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Doc ID: 625609.1
Date Last Revised: 12/30/2004
Title: Pick, Pack and Ship for ERP8
Abstract: The Pick, Pack and Ship enhancement provides the ability to create and/or update Container information and Advanced Ship Notice (UCC-128) information, Shipment Pieces information, and Shipment Tracking Numbers information during Warehouse Cartonization, Warehouse Pick Confirmation, and Pack Confirmation/Carton Reorganization.
Table of Contents
Overview Process Flow Cartonization and Carton Reorganization (P4620) Carton Detail Information (F4620) Structure Shipping Carton Overview Carton Recommendation Methods for Items in the U/M Definition By Item (P46011) Carton Detail Inquiry (P4621) Carton Reorganization (P4620) Dimensionless Carton Setup UCC-128/ASN Processing Setup UPC/SCC Codes for Items Setup ASN Information for Customers Define Shipment Configurations Warehouse Setup Shipment Pieces Shipment Tracking Work With Generating Tracking Numbers Tracking Number
The Pick, Pack and Ship enhancement provides the ability to create and/or update Container information and Advanced Ship Notice (UCC-128) information, Shipment Pieces information, and Shipment Tracking Numbers information during Warehouse Cartonization, Warehouse Pick Confirmation, and Pack Confirmation/ Carton Reorganization. Pick, Pack and Ship functionality requires both the Warehouse and Transportation Management systems for the ERP 8.0 release. This enhancement was made to solve the following Picking and Shipping models: Case Picking; Pick, Pack and Ship; Pick to Ship.
Note: If using UCC-128 process to support Advanced Shipping Notice processing, please setup this process before setting up Pick, Pack and Ship. The Pick Pack and Ship can be divided into four different distinctive processes that can be used together or individually:
Cartonization and Carton Reorganization o Allow for Carton and/or Item reorganization for the shipment. o Ability to do Warehouse Cartonization to Totes. o Ability to mix different items in a carton or only allow one item per carton to support shipping items stored in the warehouse in shippable containers. o Add weight restrictions to warehouse cartonization. o Dimensionless (Generic) Cartons. Shipment Pieces o Create Shipment pieces defined as a crate or container with a Container Code and a Container ID. o Proof of Delivery by Piece is not automatic and requires a push of the information. Reference Number o Ability to automatically generate Shipment Tracking Numbers by the user’s definition. UCC128 o Ability to create and/or update Advanced Ship Notice (UCC-128) information.
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Cartonization and Carton Reorganization (P4620)
A new application, Carton Reorganization (P4620), can be used to move Items and Cartons into other existing or new Cartons and Palletize Items. This application is optional. A new table, Carton Detail Information (F4620), has been added to link together the Warehouse Suggestions (F4611), SO Pack Confirm Detail (F4216), Shipment Pieces (F4943), and Shipment Reference Numbers (F4217) tables.
Carton Detail Information (F4620) Structure
The Carton Detail Information (F4620) file contains information needed to get the Warehouse Suggestions (F4611), SO Pack Confirm Detail (F4216), Shipment Pieces (F4943), and Shipment Reference Numbers (F4217) records. It can hold any number of levels in the Carton Structure (e.g. Container - Pallet - Case - Box - Inner Pack - Items) and contains a Carton Status for each Carton. Key fields for Carton Detail Information (F4620) file: Primary Key
UKID - Unique Key ID (Assigned by the System). The F4620 Unique Key ID (UKID) and Carton ID (CRID) both come from P00022.
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CRID - Carton ID ITM - Item Number LOT - Lot Number UOM - Unit of Measure DOCO - Order Number DCTO - Document Type KCOO - Order Company LNID - Order Line Number SFXO - Order Suffix
Shipping Carton Overview
Shipping Cartons are used to ship items. The system uses the information to determine a shipping carton during carton recommendation. Container and Carton Codes (P46091) program is used to define Shipping Cartons and the gross cubic dimensions of the container. Carton Recommendation must be turned on. Methods and fill percentages can then be setup for Carton Recommendation. System Process
Steps for Setup
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Set up the 46/EQ UDC Table with all potential cartons, containers and totes. Define Shipping Carton dimensions, weight and capacity in the Container and Carton Codes (P46091) application. Turn on Carton recommendation in the Location Profile (P46020) application Set up Carton Recommendation Methods for Items in the Item unit of Measure Definition (P46011) application. Define fill percentages for items or item groups. In the Item/Carton Setup by Item or Item Group (Item unit of Measure Definition) (P46011) application. Task and Trips (P46471) Processing Options set up. Carton Reorganization (P4620) set up.
