FS 288575 DH-8GXFKZ Picker to select correct carton
DHL
Picker to select correct carton
Calidus Mobile
20th June 2011 - 1.0
Reference: FS 288575 DH-8GXFKZ
Contents
Functional Overview
Client Requirement
Request for functionality to display on the RDT terminal, prior to start of Picking Task, to enable Picker to select correct size carton for Pick based on the size of the order - an initiative to reduce packaging.
Solution Overview
The existing Stock Drip Feed message will be modified to include the dimensions (depth, width, height) of the stock codes.
The Pallet Types Drip Feed message will be modified to include the dimensions of the cartons (i.e. the Pallet Types).
When the RDT process assigns a pick to an RF user (for Actavis, this is a single order), the RF unit displays an optional summary screen, showing the total quantity of stock to be picked. Calidus Mobile will also calculate the total volume of picks on this order and display a number of suggested Carton Types (Pallet Type) capable of holding the contents of the order. The screen will display the carton plus the number of this type required. Each carton type suggested will have its own line.
Note: The smallest number of smallest carton types capable of holding the entire contents of the order will be suggested.
Examples:
There are 3 carton types:
- Small - can hold up to 30cc
- Medium - can hold up to 50cc
- Large - can hold up to 100cc
- If the order volume is 30cc, the system will suggest 1 small carton.
- If the order volume is 40cc, the system will suggest 1 medium carton.
- If the order volume is 60cc, the system will suggest 1 large carton.
- If the order volume is 100cc, the system will suggest 1 large carton.
- If the order volume is 110cc, the system will suggest 1 large carton and 1 small carton.
Note: In the final example, it may be more efficient in space utilisation within the carton to suggest 2*small cartons and 1*large cartons. This mechanism is, however, more efficient on the number of cartons and, therefore, more efficient for the picker.
The display of these suggested carton sizes will be rule-controlled in Calidus Mobile.
Scope
- The changes will be made to version 3.4 of the Calidus Mobile system and version 4.14 of the Calidus WMS only.
Set-up
Pre-requisites
A valid Calidus Mobile system must be connected to a valid Calidus WMS.
Menu Structure
None
Data
WMS
Enter the pallet type dimensions ONLY for those pallet types you wish to use as carton storage using the Pallet Types Maintenance screen WHS0045. If the WCS interface is enabled, this information will be automatically sent to the WCS. If not, enable the interface and type 'SEND' at the Action prompt.
Ensure that the Owner rule STDF is created and enabled for those owners requiring it.
Enter the stock case dimensions using the Stock Maintenance screen STKSTOC01B, Further Options (99), then Physical Attributes (06). If the WCS interface is enabled, this information will be automatically sent to the WCS. If not, enable the interface and type 'SEND' at the Action prompt of the top Stock Maintenance screen (STKSTOC01B).
WCS
Enable the new Picking rule 'Calculate Packs' for either the Owners requiring it, or against the Warehouse if no Owner values exist.
Functional Description
WCS Database Changes
A new Owner and Warehouse rule will be created in the Calidus Mobile database, called 'Calculate Packs'. This rule will be on the 'Picking and Post-Picking Activities' group and will have the description 'If enabled, the Pick Information screen displayed initially in the Part Picking module will display the required cartons for the volume of picks'.
The rule will have values 'Y' and 'N', with the default value being 'N'.
The existing 'Pallet Types' table will be modified to store the width, depth and height of the pallet types. The fields will all be of large numeric type.
The existing 'Stock' table will be modified to store the width, depth and height of the stock unit, as above.
WHS0909 - Stock Drip Feed
The existing Stock Drip Feed message will be modified to include the dimensions (depth, width, height) of the stock codes.
