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TLIA 1207C *

MC #

Armstrong’s*Driver*Education *

*

Learner*Guide *

TLIA 12 07C * MC # Armstrong’s*Driver*Education * * Learner*Guide *

Pick*and*process*orders**

TLIA 12 07C * MC # Armstrong’s*Driver*Education * * Learner*Guide * Pick*and*process*orders **

TLIA1207C Pick and process orders

Contents

What this Learner’s Guide is about

4#

Planning your learning

5#

How you will be assessed

8#

Section 1

10#

How are customer orders received?

10#

Section 2

18#

Where is stock located?

18#

Section 3

22#

What are the principles of Occupational Health and Safety?22#

Section 4

36#

How is stock picked?

36#

Section 5

46#

How are picked stock items checked?

46#

Section 6

52#

What are the methods used to replenish stock levels?

52#

Additional resources

62#

Feedback on activities

64#

TLIA1207C Pick and process orders

What this Learner’s Guide is about

This*Learner’s*Guide*is*about*the*knowledge*and*skills*you*require*to* pick*and*process*orders*in*accordance*with*workplace*requirements* include:*identifying*workplace*orders,*picking*processes,*policies*and* procedures,*picking*and*despatching*orders,*and*recording*stock* levels.** *

The*activities*are*designed*to*give*an*opportunity*to*practise*and* demonstrate*your*skills*and*knowledge. *

The*Elements*of*Competency*from*the*unit* TLIA1207C *Pick*and*process* orders*covered*in*this*Learner’s*Guide*are*listed*below. *

Identify*workplace*order*picking*processes,*policies*and*procedures*

Pick*and*despatch*an*order*

Record*stock*levels *

This*unit*of*competency*is*from*the*Transport*and* Logistics *Training* Package*(T LI07). *

*

TLIA1207C Pick and process orders

Planning your learning

It*is*important*to*plan*your*learning*before*you*start*because*you*may* already*have*some*of*the*knowledge*and*skills*that*are*covered*in*this* Learner’s*Guide.*This*might*be*because: *

you*have*been*working*in*the*industry*for*some*time,*

and/or*

you*have*already*completed*training*in*this*area. *

Together*with*your*supervisor*or*trainer*use*the*checklists*on*the* following*pages*to*help*you*plan*your*study*program.*Your*answers*to* the*questions*in*the*checklist*will*help*you*wor k*out*which*sections*of* this*Learner’s*Guide*you*need*to*complete. *

This*Learner’s*Guide*is*written*with*the*idea*that*learning*is*made*more* relevant*when*you,*the*learner,*are*actually*working*in*the*industry.* This*means*that*you*will*have*people*within*the*enterprise*who*can* show*you*things,*discuss*how*things*are*done*and*answer*any* questions*you*have.*Also*you*can*practise*what*you*learn*and*see*how* what*you*learn*is*applied*in*the*enterprise. *

If*you*are*working*through*this*Learner’s*Guide*and*have*not*yet*found* a*job*in*the*industry,*you*will*need*to*talk*to*your*trainer*about*doing* work*experience*or*working*and*learning*in*some*sort*of*simulated* workplace.* *

TLIA1207C Pick and process orders

Section 1: How are customer orders received?

Are*you*able*to:*

1. identify*how*warehouses*receive*orders**

Yes $

No$

 

from*customers?*

*
*
*
*

2. list*in*order*of*frequency*how*your*

 
 

warehouse*receives*each*type*of*customer*

order?*

*
*
*
*

3. describe*the*most*important*pieces*of* information*on*customer*orders? *

 
*
*
*
*

Section 2: Where is stock located?

 

Are*you*able*to:*

 

Yes $

No$

1.

locate*stock*items*in*your*warehouse*

without*assistance?*

*
*
*
*

Section 3: What are the principles of Occupational Health and Safety?

Are*you*able*to:*

Yes $

No$

1. describe*the*basic*occupational*health* and** safety*(OHS)*rules? *

*
*
*
*

2. list*the*OHS*rules*used*in*your*warehouse? *

*
*
*
*

Section 4: How is stock picked?

Are*you*abl e*to:*

Yes $

No$

1. tell*someone*how*stock*items*are* recognised*in*most*warehouses? *

*
*
*
*

2. list*the*information*that*is*commonly*

stored*on*stock*labels*for*all*stockgroups*in*

your*warehouse?*

*
*
*
*

TLIA1207C Pick and process orders

Section 5: How are picked stock items checked?

Are*you*able*to:*

1. describe*the*methods*used*in*your*

Yes $

No$

warehouse*to*check*that*the*stock*items*

you*have*picked*are*correct?*

*
*
*
*

2. use*a*warehousing*record*system*to* confirm*that*picked*stock*items*have*been* correctly*deducted*from*stock*holdings? *

*
*
*
*

Section 6: What are the methods used to replenish stock levels?

