The following sections relate to how the ViewPoint Logistics currently handles pick-line, including Setup, Replenishment, and Putaway.

For a list of the core applications for handling stock locations in VL, see SL - Stock Locations.

How it Works

The method of creating an Order in the system follows a "top down" pattern, beginning with the allocation of inventory to the Order at the Product level.

This is what happens in the Deferred Order process, where the system will check to see if the Product required is a valid Product before accepting the Order line.

The system can be configured to allocate stock at this level, which means that it does not care what Lots are available or where they are, only that somewhere in the Warehouse some of the Product exists in a salable status.

In normal Order entry, allocation of inventory is done at the Product and Lot levels. In this situation, the system does not care where the Product exists in the Warehouse, but it has already committed a quantity of the Product and a specific Lot to the Order.

It is at this point that FIFO (First In First Out) has been satisfied, according to whatever rules are being used.

When the Order print process (program OE.03 [Print Shipping Documents]) is carried out, the final inventory allocation process is completed by the system, assigning the appropriate Locations based on the user-assigned Pick criteria. It is important to note, however, that the Pick assignments are going to happen within the Lot assignments that have already been made.

Example:

Fixed Pick Locations

The system currently is programmed to deal with fixed Pick Locations. This means that the system expects the Warehouse to have a designated Pick home for each Product that is eligible for the Pick-Line process.

These Pick homes can be set up for the exclusive use of a particular Product (the normal use) or contain more than one Product (very difficult to replenish accurately in this case). The system currently does not handle the flexible Pick Location scenario.

In driving the Pick process for the fixed Pick Location, the system uses what is called Total Pick-Line. This involves sending all Picks to the Pick Location until it is depleted, and then a replenishment must take place; otherwise the Picks will go to the Bulk/Overflow Locations.

Replenishment Process

It is very important to develop a well-thought-out replenishment process, because FIFO is performed at the Lot level.

Sometimes, long before the actual Locations are assigned, the Pick-Line must have sufficient inventory when the Order commit process occurs. Otherwise the system will not be able to adhere to the chosen Pick-Line rules.

Pick-Slip Selection With Pick-Line

This is the sequence of steps taken by the system.

1. The system assigns the Lot first and then the Location.
2. The system tries to pick from the oldest Lot.
3. If there is no stock in the Pick-Line, the system goes to the next Warehouse Location.
4. If there is less than one Pallet in the Order, the system will try to pull stock from the Pick-Line first.
5. If there is more than one full Pallet in the Order, the system goes to the Warehouse or to the Bulk Location.
6. If there are two full Pallets and a partial Pallet in the Order, the system will pull two from Bulk and the partial from the Pick-Line, if the oldest Lot is in the Pick-Line.

Further Notes

The Pick-Line is set up for smaller quantities of rapidly moving stock. It allows the Picker to go to the same place for such stock.

If the Order is for a quantity greater than the maximum in the Pick-Line, the Picker will be sent to the Bulk or Overflow Location for stock.

Smaller case Lots would be pulled from the Pick-Line if not exact Pallet loads.

If the Pick-Line Location is emptied with inbound EDI Orders, the system automatically reverts to picking in A-type sequence (ie. empty maximum Locations), sending the Picker to the next Lot in the sequence.

The Pick-Line works best for straight Pick-Line usage. It does not work if you are trying to ship Pallet-loads from Bulk and less-than-Pallet from the Pick-Line, regardless of FIFO by Lot.

The Lot is chosen first. So, if the oldest Lot is not in the Pick-Line, the system will not send the Picker to the Pick-Line.

Picking of all small/broken Pallet quantities from the Pick-Line is not currently available.

Setup

CR.62 [Client's Inventory Products]

In Field 60 (Stock Locator Pick Method), enter C (for Pick-Line).

In Field 71, enter the maximum quantity of this Product to be kept in the Pick-Line.

SL.78 [Storage Types / Type Profiles]

Use this program to identify storage types and preference profiles.

At least one storage type must be created. Storage Type Preference Profiles need to be defined if Verified Passive Putaway (VPP) or Active Putaway (AP) functionality will be used.

SL.90 [Locations]

In Field 8 of each Pick-Line Location in the Warehouse, enter P (for Pick-Line).

SL.95 [Pick-Line Products]

In Fields 5 (Minimum Pick-Line Quantity) and 6 (Maximum Pick-Line Quantity), enter the minimum and maximum quantities of each Product to be kept each Warehouse Pick-Line Location.

Replenishment

SL.51 [Replenishment Report]

SL.01 [Location Adjustments (Move)]

Use this program to move stock from Bulk Locations to the Pick-Line, to replenish stock.

Putaway Modes

The Stock Location (SL) system may be configured to use one (or more) of the following Putaway modes:

Passive Putaway essentially allows the user to place stock in any location. The system will NOT verify it is put in an appropriate location, nor suggest the best location. Typically this mode in used in smaller operations, and facilities that have very few clients and/or homogeneous stock.

Verified Passive Putaway (VPP) allows the user to place stock in any location providing it matches a product's putaway requirements; i.e., storage zone and type, product separation, and popularity. If the product does not match the selected location then the user must enter a password. The selection is placed in a log for later review. This mode is used when multiple clients are present that have a heterogeneous mix of stock. Typically stock is segregated within appropriate and accessible
locations based on order demand. VPP may be activated per Client/Product.

Active Putaway (AP) mode will suggest the best location based on the product putaway requirements; i.e., storage zone and type, product separation and popularity. It is similar to VPP except that it also considers the space requirements of the product and available space within locations. This option may only be used if dimensions are defined/attached to all products and locations.

Allowed Putaway Mode Combinations:

1. Passive (all Clients/Products)
2. Passive and VPP (for specific Clients/Products)
3. VPP (all Clients/Product)
4. Active/Space Management (all Clients/Products)