The following fields will be added to the MBX_EXWMS_PALDET message already sent to the WCS:
| Field | Type | Size | Offset | Value |
|---|---|---|---|---|
| MBX_RECORD_TYPE | ZONED UNSIGNED | 3 | 0 | 162 |
| MBX_DATE_TIME_STAMP | CHARACTER | 14 | 3 | DTS |
| MBX_PALLET_NO | CHARACTER | 8 | 17 | 0 |
| MBX_PALLET_LOC | CHARACTER | 10 | 25 | Pick Location |
| MBX_OWNER_CODE | CHARACTER | 3 | 35 | Stockist Code |
| MBX_PRODUCT_CODE | CHARACTER | 35 | 38 | Stock Code |
| MBX_DESCRIPTION | CHARACTER | 30 | 73 | Description of Stock |
| MBX_QUANTITY | ZONED UNSIGNED | 5 | 103 | Factor 2/3 |
| MBX_CUST_BATCH | CHARACTER | 25 | 108 | UOM |
| MBX_WMS_ROT | CHARACTER | 14 | 133 | HAZ+CHILL+MANU+SELLBY+BATCH +SEALS Required (1 character, Oracle Only) +Trace Code Required (1 character, 414 only) |
| MBX_RDT_ID | CHARACTER | 2 | 147 | Blank |
| MBX_LAST_PICK_FLAG | CHARACTER | 1 | 149 | Blank |
| MBX_STATUS_FLAG | CHARACTER | 1 | 150 | A/D/X |
| MBX_MANU_DATE | ZONED UNSIGNED | 8 | 151 | Factor 1/2 |
| MBX_PRODUCT_SELLBY_DATE | ZONED UNSIGNED | 8 | 159 | STD Pallet Qty |
| MBX_COMPANY_CODE | CHARACTER | 3 | 167 | Blank |
| MBX_WAREHOUSE_ID | CHARACTER | 3 | 170 | Blank |
| MBX_CUST_PALLET_NO | CHARACTER | 25 | 173 | BARCODE of STOCK_UOMS |
| FILLER/LONG_DESCRIPTION | CHARACTER | 40 | 198 | Blank |
| FILLER/LONG_DESCRIPTION_2 | ZONED UNSIGNED | 10 | 238 | DESCRIPTION_2 of STOCK |
| FILLER/PACK_SIZE | CHARACTER | 10 | 248 | SIZE_PACK of STOCK |
| FILLER/MEASURE_TYPE | ZONED UNSIGNED | 11 | 258 | MEASURE_TYPE of STOCK |
| FILLER/GOODS_RECEIPT_INFO_MSG | ZONED UNSIGNED | 8 | 269 | TEXT_LINE_1/2/3 of CUST_PRODUCT_TEXT |
| FILLER/DESCRIPTION_3 | CHARACTER | 40 | 277 | TEXT_LINE_1/2/3 of CUST_PRODUCT_TEXT |
| FILLER/CASE_DEPTH | ZONED UNSIGNED | 4 | 317 | CASE_LENGTH of STOCK |
| FILLER/CASE_WIDTH | ZONED UNSIGNED | 4 | 321 | CASE_WIDTH of STOCK |
| FILLER/CASE_HEIGHT | ZONED UNSIGNED | 4 | 325 | CASE_DEPTH of STOCK |
| FILLER/TERMINATOR | CHARACTER | 1 | 329 | "X" |
WHS0045 - Pallet Types Drip Feed
The Pallet Types Drip Feed message will be modified to include the dimensions of the cartons (i.e. the Pallet Types).
The following fields will be added to the MBX_EXWMS_PALTYPEUPD message already sent to the WCS:
| Field | Type | Size | Offset | Value |
|---|---|---|---|---|
| MBX_RECORD_TYPE | ZONED UNSIGNED | 3 | 0 | 271 |
| MBX_DATE_TIME_STAMP | CHARACTER | 14 | 3 | Current Date/Time |
| MBX_PALLET_TYPE | CHARACTER | 4 | 17 | PALLET_TYPE of WARE_PALLET_TYPES |
| MBX_STATUS_FLAG | CHARACTER | 1 | 21 | A/D/X, depending on status |
| MBX_COMPANY_CODE | CHARACTER | 3 | 22 | Common company code |
| MBX_WAREHOUSE_ID | CHARACTER | 3 | 25 | Common Warehouse ID |
| FILLER/PALLET_DEPTH | ZONED UNSIGNED | 4 | 28 | PALLET_DEPTH of WARE_PALLET_TYPES |
| FILLER/PALLET_WIDTH | ZONED UNSIGNED | 4 | 32 | PALLET_WIDTH of WARE_PALLET_TYPES |
| FILLER/PALLET_HEIGHT | ZONED UNSIGNED | 4 | 36 | PALLET_HEIGHT of WARE_PALLET_TYPES |
| FILLER/TERMINATOR | CHARACTER | 1 | 40 | X |
WCS-Server - Message Receipt
The WCS Server Incoming Message Processors for message types 271 and 281 will be modified to receive the new fields specified above. The message structures will be modified to hold these new fields.
WCS-Server/RDTMenu1 - Logon Request
The Logon request procedures in WCS-Server and RDTMenu1 will be modified to receive the new Owner/Warehouse rule 'Calculate Packs' in the logon message, taken from the warehouse object.
WCS-Server - Part Pick Request
When an initial Pick Request is received by the WCS Server, the process must calculate the required cartons for the tasks being assigned to the user.
