Pick Exception Handling

IN THIS TOPIC

• Definitions
• Mobile Pick flow
• Alternative pick flow
• Short Quantity Mobile Pick Flow
• Halt/Resume Picks
• Additional Alerts and Notifications

Operational overview for troubleshooting picking operations when deviating from standard picking methods. including situations such as; alternative location picking, short picking, retail order pick exceptions, halting picks, and resuming picks. 

Mobile Pick Workflow

Standard Operation 

Using your mobile device, follow these steps to perform a normal pick operation.

1. On the home screen, tap Pick Goods 

2. Using the batch label generated by waving shipments, scan the batch ID barcode, as shown below

3. Proceed to system recommended location for SKU/LPN

4. Scan location barcode to initiate picking process

5. Scan SKU Barcode to add the SKU

6. Enter the Amount of UoM physically picked

7. Scan the Destination for pack station or OB staging 

Alternative Locations Mobile Pick Workflow

Alternate Locations Picking Scenarios

When it comes to picking through locations that deviate from the original system recommended location, there are several paths depending on the situation that arises . This section will provide a quick overview of the different alternate location paths before diving into a more detailed process.

Exception Path A) Location is too far away - If recommendation suggests a location that is farther away than the closest location containing SKU/LPN.

Exception Path B) SKU/LPN not found at location - If SKU systematically shows in this location through the pick recommendation, but physically is not in that location.

Exception Path C) Goods are damaged or unusable - If SKU/LPN is damaged or unusable, suggests an alternative location to pick from if available.

A) Location is too far away

1) Begin picking operation as normal

2) Tap the three dots next to recommended pick to get a dropdown.

3) Tap Location is too far away

4) Device will find alternative locations where SKU is available to pick

5) If first result isn't a desired location, Repeat process

6) If alternate location is acceptable, continue to pick location.

B) SKU/LPN is not found at location

1) Begin picking operation as normal

2) Tap the three dots next to recommended pick to get a drop down

2) Tap the three dots next to recommended pick to get a drop down

3) Tap SKU not found at location

4) Device will find alternative locations, If first result isn't a desired location, repeat the process

5) If alternate location is acceptable, Resume picking and scan the Barcode

6) Immediately inform Manager of SKU shortage at recommended location, Manager will need to perform cycle count of SKU/location

C) Goods are damaged or unusable

1) Begin picking operation as normal, as outlined in the Standard Operation section on page 3 of this SOP.

2) Tap the three dots next to recommended pick to get a drop down

3) Tap Goods are damaged/unusable

4) Device will find alternative locations, If first result isn't a desired location, repeat the process

5) If alternate location is acceptable, Resume picking and scan the Barcode

6) Immediately inform Manager of SKU shortage at recommended location, Manager will need to perform cycle count of SKU/location

Short Quantity Mobile Pick Workflow

Insufficient Quantities/Incomplete Pick

When unable to complete a batch due to a lack of inventory, complete the following steps to perform a short pick. 

1) Begin picking operations as normal, as outlined above in this SOP.

2) If there is an insufficient quantity of SKUs available at the system recommended location

Search for alternate locations that this SKU could be located in, as outlined in Alternate Pick Locations workflow.

3) If there is still an insufficient quantity of SKU available to complete pick, after performing Alternative Locations workflow, then proceed with step 4

4) Scan system recommended location where SKU is located

Enter quantities physically picked

Tap green checkmark to finish pick

Tap CONFIRM, in the Insufficient Quantity pop up on the bottom of the screen

Tap DROP OFF ITEMS on the lower bottom right hand corner of the screen to proceed to the next step

5. Continue with the pick operation as normal, Confirming Pick Incomplete upon scanning (depositing) to pack station.

6. Immediately inform the manager about insufficient quantity at the system recommended location after completing a short pick. Additional actions must be taken by warehouse management for full completion of a short pick.

Note: When completing a short pick there will be no reminder within the Flexe system that the batch remains open.