Are*you*able*to:*

1. describe*how*a*warehouse*usually*

Yes $

No$

replenishes*its*stock*levels?*

*
*
*
*

2. replenish*stock*levels*accurately*in*your* warehouse? *

*
*
*
*

TLIA1207C Pick and process orders

How you will be assessed

Assessment*of*this*Unit*of*Competency*will*include*observation*of*real* or*simulated*work*processes*usi ng*workplace*procedures*and* questioning*on*underpinning*knowledge*and*skills.*It*must*be* demonstrated*in*an*actual*or*simulated*work*situation*under* supervision.*

You*will*be*required*to: *

state*how*to*identify*required*stock*items*from*a*customer*

order**

demonstrate*how*to*safety*lift*stock *

pick*stock*items*against*a*customer*order*

identify*storage*locations*to*replenish*reserve*stock*areas. *

TLIA1207C Pick and process orders

TLIA1207C Pick and process orders

Section 1

How are customer orders received?

TLIA1207C Pick and process orders

Section outline

Areas$covered$in$this$section $

Sources*of*customer*orders *

Information*included*on*customer*orders *

TLIA1207C Pick and process orders

How are customer orders received?

Your*warehouse*will*probably*receive*orders*from*customers*in* different*ways.*How*often*this*happens*and*the*method*will*depend* on*the*type*of*warehouse*and*its*functions.*For*example,*food*is* usually*ordered*often*and*delivered*quickly,*especially*if*it*is* perishable.*Items*like*furniture*will*usually*be*ordered*in*quantities* that*make*large*deliveries*more*cost*effective.*No*matter*how*an* order*comes*into*your*warehouse,*there*wi ll*be*certain*information*on* the*order.*This*information*will*be*very*important*to*you*and*your* workmates*so*that*you*can*process*the*order.*

Some*warehouses*have*customer*service*departments*that*receive* orders*from*customers*and*process*them*onto*computer s.*In*these* situations,*storespersons*will*only*use*the*paperwork*from*the* computer,*and*will*rely*on*other*departments*to*make*sure*that*the* information*is*correct*on*each*order.*

This*section*provides*activities*in*understanding*how*your*warehouse* receive s*its*orders*and*the*most*common*types*of*methods*involved. *

TLIA1207C Pick and process orders

Activity 1: How does my warehouse receive orders?

In the spaces provided, write down the different ways in which your warehouse can receive customer orders.

List them in order of frequency, with the most common first and so on.

1.

2.

3.

4.

5.

TLIA1207C Pick and process orders

What important information is usually found in a customer order?

A*customer*order*will*contain*many*pieces*of*information.*The*type*of* things*written*on*customer*orders*will*be*different*depending* on:*

what*is*being*ordered *

from*where*it*is*being*ordered*

where*it*will*be*delivered *

when*it*will*be*delivered*

how*it*will*be*delivered. *

However,*each*customer*order*will*contain*a*few*key*pieces*of* information*which*will*easily*identify*an*order.*These*wil l*be*important* when*you*and*your*workmates*need*to*locate*and*refer*to*each* particular*customer*order. *

TLIA1207C Pick and process orders

Activity 2: What is the key information on a customer order?

Look at the following example of an order that could have entered your warehouse.

Bloggs and Co. Stationers

‘Your Write With Us’

Bloggs and Co. appear on Accounts Dept. shipping 4 th Floor, Stamford Trading House

PURCHASE ORDER

The following number must

all related correspondence,

papers, and invoices:

190 Canterbury Road Brighton TAS 7600

Reference Number: 509 356

Phone: (03) 6245 6999

TO:

Aust. Warehouse Co. Accounts Dept. Aust. House Tottenham Road FOOTSCRAY WEST VIC 3012

SHIP TO:

Bloggs and Co. Unit 2 Latrobe Training Estate EAST BRIGHTON TAS 7610

ORDER DATE

ORDER NO.

 

SHIP VIA

TERMS

   

QUANTI

PRODUC

UNIT

 

DESCRIPTION

UNIT

TOTA

TY

T

 

PRICE

L ($)

CODE

($)

8

P801258

PACKET

 

Paper 80gsm White

$6.87

$54.96

2

OHP5978

BOX

 

Pens black OHP perm

$2.20

$4.40

10

AB1385

 

1 Diary A4 week plan

 

$5.50

$55.00

1

W98765

 

1 Wall year planner

 

$10.12

$10.12

       

TOTAL

$124.48

 

TLIA1207C Pick and process orders

In the spaces below, list the most important pieces of information contained in that order, starting with the most important first.

You may need to discuss this with workmates or your trainer.

Reference number

Order number

Product codes

Product description

Customer telephone

There is feedback on this activity at the back of this Learner’s Guide.