Carton Setup (P46091)
Containers/Cartons/Totes must be defined with dimensional information as they can attribute to the space availability calculation for a warehouse location. Meaning that, a container/carton/tote can take available space out of a location when the system calculates the “optimal” putaway/pick/replenish choices for product. Shipping Container is defined if the dimensions of a shipping container should be considered within the usable space available in a location; this flag must be turned on. If the flag is off, the system will ignore the dimensions. For example, a pallet will take up some of the usable space in a location so it would need to be considered if putting away the product on a pallet in a location. If using cartons the Shipping Y/N flag must be set to Y for cartons, otherwise the system will use the setup for containerization Tote Container designates whether a shippable carton or a tote will be recommended Available Carton enables the system to suggest cartons/totes when picking. The Shipping Container flag must also be set if planning to ship out this carton as well.
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Dimensions – Physical dimensions of carton/tote. Cubes– System calculated once the dimensions are entered. Weight – The weight of one empty storage container/shipping carton. The system will add this weight to the weight of the item. Maximum Weight – The weight limit that carton/tote can hold. Tolerance – Tolerance indicates the minimum and maximum percentage the carton should be filled for shipping. This is used with shipping carton s. Ship Priority – Shipping priority is used to determine which carton it should consider 1st, 2nd, 3rd, etc. in carton recommendation. Priority 1 to largest, it will have system look from large to small. This is used with shipping carton s. Shipping Container/Tote Container – Designates whether unit is internal or shippable. This is an either/or setting and should say Carton, not Container. o (YES = Shipping Carton and Storage container) o (NO = is only a storage container) Available Carton – (Shipping Carton) Designates if the unit is available for shipping recommendation in the Carton Selection process. Create UCC128. Dimensionless Carton.
Location Profile (P46020) Turn on Carton recommendation in Location Profile (P46020). To enable carton recommendation the recommend Carton flag needs to be checked for this specific location. Based on the Picking instruction, the carton recommendation flag should be turned on for all the picking locations.
Carton Recommendation Methods for Items in the U/M Definition By Item (P46011)
Assign Carton Recommendation Method:
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Carton Rcmd Method blank = none Carton Rcmd Method Set to 1 = Volume based o Base recommendation on the Volume of the item and shipping carton. Carton Rcmd Method Set to 2 =Percent based o Base recommendation on the Percentage of the carton the item will occupy. When using fill percent the system does not use FC at all. Note: Examples use Percentage Based.
The maximum capacity of the shipping carton will be determine by the Carton Rcmd Method:
If method one is selected then the system will compare the volume of the Item UOM (P46011) to the volume of the Carton (P46091) and based on this it will allow certain number of Item into the carton.
If Carton Rcmd Method is selected to 2, then the system will allow certain number of Items based on the set up on the Item/Carton Set up By Item/Group program (P46013).
Item/Carton Set up by Item (P46013) Define fill percentages for items or item groups, in the Item/Carton Setup by Item or Item Group (P46013) program off menu G46311. Fill in the Container Code if the storage container needs to be considered as part of the item dimension, i.e. the item will be in a storage container when it is picked to be shipped. Example
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The carton can be field up to 100% (4 EA). 25% means this item takes up (fills up) 25% of the carton. This indicates how much a single quantity of the UOM including a Storage Container will take up in the carton.
Task and Trips (R46471) Processing Options
Processing Options for the Task and Trips (R46471) UBE have to be set to perform Carton Recommendation and to create carton details. Location Selection Driver (R46171) calls a version of Task and Trips (R46471) to perform carton recommendation. o Carton Recomnd Tab: Set to processing option #1 to a value of '1'.
Carton Detail Tab o Set to processing option #1 to a value of '1' and enter in the Version of the Carton Reorganization (P4620) in processing option #2.
Processing Options for Cartonization (P4620) When suggestions are created the Task and Trip Creation (R46471) calls a version of the Carton Reorganization (P4620) program that will create carton details into the Carton Detail Information (F4620) table. To test the basic carton detail operations, assuming that UCC-128 numbers will not be generated, Shipment Pieces will not be created and a Reference Number will not be originated. The first three options on the Process tab should be blank, and the rest of the tabs should be set up as follow:
With Pick, Pack and Ship, Cartons can have four different statuses (10, 20, 30 and 40). These statuses will be updated according to the Processing Options in the Status Tab of the Carton Reorganization (P4620). Note: Carton Status 40 is designed to be used only by an external EnterpriseOne process.