The WCS Server already calculates the number of cases and units required by the tasks being assigned to the user. This code must be modified to calculate the volume required per pick task, if the new Warehouse/Owner rule 'Calculate Packs' is enabled. This will be achieved by linking to the Stock record (which it does already to calculate cases and units values).
- The Stock Case Volume will be calculated by multiplying the Case Height, Depth and Width values together.
- The Stock Unit Volume will be calculated by dividing the Stock Case Volume above by the unit to case factor (Factor_1_2 of the Stock record).
Note: These values may be calculated in advance and stored against the Stock record at the point of receiving the Stock Drip Feed message, if required.
The Pick Task Volume required for the pick task will be the number of cases required for the pick task multiplied by the Stock Case Volume, plus the number of units required for the pick task multiplied by the Stock Unit Volume.
All of these Pick Task Volumes for all tasks on the allocated pick tasks will then be summed to provide a total volume required.
The cartons required will be calculated by retrieving a list of all the potential cartons used by the operation (from the Pallet Types table, where the pallet types have dimension information only.
- The Pallet Volume will be calculated by multiplying the Pallet Height, Depth and Width values together.
Note: This value may be calculated in advance and stored against the Pallet Type record at the point of receiving the Pallet Type Drip Feed message, if required.
The records should be retrieved in Ascending Carton Volume sequence.
In order to calculate the number of cartons required, the WCS Server will loop through the Pallet Types records from smallest to largest. If the Pallet Volume is greater than the Running Total Pick Task Volume, the pallet type will be added to a Suggested Cartons list and the process will exit. If the end of the Pallet Types records is found and the Pallet Volume is not greater that the Total Pick Task Volume, the last (i.e. largest) carton will be added to the Suggested Cartons list, the Running Total Pick Task Volume will be reduced by the Pallet Volume of the last carton and the process will begin again.
The process will continue until a Pallet Volume is found that is greater than the Running Total Pick Task Volume. Every time a Pallet Type is added to the Suggested Cartons list, the process will check whether one of these pallet types has already been suggested. If not, one will be added with quantity 1. If found, the quantity will be updated by 1.
When completed, the Suggested Cartons will be placed in a string and added to the end of the Pick Reply message, so that the RDT process can extract these if necessary.
Examples:
There are 3 carton types:
- Small - can hold up to 30cc
- Medium - can hold up to 50cc
- Large - can hold up to 100cc
- If the order volume is 30cc, the system will suggest 1 small carton.
- If the order volume is 40cc, the system will suggest 1 medium carton.
- If the order volume is 60cc, the system will suggest 1 large carton.
- If the order volume is 100cc, the system will suggest 1 large carton.
- If the order volume is 110cc, the system will suggest 1 large carton and 1 small carton.
RDTMenu1 - Part Picking
When the RDT process assigns a pick to an RF user (for Actavis, this is a single order), the RF unit displays an optional summary screen, showing the total quantity of stock to be picked. Calidus Mobile will also calculate the total volume of picks on this order and display a number of suggested Carton Types (Pallet Type) capable of holding the contents of the order.
The WCS Server will send across the suggested cartons with first pick request, at the end of the Pick Reply message, as seen in the previous section.
If the new Owner/Warehouse rule 'Calculate Packs' is enabled, the screen will display the carton plus the number of this type required. The display will be before the total quantity to pick on this screen. Each carton type suggested will have its own line. The screen will display the carton type passed, ' * ' and then the number of each carton type required. The display will be as follows:
Cartons: TYPE1 * 2 TYPE2 * 1
Note: Only the initial Order Summary screen display will be modified to display this carton information - if the screen is displayed between order lines, this will not be included.
Note: If the screen display is not big enough to display this and all the other information on the screen, the screen must be modified to page the information, scrollable by the user pressing the UP and DOWN cursor keys.