TLIA1207C Pick and process orders

TLIA1207C Pick and process orders

Section 2

Where is stock located?

TLIA1207C Pick and process orders

Section outline

Areas$covered$in$this$section $

Stock*systems*

TLIA1207C Pick and process orders

Where is stock located?

Stock*is*located*in*many*different*areas*of*a*warehouse.*Often*the* areas*are*chosen*so*that*similar*items*of*stock*can*be*stored*close*to* one*another.*At*the*same*time,*items*that*are*linked*on*customer* orders*may*be*stored*close*to*each*other.*Your*warehouse*will*have* planned*these*areas*so*that*the*processes*involved*in*picking*and* processing*orders*are*completed*as*easily*and*efficiently*as*possible.** These*processes*include: *

finding*stock*

picking*stock*

dispatching* orders*and**

replenishing*stock*levels. *

Some*stock*is*regarded*as*dangerous*or*hazardous.*These*items*are* placed*into*groups*called*Classes*of*Dangerous*Goods.*These*Classes* define*the*special*ways*that*dangerous*and*hazardous*stock*must*be* handled,*stored* and*transported.*Your*company*will*have*specially* chosen*employees*to*work*with*this*stock.*They*will*make*sure*that*

items*of*this*type*are*stored*in*safe*and*secured*areas,*where*they*will*

not*be*touched*by*people*who*do*not*know*how*to*correctly*handle*

t hem.*These*areas*are*also*chosen*so*that*any*accidents*with*

dangerous*or*hazardous*stock*will*cause*the*least*possible*damage. *

Valuable*stock*is*usually*locked*in*secure*areas,*so*that*it*can*be* protected*from*thieves.*When*locked*away,*only*those*storespe rsons* who*have*permission*to*handle*that*stock*will*be*allowed*to*enter* those*areas.*

You*will*have*to*learn*stock*locations*for*items*with*which*you*usually* work.*You*will*also,*of*course,*be*required*to*strictly*observe*all* company*rules*about*stock*handl ing*and*security.*

*

TLIA1207C Pick and process orders

Activity 3: How are stock items stored in a warehouse?

Look at the following picture of a typical warehouse stacking system.

following picture of a typical warehouse stacking system. Match the correct description against the number that

Match the correct description against the number that is given on the picture.

Description

Number

Row

Stack

Shelf

Level

Bin

There is feedback on this activity at the back of this Learner’s Guide.

TLIA1207C Pick and process orders

Section 3

What are the principles of Occupational Health and Safety?

TLIA1207C Pick and process orders

Section outline

Areas$covered$in$this$section $

Correct*lifting*and*moving*of*stock*items*

TLIA1207C Pick and process orders

What are the principles of Occupational Health and Safety?

The*three*main*principles*in*OHS*are: *

a. identify*the*risks*

b. assess*the*risks*

c. control*the*risks. *

OHS*is*very*important*in*every*workplace.*The*three*principles*must*be*

followed*at*all*t imes,*so*that*accidents*are*avoided.*In*1994,*workplace*

accidents*in*Australia*cost*$200*million*in*lost*production.*Back*injuries*

were*the*most*frequent*results*of*these*accidents.*Every*workplace*

must*pay*a*workers’*compensation*insurance*premium*to*cove r*the*

costs*of*these*accidents.*The*average*cost*of*workers’*compensation*

insurance*is*$10*000*for*each*workplace. *

When*you*handle*stock,*you*must*make*sure*that*you*do*not*lift*items*

which*you*think*are*too*heavy*for*you.*You*should*always*use*

mechanical*lifting*aids*whenever*possible.*In*this*way,*you*will*follow*

good*OHS*practices*and*avoid*injuries. *

Look*at*the*following*pictures.*They*show*you*how*to*correctly*lift*

objects,*making*sure*that*back*injuries*are*avoided. *

*

*

* * * *
*
*
*
*

*

Incorrect* Bending*&*Lifting *

TLIA1207C Pick and process orders

* * * *
*
*
*
*

Correct*Bending* &*Lifting *

TLIA1207C Pick and process orders

*

* * * Unsafe*a *Too* heavy * * * * * * * Use*mechanical* aids*when*lifting*
*
*
*
Unsafe*a *Too*
heavy *
*
*
*
*
*
*
Use*mechanical*
aids*when*lifting*
heavy*objects*
*
* * * * * Avoid*above*shoulder*reach * Avoid*forward*bending*of*the* back * * * * * *
*
*
*
*
*
Avoid*above*shoulder*reach *
Avoid*forward*bending*of*the*
back *
*
*
*
*
*
*
*

Avoid*twisting*of*the*back *

*
*

Avoid*sideways*bending*of*the* ba ck *

TLIA1207C Pick and process orders

Some*of*the*symbols*you*may*see*in*your*warehouse*are*on*the* following*pages.*These*tell*you*how*you*should*handle*stock*items*in* the*warehouse.*They*are*good*tools*to*use*in*achieving*good*OHS. *