Troubleshooting/Submitting Pallet Quantity

If a pallet quantity is submitted prior to the pick, the error listed in the previous step will occur, preventing the retail order to be picked 

1) To fix this issue, you must perform the Move Goods function on the mobile device, and move the goods to an outbound staging location. This will complete the pick and allow for the parcel order to be confirmed and shipped out

2) Open the mobile device and tap the Move Goods function

3) Scan the location where the inventory is currently located

4) Scan the barcode of the item and enter the quantity picked 

5) Tap the green checkmark when the quantity has been entered 

If there are additional items to move for the retail order, repeat step 4

6. Once all items that need to be picked for the retail order, tap Put Away, and continue to step 7.

The bottom of the screen will show total number and quantity of items scanned during the move

7) Scan the Outbound location your parcel order is being staged at

8) Scan the barcode of the item and then enter the quantity that is being moved

9) Tap the Green checkmark to confirm the quantity

10) Move is finished and the parcel order can be completed in Flexe

Halt/Resume Picks

Halt Pick

A process in which a user may pause or halt a picking operation. 

1) Begin picking process as normal, as outlined in the Standard Operation, then upon reaching the Pick Goods screen proceed to step 2

2) Back out of the operation using the back arrow, selecting YES on the Halt Pick screen

In the event that you’re unable to halt please reach out to [e-mail]

Resume/Drop Off Pick

Note that resuming a halted pick will only allow the picker to deposit goods picked prior to halting the task, to resume picking the batch that was halted, follow these steps. 

1) Select Pick Goods on the home screen

2) Select Resume on the Halted Order Pick located underneath the New Pick option

3) Selecting Resume for a halted task

4) Proceed with previously picked goods to pack station,

If batch was not fully completed prior to Halting, finish depositing goods at a pack station

5) Scan (deposit) to pack station,

If batch was not fully completed, rescan batch ID and perform picking process as normal as outlined in the Standard Operation section

Additional Alerts & Notifications

Short pick & full pick notations

When using the Lookup app you can find the status of a Picked batch by scanning the barcode of the batch, it provides a color coded notation that describe the current status of the pick, 

Green is completed

Purple is in progress

Gray is not started

Common Issues

This section will describe a variety of additional alerts and notifications that may arise during the pick process. If issues or errors arise that have not been demonstrated in this scope, reach out to [e-mail].

Above maximum pick quantity/Over pick

This error can occur during the Pick Goods process when entering the quantity of an item. The system will not allow for a quantity over what was requested to be picked 

If the quantity entered matches what is being requested in the pick, and this error still occurs, reach out to [e-mail]

Cart in use

1) You will see "Cart in use" if you are attempting to pick multiple orders to the same MHE

Definitions & Abbreviations

• Batch: A grouping of shipments where products are picked in bulk quantities from warehouse locations, and then split out into individual orders at a pack station.
• Batch ID: Referring to barcode associated with the printed mobile pick list label, the batch ID is used to initiate picking operations for a batch of goods.
  
• Order: A customer request to move inventory. 
• Locations: Refers to a specific section of a warehouse, used to quickly find products.
• Drop: Refers to the systematic movement of a picked LPN to the designated preferred staging location.
• SKU: Abbreviation for Stock Keeping Unit, this is a unique identifier for an item down to size, color, and style (if applicable).
  
• LPN: License Plate Number. Unique pallet identifier used to maintain pallet information through the inventory movement process.
• Lot Code: Identification number for goods, such as an expiration date, enabling traceability within the Flexe platform for systematic driven picking logic.
  
• Mobile Device: Flexe supplied handheld unit enabling LPN picking within the warehouse.
• Pack station: A location within the Flexe system, specifically used for finishing Pick Goods operations and for initiating Scan & Pack operations.
• Move Items: The process in which, using the mobile device and scanner, to move any number of items from one location to a different location within the warehouse.
• Preferred Staging Location: A Location set up within the Flexe platform, specifically used for staging outbound orders prior to their loading for shipment.
• Shipment: Represents the movement of goods from a warehouse to their final destination. A shipment can be a single line, multiple lines, or portions of single or multiple lines.
• Deposit Goods/Put Away: A process in which an item is dropped off physically and scanned to a final location, most often a pack station during a pick.
• Pick Goods: Picking is the process of finding and extracting products from a warehouse to fulfill customer orders. Through the Flexe system this involves scanning a batch ID to direct the finding and extracting of items, from locations within the warehouse, and depositing them at a pack station. Which then, a packer will further process the order, to complete the shipment.