Order Picking

The Order Picking feature provides picking routines to improve order book fulfillment and the management of the pick processes.

It is an extension of the multi-bin functionality that is currently available in SYSPRO.

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Exploring

A destination bin is configured as a dispatch bin (typically located in the dispatch area) and is required when you create a pick.

Once a pick is completed, a bin transfer is created (i.e. from the bin allocated against the stock code on the sales order to the destination bin entered).

This is the warehouse optionally configured to store variances arising during picking. The quantity that is short is moved to the lost and found warehouse at the time the pick line or entire pick is completed and set to C - Picked.

The lost and found warehouse is only enabled if a warehouse is defined at the Lost and found warehouse setup option and Process to lost and found warehouse is selected at the Accounting for shortages option (Warehouse Maintenance) .

This is the process of finding and extracting products from a warehouse bin to fulfill customer orders.

This is a bin transfer movement type that applies when you complete a pick. The quantity picked is transferred from the sales order bin to the destination bin.

This is a report that details the items required for picking and where to locate them.

A picking slip can only be printed once a pick has been created. Thereafter, you can print the pick at any time until it is complete.

This is a warehouse picking sequence where the picker walks down one isle and up the next, picking items along the way. The postman walk picking sequence is depicted in the image below:

A sales order may be set aside to create a pick at a later stage. These sales orders have not yet allocated stock.

You use the Pick Review program to select these sales orders (at a later stage) to create a pick.

Sales orders are used to record the sale or transfer of goods and services to both internal and external customers.

It forms a temporary legal contract between your company and the customer, as well a providing an audit trail of goods sold or transferred.

This denotes a scenario where the original quantity for a sales order cannot be satisfied with the actual quantity found in the bin, resulting in an outstanding quantity for the sales order line.

If you decide to complete this pick while there is outstanding quantity, the outstanding quantity is placed on back order.

Within SYSPRO, a warehouse represents an actual warehouse containing your inventory items (i.e. a physical warehouse) or a grouping of your inventory according to specific characteristics of the item (i.e. a logical warehouse).

For example:

You may want to split your inventory raw materials and finished goods into different logical warehouses even though they are located in the same physical warehouse.

You maintain warehouses using the Warehouse Maintenance program.

This is a warehouse picking sequence where the picker walks in a zig-zag pattern, picking from a bin in one aisle and then moving diagonally across to the next bin in the opposite isle, and so on. The Z-pick sequence is depicted in the image below.

Topics

Warehouse Management System

Setup programs

Pick Maintenance

Setup Options

Processing programs

Pick Review

Browse programs

Browse on Picks

Query programs

Pick Query

Other programs

Allocated Bins, Lots & Serials Browse

Stock Codes in Stock Take

Picking Options

PDF and Video Resources

Feature Guides

Starting

To use this feature, the following setup option(s) must be enabled:

Setup Options > Configuration > Distribution > Inventory

  • Multiple bins
  • Associate serials by bin
  • Fixed bins
  • Show Warehouses (hyperlink)
    • Picking cycle in use
    • Accounting for shortages
      • Process as stock adjustments
      • Process to lost and found warehouse
    • Lost and found warehouse

You can secure this feature by implementing a range of controls against the affected programs. Although not all these controls are applicable to each feature, they include the following:

  • You can restrict operator access to activities within a program (configured using the Operator Maintenance program).
  • You can restrict operator access to the fields within a program (configured using the Operator Maintenance program).
  • You can restrict operator access to functions within a program using passwords (configured using the Password Definition program). When defined, the password must be entered before you can access the function.
  • You can restrict access to the eSignature transactions within a program at operator, group, role or company level (configured using the eSignature Setup program). Electronic Signatures provide security access, transaction logging and event triggering that gives you greater control over your system changes.
  • You can restrict operator access to programs by assigning them to groups and applying access control against the group (configured using the Operator Groups program).
  • You can restrict operator access to programs by assigning them to roles and applying access control against the role (configured using the Role Management program).

Solving

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Using

The Sales Order Picking Cycle flow depicts the basic order picking cycle that follows a standard sales order entry (a warehouse enabled for picking is assumed).

There are many roles that perform these tasks within the overall process, each driven by specific process stages.

Process Stage Role

Order maintenance – Create pick
  • Sales order clerk

Back Order Release (order fulfillment) –Create pick
  • Sales order clerk
  • Warehouse manager

Add order release to existing pick
  • Sales order clerk
  • Warehouse manager

Monitor pick work-to-list
  • Warehouse manager

Perform / Record pick maintenance
  • Warehouse clerk

Cancel pick
  • Warehouse manager
  • Sales order clerk
  • Sales Management

Confirm pick (2nd stage)
  • Warehouse clerk
  • Dispatch clerk

Complete pick
  • Warehouse clerk
  • Dispatch clerk

The following indicates areas in the product that may be affected by implementing this feature:

This is a new program that lets you maintain picks.

This is a new program that lets you view sales order lines that have been released for picking, but not yet included in a pick.

This is a new program that lets you view pick header and detail lines.

This is a new program that lets you reserve an order for picking, create a new pick or add to an existing pick.

This is a new program that lets you view the details of picks.

This is a new program that displays the stock items that are stocked in a selected bin.

This is a new program that lets you view the lots, bin and/or serial allocations recorded in the Sales Order Entry program.

This is a new program that lets you review stock items that were placed in the lost and found warehouse during the picking process or cycle counting.

Once investigated, stock items can be adjusted or transferred to the warehouse from which it came or to another warehouse.

The following column has been added to the Warehouse Values list view:

  • Allocated to picking

The following fields have been added to the Sales Order Selection tab when selecting Preferences from the Options menu:

  • Released for picking (R)
  • In picking (P)

The following Include/exclude option field has been added to the SO Reserved Stock Review Criteria pane:

  • Lines in 'Picking' status only

The following columns have been added to the list view:

  • Lost and found warehouse
  • Picking cycle

The following fields have been added to the Warehouse Maintenance pane:

  • WMS control section:
    • Picking cycle in use
    • Accounting for shortages
    • Lost and found warehouse

The following field description has changed in the Stocked Line pane:

  • Ship quantity becomes Reserved quantity when using order picking.

The following new program can be accessed when order picking is enabled:

  • Picking Options (launched when ending the order with items from a picking enabled warehouse).

The following new programs can be accessed when order picking is enabled:

  • Pick Review (launched when allocating sales order lines to a pick).
  • Picking Options (launched when ending the order with items from a picking enabled warehouse).

A link to the Stock Codes for Bin has been added to the following field in the list view:

  • Bin

The following field has been added to the Include preferences:

  • In picking (P)
  • Released for picking (R)