*

THIS$ WAY$UP $

FRAGILE $

Your*warehouse*may*store*haza rdous*or*dangerous*goods.*In*these* cases,*goods*packages*will*have*warning*signs,*similar*to*the*examples* below,*attached*to*them.*If*you*do*not*understand*these*signs*and* similar*diagrams*in*your*warehouse,*ask*your*trainer*for*help. *

* * * * *
*
*
*
*
*

TLIA1207C Pick and process orders

*
*
*
*

*

*

Activity 4: What are the things to be considered when assessing the load to be moved?

Write below some of the OHS methods that you should think of when stock items are to be moved.

TLIA1207C Pick and process orders

There is feedback on this activity at the back of this Learner’s Guide.

TLIA1207C Pick and process orders

The*range*of*items*that*you*may*be*required*to*lift*or*move*will*vary.* You*must*know*the*precautions*you*should*take*when*lifting*stock* items,*so*that*you*prevent*i njury*to*your*workmates*and*yourself.*You* should*never*attempt*to*lift*stock*without*first*considering*whether*it* will*be*safe*to*do*so.*

Workplace*accidents*and*workers’*compensation*claims*are*very*high* in*Australia.*Many*of*these*result*from*poor*lifting*practices.*When*you* move*or*lift*stock*items,*your*company*will*expect*you*to*use*correct* lifting*practices.*If*you*are*unsure*of*how*to*move*or*lift*stock*items,*or* if*you*are*unsure*of*your*physical*ability*to*lift*or*move*them,*you* should*ask*your*trai ner*or*your*workmates*for*help. *

TLIA1207C Pick and process orders

Activity 5: What precautions should I take when lifting stock items?

Write down in the spaces some of the things you must remember to do when you have to manually lift or move stock.

There is feedback on this activity at the back of this Learner’s Guide.

TLIA1207C Pick and process orders

You*will*need*to*use*different*lifting*methods*or*equipment*to*lift* different*stock*items.*You*should*work*out*the*amount*of*assistance* or*choose*the*correct*lifting*equipment*before*you*start*lifting*any* stock.*When*doing*this,*you*should*take*into*account*the: *

weight *

size*

shape*

contents**

possible*movement*of*the*load. *

You*must*think*about*your*own*strength*and*lifting*ability,*and*the* amount*of*help*you*may*need*and*how*quickly*you*c an*get*it.*

TLIA1207C Pick and process orders

Activity 6: How should I correctly lift packages of different weights, shapes and sizes?

Look at the table of stock items on the following page.

In the last column, write the most appropriate lifting method for each item.

Choose the lifting method from the list below:

Forklift truck

hand trolley

manually (assisted)

manually (alone)

authorised personnel.

TLIA1207C Pick and process orders

Item

Weight

Shape and size

Description

Method

Reams of

15

kg

Rectangular box

Reams of 15 kg Rectangular box  
 

paper

 

30cm x 20cm x

45cm

Filing cabinet

25

kg

Rectangular box

Filing cabinet 25 kg Re ctangular box  
 

(2 drawer)

 

45cm x 60cm x

75cm

Desk

20

kg

Rectangular

Desk 20 kg Rectangular  
 
 

200cm x 130cm x

100cm

Photocopier

60

kg

Cubic

Photocopier 60 kg Cubic  
 
 

150cm x 150cm x

150cm

Poison

10

kg

Container

Poison 10 kg Container  
 
 

20cm 2 x 50cm

There is feedback on this activity at the back of this Learner’s Guide.

TLIA1207C Pick and process orders

Ask your trainer to select some stock items that weigh between 10kg and 25kg.

You are required to move these items from one location in your warehouse to another.

Your trainer will observe you doing this task, and check that you used correct OHS lifting techniques.

Remember to work out if you are strong enough to lift the stock items, and make sure that you bend and lift correctly, and avoid twisting your spine. Your trainer will also make sure that any lifting equipment you chose for this task was safely and properly used.

TLIA1207C Pick and process orders

Section 4

How is stock picked?

TLIA1207C Pick and process orders

Section outline

Areas$covered$in$this$section $

Stock*units *

Stock*labels

TLIA1207C Pick and process orders

How is stock picked?

