to Ready. This means it is now ready to be placed in a package and have the package sealed and closed.
      • On the pack plan: The Qty to Pack is reduced by the same amount that the BOL item Qty to Pack was reduced.
      • On the sales order: The Unplanned Qty increases, and this sales order item can be (re)planned as part of another wave of work at a later time.
    • There is an error during Force Ready if the sales order line referenced by the BOL item is part of a sales order that is required to ship complete.
    • See also Packing BOL items.
  • If a sales order needs to be removed from the wave:
    • You can remove a sales order from a wave up until the bill of lading becomes Closed and the inventory leaves the warehouse. Any inventory that has been transferred, for example inventory that has been picked from its original location and delivered to the packing station, is left in the location it is currently in.
    • See also Inventory reporting for wave fulfillment.

See Also

Monitoring waves of work

How to monitor pick to staging waves

Using the Explore screen

Using an activity line manager to view details for a wave of work

Finding unplanned items

Inventory reporting for wave fulfillment

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