Basic Cartonization and Carton Detail Example The following example is to show the results of the basic cartonization and carton detail process. A sale order is entered when the shipment is approved the warehouse request is also generated.
On the report generated by the Move Slips (R46472) notice that two cartons (CTN1 with 17 EA on it and CTN3 with 3 EA) were recommended for the order. First Move Slip (R46472) shows Carton CTN1 used up to its maximum capacity and one task will be generated for each carton (17 EA).
The second Move Slip (R46472) shows a second carton recommended with the remaining quantities on the Sales Order (note that since there are only 3 EA left, the system recommends a smaller carton).
System Considerations The system will process lines on a sales order as follows. It will take the first line put it to the 1st sequence number carton. It will go to the 2nd line of the order and if the system is looking at the same box the system will attempt to put it into that carton. If it fits it goes to the third line to process. If the second line doesn’t fit, the system takes that line from the first box and goes to the next carton. The first box will have the first item and then the system will attempt to downsize the box. The system also does not use tolerances as hard rules. For example, if a box is 100 Cubic inches large and the minimum percent setup is as 85% and the next largest box is 50 cubic inches, there is a gap between the 2 boxes. If an order comes through that is for 60 cubic inches, the system will suggest the largest carton even though it is below the minimum tolerance. It is advisable that the minimum tolerance for a box overlaps the maximum tolerance for the next largest box.
Carton Detail Inquiry (P4621)
When Carton Reogranization (P4620) creates carton detail the system populates those details into the Carton Detail Information (F4620). Carton Detail Inquiry (P4621) is designed to inquire on a particular order or shipment and to display all the details for each individual carton.
Drill down on Carton Detail to display items in the Carton.
Carton Detail Inquiry (P4621) allows the details on the Carton Detail Information (F4620) to be inquired only, and no changes are allowed at this point. In order to make changes the online version of the Carton Reorganization (P4620) can be used.
Carton Reorganization (P4620)
Reorganization is done by Shipment Number, and Pick Confirm (P4617) must be complete to see the 'carton' in the application. A Tree Structure is used for easy reorganization. This program allows for changes to be made to each detail, Items can be reorganized into different cartons, combined into one carton, or even can be moved out of a carton.
This application also allows the UCC-128 information to be manually entered or automatically entered if the check boxes are enabled (UCC-128 must be setup for this process to be automatic).
As an example of reorganization a new carton is added and some Items moved into this new carton.
Carton CNT2 is added and then 10 EA are moved into the carton
The Confirm form exit has to be taken in order to accept the changes. Confirm the reorganization of the cartons move in Carton Reorganization (P4620) to move the status to 30 (according to the Processing Option behind the Carton Reorganization (P4620) program) and shipments can then be confirmed. The reorganization process is not mandatory and shipments can be confirmed without changes to cartons or carton statuses.
Dimensionless Carton Setup
In the Carton Code (P46091) program, Containers/Cartons/Totes do not have to be defined with dimensional information, if they do not attribute to the space availability calculation for a warehouse location. The dimensionless carton will automatically take the dimensions of the Item UOM set up in Item Unit Of Measure Definition (P46011), in this case carton CTON will take the dimensions of 1 CA of Item MB2.The same carton can be use for different Items and different UOM using the Item UOM dimensions.
In the Item/UOM Definition (P46011) program set up Container Code field with the Dimensionless Carton Code only at the UOM level the Item will be stored in. By putting CTON in this field, item MB2 will be stored in the warehouse in this container. This is typically where the 'OWN' container is defined for 'case pick'. Most of the time, if a container code is defined here, Carton Rec Method should be left blank. This a 1 to 1 match, only 1 CA of MB2 is stored in a CTON carton.
Create UCC-128 is optional.
Carton Detail Inquiry (P4621)
When a dimensionless carton is used the carton information will not be stored in the container field on the Warehouse Suggestions (F4611) table and will not be displayed on the Move Slips (R46472) as in Carton Recommendation. The carton information however will be obtainable in the Carton Detail Inquiry (P4621) program and it will be available for reorganization on the Carton Reorganization (P4620) after the suggestion has been confirmed in the Warehouse Movement Confirmations (P4617) program.
On this example the system assigns one CTON carton code per each CA of Item MB2 and after Pick Confirmation (P4617) the order is ready for Carton Reorganization (P4620) or to be Ship Confirmed (P4205) with no changes.