Stock*items*stored*in*warehouses*vary*greatly.*However,*all*stock* items*will*have*a*label*attached*to*them*which* gives*information*about* their*contents*and*location.*Labels*may*be*similar,*even*though*they* are*attached*to*items*of*different*size,*weight,*shape,*etc.*

Stock*may*be*packaged*in*different*ways.*These*may*be*called* “cartons”,*“boxes”,*“units”,*“shippers”,* etc.*Each*of*these*has*a* different*meaning,*and*you*will*need*to*know*the*differences*when* picking*stock.*For*example,*there*are*huge*differences*between*a* carton*of*matches,*a*packet*of*matches*and*a*box*of*matches. *

Warehouses*do*not*often*receive*stock*i n*the*same*units*of*quantity* that*customers*have*ordered.*You*will*need*to*understand*the* different*names*used*to*describe*different*amounts*of*stock*items.* The*names*used*may*also*vary*from*warehouse*to*warehouse,*so* checking*of*the*correct*quantities*to*which*each*unit*of*stock*refers* will*be*very*important.*For*example,*someone*may*refer*to*a*‘shipper’,* whereas*someone*else*may*refer*to*the*same*quantity*as*‘packets’.* You*will*need*to*check*item*quantities*and*names*very*carefully,*so* that*you*actually*p ick*what*customers*have*ordered.*

Stock*picking*is*usually*done*by*people,*either*by*hand*or*using*Forklift* trucks.*In*this*section,*the*tasks*you*are*required*to*do*will*be*by*hand* only,*unless*you*have*already*obtained*a*licence*to*operate*a*Forklift* truck.*Your*trainer*will*make*sure*that*you*do*not*use*a*Forklift*truck* without*a*licence. *

TLIA1207C Pick and process orders

Activity 7: How do I identify stock items?

Look at the list below of different ways to recognise stock items.

Place a tick against each method used to recognise stock in your warehouse.

labels

alphanumeric codes

bar codes

visual recognition

diagrams

stock characteristics *

photographs

text descriptions.

* Characteristics of stock items could be size, shape, weight, smell, sound, touch, etc.

List below any other ways to recognise stock items used in your warehouse, or any other warehouse you know.

TLIA1207C Pick and process orders

The*main*pieces*of*information*on*customer*orders*were*shown*in*

Section*one.*There*will*also*be*key*pieces*of*information*in*stock*labels*

so*that*they*can*quickly*be*identified*and*located.*In*some*instances,*

the*information*on*a*customer*order*and*your*warehouse*stock*label*

may*match.*You*will*need*to*know*which*stock*items*are*being*talked*

about*if*different*codes*or*information*is*on*a*label*compared*to*a*

customer*order.*

TLIA1207C Pick and process orders

Activity 8: What information is contained in stock labels?

Look at the sample stock label below and the list of stock label descriptions.

00000 0032

00164

AC.68.2.1

ITEM: ARDMONA PEARS

425.00GM

OM

PO 00342424

EXPR DATE 04-18-96

0012

REC 00097

QTY 0000032

DATE :04-18-96

TIME: 13:25

SLOC AC.68.2.1

CASES 32

1387630

OM PO 00342424 EXPR DATE 04-18-96 0012 REC 00097 QTY 0000032 DATE :04 -18-96 TIME: 13:25

TLIA1207C Pick and process orders

Next to each description, write the information from the sample stock label that matches the description.

Description

Answer

Alphanumeric codes

Content description

Content quantity

Consignment quantity

Critical dates

Storage location

There is feedback on this activity at the back of this Learner’s Guide.

TLIA1207C Pick and process orders

Choose a stock label for a stock item stored in your warehouse.

Fill in the spaces below, using the information shown on that label.

Description

Answer

Alphanumeric codes

Content description

Content quantity

Consignment quantity

Critical dates

Storage location

TLIA1207C Pick and process orders

Activity 9: What are the names that I need to know that describe the quantities of stock received in warehouses?

Look at the following list of names that describes different ways that stock items are packaged.

You have to decide which name indicates that stock items may be in smaller packages inside the original package.

List the names in order, so that the largest is first and the smallest is last. Two correct answers have been provided for you.

For example, packets of stock are usually placed in boxes, so boxes would be above packets in your list.

You may need to discuss these names with your workmates or trainer, so that you understand the differences between each name. You may, in fact, not use some of these names in your warehouse. If this is the case, leave those names out of your answer list.

Cartons

Pallets

Boxes

Packets

‘Singles’

Cases

‘Shippers’

‘Inners’

Units

Pallets

Singles

Write down below any other names used in your warehouse to describe quantities of stock items.

There is feedback on this activity at the back of this Learner’s Guide.

TLIA1207C Pick and process orders

TLIA1207C Pick and process orders

Section 5

How are picked stock items checked?

TLIA1207C Pick and process orders

Section outline

Areas$covered$in$this$section $

Matching*customer*orders*with*picked*stock*items *

Checking*codes,*packages*and*descriptions *

TLIA1207C Pick and process orders

How are picked stock items checked?