Appendix A: TEST PLAN
| Test Script / Scenario Reference | Picker to select correct carton | Call Number(s): 288575 DH-8GXFKZ |
| Test Script / Scenario Description | Test the new Carton Suggestion functionality | PASS / ISSUES / FAIL |
| Menu Access | RDT Main Menu, Picking option. | |
| Pre-requisites | See the Setup section for details. | Tested By: |
| Test Objective | Test that: the new WCS rule can be set; the dimensions standing data is interfaced correctly to the WCS and; the correct number of cartons are suggested as required based on the pick tasks assigned to the user. | Date: |
| Step | Action | Result | Remarks | P/F |
| 1 | WCS Maintenance | |||
| 1.1 | Ensure that the new 'Calculate Packs' rule is available on the Warehouse and Owner maintenance screens. | The rule is available | ||
| 1.2 | Ensure that the values available are as designed, that the rule defaults correctly, that the help is as designed and that the values can be saved. | As expected. |
| Step | Action | Result | Remarks | P/F |
| 2 | Standing Data | |||
| Ensure that the RF interface is enabled. | ||||
| 2.1 | Enter dimensions against a new pallet type. Save. | The new pallet type should be created in WCS. The dimension values should be included. |
||
| 2.2 | Type 'SEND' at the Action prompt. | All pallet types should be sent to the WCS. Dimensions for those that have them should be included. Those without should be created with default value 0. |
||
| 2.3 | Enter dimensions against a stock code. Save. | The stock code should be created in WCS. The dimension values should be included. |
||
| 2.4 | Type 'SEND' at the Action prompt. | All stock codes for the owner should be sent to the WCS. Dimensions for those that have them should be included. Those without should be created with default value 0. |
| Step | Action | Result | Remarks | P/F |
| 3 | Part Picking | |||
| Create orders with two dimensioned Stock items. Ensure that each order increases in volume, one order using the smallest pallet type, one using the largest, one exceeding the largest pallet type, one requiring more that two large pallet types, one of a case volume that is less than the large pallet type, plus a unit volume that takes it over this one that spans multiple pick groups (or split the pick group manually) where one pick group requires a small pallet type and one requires a large pallet type. |
||||
| 3.1 | Start Part Picking, ensuring that the user is provided the smallest order. | The RDT will display a summary screen showing that one of the small pallet types is required to fulfil the order. | ||
| 3.2 | Complete this pick. Ask for another order, ensuring that the second order is selected. | The RDT will display a summary screen showing that one of the large pallet types is required to fulfil the order. | ||
| 3.3 | Complete this pick. Ask for another order, ensuring that the third order is selected. | The RDT will display a summary screen showing that one of the large pallet types and one other are required to fulfil the order. | ||
| 3.4 | Complete this pick. Ask for another order, ensuring that the fourth order is selected. | The RDT will display a summary screen showing that two of the large pallet types and one other are required to fulfil the order. | ||
| 3.5 | Complete this pick. Ask for another order, ensuring that the fifth order is selected. | The RDT will display a summary screen showing that one of the large pallet types and one small are required to fulfil the order. | ||
| 3.6 | Complete this pick. Ask for another order. The user will be provided the first (small) pick group. | The RDT will display a summary screen showing that one of the small pallet types is required to fulfil the pick. | ||
| 3.7 | Complete this pick. Ask for another. The user will be provided the second (large) pick group. | The RDT will display a summary screen showing that one of the large pallet types is required to fulfil the pick. |
Appendix B: Quote & Document References
 Warning: | Unknown costs for client/year (EXL/2011) |
| Cost Details | ||||
| Activity | Estimate No. of Days |
No. of Days | Rate per Day (£) | Cost (£ Exc. VAT) |
| Requirements | 0.00 | 0.00 | 510 | £0.00 |
| Change Request Evaluation | 0.75 | 0.75 | 510 | £382.50 |
| Functional Specification | 0.75 | 0.75 | 510 | £382.50 |
| Technical Specification | 0.00 | 0.00 | 510 | £0.00 |
| Development | 3.25 | 3.25 | 459 | £1,491.75 |
| Testing and Release | 1.00 | 1.00 | 459 | £459.00 |
| Implementation | 0.00 | 0.00 | 459 | £0.00 |
| TOTAL | 5.75 | 5.75 | £2,715.75 | |
| Estimate excludes training, release to live and go live support. |
B.1 References
| Ref No | Document Title & ID | Version | Date |
| 1 | EST 288575 DH-8GXFKZ Picker to select correct carton | 2.0 | 13/06/2011 |
B.2 Glossary
| Term or Acronym | Meaning |
|---|---|
| Ad Hoc | A task instigated on the device (spec. Ad Hoc Pallet Move), rather than a task instigated from the WMS and Stock Control. |
| Advice Note Number | An external reference linked to a Goods Receipt. |
| Aisle | A component of a location; usually a space through rows of racking or storage locations; a collection of locations; |
| Anchor Point | A starting location for a search for a suitable storage location; auto-putaway location suggestion start point. |
| Area | A collection of aisles; an area in the warehouse for a particular purpose. |
| Batch | A production batch of a product; a quantity of product that is considered to have the same characteristics; |