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The process of using Advanced Ship Notices (ASN) in conjunction with serialized shipping container labels is commonly known in the retail industry as UCC128 compliance. An Advanced Ship Notices (ASN) is an EDI document sent by the supplier to the customer when goods are shipped. It identifies what was shipped and how it was shipped. This EDI transaction in combination with a bar coded serialized shipping container label (applied by the supplier prior to shipment), automates the receipt process. As the retailer receives the goods, the shipping labels are scanned and then matched to the Advanced Ship Notices (ASN) to generate internal transaction records.
Set Up UPC/SCC Codes for Items
To identify items for Advanced Ship Notices (ASN) purposes based on UPC/SCC codes. A Universal Product Code (UPC) identifies the lowest saleable unit of a specific product (usually the primary unit of measure).The UPC code is the same as an European Article Number (EAN), the two codes are interchangeable. A Shipping Container Code (SCC)
identifies an “intermediate pack” of a specific product. These codes are fixed and are either pre-printed on the product or applied as a label. UPC information is held in the Item Master Tag (F4101T) file in the UPC Number (UPCN) data item. Set up UPCs/SCCs for items in Item Master Information (P4101) and take the Storage/Shipping row exit.
Each item can have only one UPC and up to 8 SCCs, which are optional (PI=1 through PI=8). UPCs are formatted such that the first 7 digits represent the company that produces the product, the next 5 digits represent the product ID, and the last digit is a system assigned check digit. For example, the UPC for MB2 is 1111111555552 Before entering a UPC for an item, the product company must be set up in the 41/UC UDC table. An item can have up to 8 SCCs, each of which represents a different Unit of Measure (UOM), or Packaging Indicator (PI). When entering a UOM, the system automatically assigns the SCC. Note in the screen print above that the SCC is the same as the UPC,
only the SCC has an extra digit on the front, and the last digit is different. The first digit represents the packaging indicator (PI) for the item. The first digit for SCC (PI = 1) will always be 1, for SCC (PI = 2) 2, and so on. The system calculates the check digit at the end of the SCC. UPC information for specific items is held in the Item Master (F4101) table.
Set up ASN Information for Customers
Before transmitting ASNs to customers, applicable information for each customer needs to be set up. Set up a default shipment configuration and shipping requirements for each customer in Customer Ship Notice Tab of the Customer Billing Instructions.
Set up a default hierarchical configuration to indicate how shipments are configured to the customer. The default can be a “Pick_Pack” configuration, which allows for any combination of products to be present in a shipment, or a “Standard Carton” configuration, which requires that only a single item be present. Indicate required shipping information for each customer for each line of business (i.e. Company).
Define Shipment Configurations
All hierarchical configurations must be defined in Hierarchical Configuration Definition (P47HL) off menu G47215. The hierarchical configuration is defaulted from the ship to address, if one is not found for the ship to then it will default from the sold to address.
To define a configuration, indicate which file field corresponds to each level in the configuration. For example, if the configuration is S O T P I (shipment, order, tare, pack, item), SDCDCD is the field in the Sales Order Detail (F4211) record that contains the shipment number for an order line. SDDOCO is the field in the Sales Order Detail (F4211) record that contains the order number. XDPLT is the field in the SO Pack Confirm Detail (F4216) record that contains the Tare number for a shipment, and so on. Define configurations by address number, or enter zero in the address book field to indicate that a particular configuration definition is applicable to all address numbers.
Warehouse Set up
The field ‘Create UCC-128’ must be flagged for every Item/UOM combination for which UCC-128 creation is needed in the U/M Definition by Item (P46011) program.
The field ‘Create UCC-128’ must also be flagged in the Container and Carton Codes (P46091) program for every Carton for which UCC-128 creation is needed.
Carton Reorganization (P4620) Processing Options
When Carton Reorganization (P4620) is run from the Task and Trip Creation (R46471) UBE or the Warehouse Movement Confirmations (P4617) application populate the appropriate UCC-128 information in the SO Pack Confirm Detail (F4216), Carton Detail
Information (F4620) and Shipment Pieces (F4943) and can be seeing online through Carton Reorganization (P4620), Carton Details (P4681), and Work with Shipments (P4915). Carton Reorganization (P4620) at reorganization time will look like the following:
Tables showing all the ASN numbers, SCC number is blank because the order was created only for EA
If UCC-128 was not generated through the Task and Trip Creation (R46471) UBE or the Warehouse Movement Confirmations (P4617) application, the same information can also be added manually to cartons/containers added from the Carton Reorganization (P4620) screen.