An*important*part*of*your*job*will*be*to*make*sure*that*you*have* correctly*picked*the*required*stock*items*to*complete*a*customer* order.*You*must*be*aware*that,*if*you*make*a*mistake*by*picking*wrong* stock*items,*incorrect*quantities*or*wrong*brand*names,*you*will*be* making*more*work*for*your*workmates*to*correct*those*mistakes.* Stock*levels*in*your*warehouse*will*also*probably*be*incorrect*as*a* result*of*those*mistakes.*Therefore,*when*your*workmates*want*to* pick*a*stock*item*to*complete*an*order,*there*may*not*be*enough*stock* in*the*storage*location*to*do*this.*This*leads*to*customers*not*receiving* their*orders,*either*on*time,*or*in*the*correct*quantities. *

If*a*customer*receives*incorrect*stock*items,*there*will*be*extra*costs* involved*for*your*company.*Items*will*have*to*be*returned*and*the* correct*stock*items*dispatched.*This*will*also*cause*a*bad*impression*of* your*work*and*the*service*that*your*company*gives.*This*will*increase* the*chances*of*your*company*losing*customers*a nd,*in*very*bad*cases,* losing*so*much*business*that*employees*might*lose*their*jobs. *

TLIA1207C Pick and process orders

Activity 10: How do I check the picked stock items against a customer order?

Look at the purchase order given in Section 1. Compare that order with the list of stock items that were picked, as shown below.

Quantity

Product

Unit

Description

Price

Total

code

($)

($)

8

P801258

Packet

Paper 80GSM White

6.87

54.96

2

OHP5977

Box

Pens Black OHP Non - Perm

2.20

4.40

10

AB1386

1

Diary A4 Month Planner

7.50

75.00

1

W98765

1

Wall Year Planner

10.12

10.12

Check this table, and if you find any errors, write the correct stock items in the following table.

Stock picking corrections:

Quantity

Product

Unit

Description

Price

Total

code

($)

($)

Ask your trainer to select a typical order from those your warehouse has received. Make sure the order has at least three stock items in it.

You should now pick the stock items from their storage locations, and record the details of these items in the following table.

TLIA1207C Pick and process orders

Picking and recording stock items:

Quantity

Product

Unit

Description

Price

Total

code

($)

($)

There is feedback on this activity at the back of this Learner’s Guide.

TLIA1207C Pick and process orders

TLIA1207C Pick and process orders

Section 6

What are the methods used to replenish stock levels?

TLIA1207C Pick and process orders

Section outline

Areas$covered$in$this$section $

Reserve*stock *

The*need*for*stock*replenishment*systems *

Stock*rotation*systems*

TLIA1207C Pick and process orders

What are the methods used to replenish stock levels?

Warehouses*need*to*replenish*stock*as*quickly*as*po ssible*so*that*the* next*order*can*be*filled.*This*means*that*when*stock*is*sent*out*to* customers,*it*must*be*replaced*in*the*stock*picking*locations*as*soon*as* possible.*The*stock*used*to*replenish*these*locations*is*sometimes*kept* in*a*special*area*of*the *warehouse*called*the*‘reserve*storage*location’.* Your*company*will*have*a*policy*that*describes*how*and*when*stock* should*be*replenished. *

Often*when*you*replenish*stock,*you*will*need*to*adjust*records*of* stock*holdings.*You*may*also*have*to*make*sure*that*stock*items*that* need*to*be*‘rotated’*(because*they*have*‘use*by*dates’),*are*placed*in* the*special*locations*where*they*will*be*picked*first*when*next* ordered.*This*system*applies*most*to*perishable*stock*items. *

Some*warehouses*have*a*computer*stock a taking*system.**This*means* the*computer*will*update*stock*records*at*night*and*will*automatically* re a order*stock*items*when*the*warehouse*stock*holdings*fall*below*a* certain*level.*If*you*do*not*have*a*computer*stock*taking*system,*your* company*will*have*anot her*procedure*to*make*sure*that*stock*items* are*rea ordered*before*they*run*out.*

Replenishing*stock*locations*is*usually*done*by*hand,*or*using*Forklift* trucks.*In*this*Learner’s*Guide,*you*are*only*required*to*do*tasks*by* hand*unless*you*already*have*a*lic ence*to*operate*a*Forklift*truck.*Your* trainer*will*make*sure*that*you*do*not*use*a*Forklift*truck*without*a* licence. *

TLIA1207C Pick and process orders

Activity 11: Where are the ‘reserve’ stock locations in my warehouse?

Obtain a copy of your warehouse floor plan, and indicate on the diagram the locations where ‘reserve’ stocks are stored.

If your company does not have a warehouse floor plan, use the spaces below to write down where these ‘reserve’ stock areas are located.