| Bay (Warehouse) | A physical loading or unloading point for the warehouse. |
| Bay | A component of a location; usually a space between uprights in racking, comprising several levels (horizontal beams). |
| Block Stack | A stable stack of pallets. |
| Bulk | Bulk storage; Usually full-pallet storage areas, racked or stacked. |
| Cancellation | The facility to cancel a task due to some problem, identified by the user when performing the task. |
| Check Digit | A short code, usually randomly generated and stored against a location, used to help identify that a user is at the right location before they proceed with a warehouse task. |
| CSV | Character-separated values; a text file with multiple rows and values, usually separated with commas. |
| C-WCS | CALIDUS WCS, the name of the OBS Logistics Warehouse Control system |
| C-WMS | CALIDUS WMS, the name of the OBS Logistics Warehouse Management system |
| Dead Leg | A movement of a truck without a pallet; wasted resource. |
| Despatch | The final physical stage of an order; handover of goods to the haulier. |
| Drive-In | A drive-in location, typically multi-level, multi-deep location. |
| Dual Cycling | Processes utilizing P&D locations for interleaving tasks in and out of specific areas, reducing dead leg movements. |
| Exchange | Specifically Pick Exchange or Task Exchange. The process of allowing a user to select a different pallet in a multi-pallet location and exchanging the expected pallet for this one. If the pallet is planned for another task, task exchange will complete this task instead of the expected one first. If the pallet is not planned, pallet exchange will swap the pallet (if suitable). |
| GR; GRN | Goods Receipt; Goods Receipt Number or Note |
| High Bay | Typically tall (greater than 5 level) racking, usually full pallet storage, usually Narrow Aisle. |
| JIT | Just In Time; processes designed to trigger at the last instant. |
| KPI | Key Performance Indicator. |
| Level | A component of a location; usually the vertical compartments of an area, delineated by horizontal beams. |
| Loading | The act of loading pallets onto a vehicle. |
| Location | A uniquely identified space in the warehouse for storage of product. There are many types, most commonly Floor locations (for example, Marshalling, Inbound), Racking or Bulk Storage Locations and Pick faces. |
| Manifest | The contents of a vehicle or container. |
| Marshalling | The act of bringing pallets for an order or load together; an area to do so. |
| Multi-deep | A location with 2 or more pallets stored sequentially i.e. only one can be accessed at a time. |
| NA | Narrow Aisle; usually any area in the warehouse that is restricted access due to space limitations, Narrow Aisles have associate P&D locations. |
| P&D | Pick-up and Drop-off locations; locations used to control the handover of pallets between distinct areas, for example between chambers and the wider area of the warehouse. |
| PI; Perpetual Inventory | The act of continuously checking locations in a warehouse, identifying and correcting product quantity issues. Usually used in Bulk environments rather than Pick Faces. In pick faces, this process is called is called Residual Stock Balance and usually takes place after picking from a pick face. |
| Pick Face | A location designed for picking part of a pallet of stock. Usually a low- or ground-level location. |
| Pick List (order) | The instructions to pick pallets or cases from locations; the paper report associated to this; the stage of preparing these instructions; the sending of these instructions to WCS. |
| PO | Purchase Order. |
| Pre-advice; Goods Receipt Pre-advice | An advanced notification of what is being received. Part of a manifest. Pre-advices can be stock and quantity, or individual pallet level. |
| Putaway | The physical move of a pallet to a storage location as a result of receiving it into the warehouse. |
| RAG | Acronym for Red/Amber/Green, a traffic light colouration system depicting (in sequence) Errors, Warnings or Informational messages. Usually used in operational monitoring to effectively display when certain processes are not working as expected. |
| RDT | Radio Data Terminal. |
| Replen; Replenishment | The act of moving product (usually a pallet) from bulk storage to a pick face. |
| Reposition | The facility to change the location of a movement or putaway when at the final destination, sue to some issue discovered when performing the task. |
| RF | Radio Frequency; An RF device is an RDT, typically used by CALIDUS WCS for executing warehouse tasks. |
| SCR; CR | Software Change Request. |
| Short Pick | The process of not fulfilling an order due to failure to identify sufficient product when picking. May also be used as a term to indicate Short Allocation. |
| SO | Sales Order. |
| Truck Types | Plants, Mechanical Handling Equipment. For example, Reach trucks, Counter-balance trucks, pallet riders, etc. |
| UOM | Unit of Measure. |
| WA | Wide Area; usually any area in the warehouse that is not restricted access due to space limitations, for example, floor areas, not Narrow Aisle. |
| WCS | Warehouse Control System |
| WMS | Warehouse Management System |
B.3 Revision History
{{#hop:1252}}
B.4 Authorised By
Phil Harding | OBS Project Manager | _____________________________ |
Darryl Horton | DHL IS Assistant Operations Manager | _____________________________ |