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Prior to Pick, Pack and Ship the shipment pieces and all the details had to be manually generated through the Work with Shipments (P4915) application. With Pick Pack and Ship the system can automatically generates shipment pieces through Carton Reorganization (P4620) based on the carton details on the Carton Detail Information (F4620) table. Carton Reorganization (P4620) will update the Container ID in the Shipment Pieces (F4943) record if the processing option is set to update. In order to create Shipment Pieces the processing option for “Transportation Shipping Pieces” behind the Carton Reorganization (P4620) called from the Task and Trip Creation (R46471) UBE or the Warehouse Movement Confirmations (P4617) application needs to be flag with a “1”.
The Number of Pieces is the total number of Shipment Pieces (F4943) records for that shipment. A shipment piece is considered the largest shipping unit. If Carton Detail Information (F4620) table contains several carton details and during the reorganization process all the containers are placed into a pallet, then the pallet will be counted as one shipment piece, hence only one record will be written the Shipment Pieces (F4943) table. In this example, one shipment has several Items per container code and all these boxes were set on a pallet at reorganization time.
Task and Trip Creation (R46471) originally suggested 3 pieces (container ID 611, 612 and 613).After Pick Confirmation (P4617) a new pallet was added and all the boxes were placed on it using the reorganization version of the Carton Reorganization (P4620) application. Row exit to shipment pieces from Work with Shipments (P4915) will show the information in the Shipment Pieces (F4943) table.
Note that the pallet code starts with the sequence number 4, since sequence 1, 2 and 3 were replaced by the pallet sequence during Carton Reorganization (P4620).
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With the Pick, Pack and Ship enhancement, functionality has been added to automatically generate Shipment Tracking numbers. In order to generate Shipment Tracking Numbers for Shipment Pieces, both Processing Option flags, shipment pieces and shipment tracking numbers, must be turned on behind Carton Reorganization (P4620).
Since there is a wide variety of tracking numbers that can be used in the transportation industry, the user has the ability to control the type and structure of the tracking number that is generated.
Work With Generating Tracking Numbers
The Work With Generating Tracking Numbers (P49005) program allows the user to enter specifications for each individual segment of the tracking number generated. A tracking number can consist of one or many segments. Individual tracking number generation specifications for each carrier and mode of transportation must be set up. Fields to activate:
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Carrier Number: Must be setup for each carrier. Mode of Transport: The specific mode the carrier provides (e.g. LTL). Document Code: Document to print this number on. (Optional) Sequence Number: Defines the order of the segments if there is more than one. Tracking Segment Length: Defines the number of digits selected for each segment. Each segment will be part of the final number and can be set up with up to six different Tracking Segment types: 1. Hard Coded: A value must be entered in ‘Hard Coded Value’ field. 2. Lookup Type: A value that will select a code from the 49/TL UDC table.
3. UDC Table: User defined UDC table, requires selection of one of 4 values: Carrier, Mode of Transport, Document Code, or Origin Address Number. 4. Next Number: Requires a next number to be set up. Cannot exceed 8 digits. 5. Check Digit: Calls a custom check digit business function. Must be the last segment and 1 digit in length. 6. External Function: A custom Business Function can be called. In the following example, the Tracking number for carrier 8571 will be produced by three different segments: a hard code value (1Z), a look up type (Carrier Number) and a 4 digits Next Number.
From Work With Generating Tracking Numbers (P49005) update the location of separators for the tracking number for label generation with the separator specified. The separator is a character value or blank space that will be stored and used ONLY during the label generation. Separators are optional.
Since next number makes up the third segment, the Tracking Number Next Number also has to be set up.
Work With Tracking Segments Next Number (P490052) is the program that will generate the last part of this example’s Tracking Number. If next numbers are going to be part of the Tracking Number most likely Carriers will provide with a valid next number range and valid expiration date
After the Carton Reorganization (P4620) is run, the reference number and the qualifier will be updated on the Shipment Reference Numbers (F4217) records. Reference qualifier is simply a value from the 41/X6 UDC table that describes the type of reference number (B/L, AWB, Shipping Label, etc.).
The Shipment Tracking number will appear in the Reference Number field in the Shipment Pieces Revision (P4915) application. Note that there are no separator characters displayed in this application, the separator characters are ONLY used for Shipping Labels.
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