TLIA1207C Pick and process orders

Stock*levels*need*to*be*ke pt*at*a*certain*level*so*that*future*customer* orders*can*be*filled,*or*in*case*of*sudden*demand*for*certain*items.* Some*types*of*stock*will*be*distributed*to*customers*at*faster*rates* than*others.*Stock*items*which*are*‘perishable’*will*need*to*be*sold* qui ckly*so*that*the*items*reach*customers*in*a*satisfactory*condition.*A* good*example*of*this*situation*is*dairy*foods,*which*must*be*delivered* to*customers*for*drinking*or*eating*before*their*‘use*by’*dates.*These* stock*items*have*a*fast*turnover,*and*their*stock*levels*may*need*to*be* different*from*most*stock*items*in*your*warehouse. *

TLIA1207C Pick and process orders

Activity 12: When do I refill the storage locations from the ‘reserve’ stock areas?

Discuss with your trainer how your warehouse stock-taking system chooses when storage locations need new stock items. Your company may have its own policy concerning stock replenishment.

Use the space below to write down details of the stock replenishment system used in your warehouse.

Storage locations are replenished when

The methods used to replenish storage locations are

TLIA1207C Pick and process orders

Certain*stock*items*will*need*to*be*‘rotated’*in*their*storage*locations.* Often,*older*stock*which*was*been*stored*will*be*moved*to*a*more* accessible*area.*This*will*mean*that*this*stock *will*be*dispatched*to*a* customer*when*an*order*is*placed*for*it.*For*example,*a*warehouse* may*want*to*distribute*stock*items*before*the*packaging*looks*old,*and* gives*a*poor*impression*of*the*items.*Faded,*dusty,*dirty*or*damaged* outer*wrappings*can*be*av oided*by*dispatching*older*stock*items* before*newer*stock*items*which*have*recently*been*received.*The*idea* of*‘rotating’*stock*is*useful*for*distributing*goods*before*they*become* out*of*date,*particularly*preserved*foodstuffs*which*have*‘use*by’* dates.*

Your*warehouse*will*have*a*plan*to*rotate*stock.*This*is*likely*to*be*

based*on:*

FIFO*

This*is*the*term*used*to*describe*the*‘first*in*first*out’*rule.* This*means*that*the*stock*which*has*been*in*the*warehouse* longest*should*be*dispatched*first.*This*is*a*simple*and* widely*used*rule. *

FILO*

This*term*means*‘first*in*last*out’.*In*this*rule,*the*stock* received*first*is*dispatched*last. *

Sometimes,*stock*rotation*will*mean*that*pallets*are*re a arranged.*This* can*include*moving*pallets*from*areas*where*stock*is*stored*to*areas* where*stock*is*picked.*

TLIA1207C Pick and process orders

Activity 13: How is stock ‘rotated’ in my warehouse?

Discuss with your trainer how your warehouse system rotates its stock levels, to ensure that stock items which are out of date or no longer in full working order are never distributed to customers.

Use the space below to write down details of how stock items are rotated in your warehouse.

Stock items are rotated when

The methods used to rotate stock items are

TLIA1207C Pick and process orders

When*you*place*new*stock*i tems*in*their*storage*locations,*you*will* need*to*place*them*so*that*they*are*easily*reached*by*you*and*your* workmates.*You*must*place*the*items*so*that*they*can*easily*be* identified*without*extra*inspections.*For*example,*you*should*not* place*items*so*tha t*their*stock*labels*cannot*be*seen,*or*where*they* will*become*damaged*by*poor*stacking. *

Pallets*need*to*be*straight,*and*cartons*and*boxes*should*fit*neatly*in* locations.*Identification*and*location*labels*need*to*be*easily*checked,* storage*areas*should*b e*free*of*rubbish,*and*stock*items*should*be* properly*located.*If*these*tasks*are*not*done,*stock*items*may*be* damaged*or*wasted,*staff*may*be*at*risk*of*injury*or*customers*may* not*receive*good*service. *

TLIA1207C Pick and process orders

Activity 14: What are the important things I need to do when placing stock items in storage locations?

Write down in the spaces below some of the things that you should do when you place stock items in storage locations in your warehouse.

There is feedback on this activity at the back of this Learner’s Guide.

TLIA1207C Pick and process orders

Additional

resources

TLIA1207C Pick and process orders

Publications : *

! Workplace!Health!&!Safety!Handbook,! Occupational*Health*&* Safety*Commission,*1992 *

Video: $

$ Manual$Handling *a *Safetycare*Series *

Web$sites: $

NOHSC*(National*OHS*Committee* – *Publications) * http://www.nohsc.gov.au/OHSInformation/NOHSCPublications/ *

Workcover*Authority*of*NSW * http://www.workcover.nsw.gov.au/ *

Victorian*WorkCover*Authority* http://www.workcover.vic.gov.au/ *

WorkCover*Queensland *

*

http://www.workcover.qld.gov.au/*

* http://www.workcover.wa.gov.au/ *

WorkCover*Corporation*of*SA * http://www.workcover.wa.gov.au/ *

ACT*WorkCover *

http://www.workcover.act.gov.au/*

WorkCover *WA *

*

*

*

Workplace*Standards*Tasmania * http://www.wst.tas.gov.au/node/WST.htm *

Work*Health*Authority*NT * http://www.deet. nt.gov.au/wha/index.html

TLIA1207C Pick and process orders

Feedback on activities

The responses provided in this section are suggested responses. Because every workplace is different, your responses may vary according to your specific workplace procedures, the equipment available and the nature of the business.

TLIA1207C Pick and process orders

Activity 2: What is the key information on a customer order?

Reference Number

509 356

Order Number

798 2275

Product Code

P801258

Product Description

PAPER 80GSM WHITE

Customer Telephone No.

(02) 456 999

Activity 3: How are stock items stored in a warehouse?

2
2

Description

Number

Example

Row

3

CE

Stack

4

CE.51

Shelf

2

CE.51.3

Level

1

CE.51.4

Bin

5

CE.51.3.2

TLIA1207C Pick and process orders

Activity 4: What are the things to be considered when assessing the load to be moved?

Can I comfortably manage the load?

Do I need assistance?

Is there another more efficient method of carrying the load?

Decide on the method to be adopted

Establish that a safe route exists for the loads to be moved.

Activity 5: What precautions should I take when lifting stock items?

1. Hold the load as close to your body as possible, and bend your knees when lifting.

2. Your body should not be twisted when a load is being lifted or carried; twisting or side-bending of the spine should be avoided.

3. The load should be lifted or carried using smooth movements to avoid excessive muscle strain.

4. The load should be carried between your mid thigh and shoulder height (if possible), using both hands (if appropriate).

5. The load should be balanced so that uneven body stresses are avoided.

TLIA1207C Pick and process orders

Activity 6: How should I correctly lift packages of different weights, shapes and sizes?

Item

Weight

Shape and size

 

Method

Reams of

15

kg

Rectangular box

Reams of 15 kg Rectangular box Manually

Manually

paper

 

(alone)

30cm x 20cm x

45cm

Filing cabinet

25

kg

Rectangular box

Filing cabinet 25 kg Rectangular box Hand trolley

Hand trolley

(2 drawer)

 

45cm x 60cm x

75cm

Desk

20

kg

Rectangular

Desk 20 kg Rectangular Manually

Manually

 

(assisted)

200cm x 130cm x

100cm

Photocopier

60

kg

Cubic

Photocopier 60 kg Cubic Forklift Truck

Forklift Truck

 

150cm x 150cm x

150cm

Poison

10

kg

Cylindrical

Poison 10 kg Cylindrical Authorised

Authorised

 

20cm 2 x 50cm

personnel

TLIA1207C Pick and process orders

Activity 8: What information is contained in stock labels?

00000 0032

00164

AC.68.2.1

ITEM: ARDMONA PEARS

425.00GM

OM

PO 00342424

EXPR DATE 04-18-96

0012

REC 00097

QTY 0000032

DATE :04-18-96

TIME: 13:25

SLOC AC.68.2.1

CASES 32

1387630

OM PO 00342424 EXPR DATE 04-18-96 0012 REC 00097 QTY 0000032 DATE :04 -18-96 TIME: 13:25

TLIA1207C Pick and process orders

Description

Answer

Alphanumeric codes

00000 0032 00164

OM0012

1387630

Content description

Ardmona Pears

Content quantity

425 grams

Consignment quantity

32 cases

Critical dates

Date Received 4/18/96

Storage location

Expire Date 4/18/96

AC.68.2.1

(Row AC, Shelf 68, Level 2, Bin location 1)

TLIA1207C Pick and process orders

Activity 9: What are the names that I need to know that describe the quantities of stock received in warehouses?

This is a suggested answer. Your answer may be slightly different due to the storage requirements in your warehouse.

Cartons

Pallets

Boxes

Cartons

Packets

Cases

‘Singles’

Boxes

Cases

Packets

‘Shippers’

Shippers

‘Inners’

Units

Units

Inners

Pallets

Singles

Activity 10: How do I check the picked stock items against a customer order?

There were two errors in the table of picked stock items. The correct items that should have been picked are:

Quantity

Product

Unit

Description

Price

Total

code

2

OHP5977

Box

Pens Black OHP Perm

$2.20

$4.40

10

AB1385

1

Diary A4 Week Plan

$5.50

$55.00

TLIA1207C Pick and process orders

Activity 14: What are the important things I need to do when placing stock items in storage locations?

1. Protect stock (light on heavy, soft on hard, avoid heat and sunlight, avoid vibration, etc.)

2. Maximise available space

3. Correct loading/unloading sequence

4. Correct labelling and documentation

5. Maintain stability of loaded stock items.