Awm2 0212

MK
Advanced Warehouse Management Volume 2

User Guide
Version8.40212
Copyright © 2003 by SSA Global Technologies, Inc.
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any
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Contents
Chapter 1: Welcome to MK Advanced Warehouse

Management
Introduction .................................................................................. 1–1
In This Guide................................................................................. 1–2
Using MK Documentation ..................................................................... 1–3
What You Need To Know ..................................................................... 1–4
Chapter 2: About AWM

Using MK to Manage Your Warehouse Needs ................................................... 2–1
AWM Features ............................................................................... 2–2
Chapter 3: Getting Started

Introduction .................................................................................. 3–1
Features ..................................................................................... 3–2
Setting Up MK Advanced Warehouse Management ............................................. 3–19
Chapter 4: Inbound Processing

Introduction .................................................................................. 4–1
Inbound Data ................................................................................ 4–2
Printing Data ................................................................................ 4–16
Locating Rule Sets ........................................................................... 4–20
Putaway Operations ......................................................................... 4–27
How Variable Pallets Are Handled ............................................................ 4–35
Contents iii
Chapter 5: Outbound Processing
Introduction ..................................................................................5–1
Pick Planning .................................................................................5–3
Shipping ................................................................................... 5–24
Production ................................................................................. 5–35
Chapter 6: Lot Control

Introduction ..................................................................................6–1
Maintain Lots .................................................................................6–2
Converting Items ............................................................................ 6–12
Chapter 7: Warehouse Administration

Introduction ..................................................................................7–1
Maintain Option ..............................................................................7–2
Displaying and Printing Options ............................................................. 7–16
Chapter 8: RF Processing
Introduction ..................................................................................8–1
Directed Versus Non-Directed RF Processing ....................................................8–2
General RF Menus and Forms ..................................................................8–6
Before You Begin ............................................................................ 8–11
RF Inbound Receipt Confirm ................................................................. 8–12
RF Inbound Putaway Confirm ................................................................ 8–17
RF Stock Transfers .......................................................................... 8–22
Viewing Locations .......................................................................... 8–24
Cycle Counts ............................................................................... 8–26
RF Outbound Picking Confirmation........................................................... 8–30
RF Outbound Floor Spot ..................................................................... 8–35
Maintaining RF Outbound Staging Areas ...................................................... 8–38
Picking RF Outbound Batches ................................................................ 8–39
RF Inventory Location Load .................................................................. 8–40
Printing RF Outbound Shipping Labels........................................................ 8–41
iv MK Advanced Warehouse Management, Volume 2, User Guide

Appendix A: Packing Algorithms
Configuration Functions ...................................................................... A–2
Packing Logic Overview...................................................................... A–8
Appendix B: Pick Resource Detail Components

Pick Resource Detail Components .............................................................. B–1
Other Labor Components ...................................................................... B–4
Appendix C: AWM Rejected Order Messages from Generate

Outbound Advice
Overview .................................................................................... C–1
Index
Contents v
Welcome to MK Advanced
Chapter
1 Warehouse Management
Introduction
Welcome to MK Advanced Warehouse Management. The advanced warehouse
management functions supported by MK include:
■ Automated matching of receipt documents to goods received
■ Calculation of optimum putaway locations
■ Pick planning with enhanced radio frequency execution features
■ Automatic selection of shipping containers
■ Rule-based automated replenishment of item locations
For a general description of the MK business management system, refer to MK

Getting Started.
Welcome to MK Advanced Warehouse Management 1–1

In This Guide
In This Guide
This guide is organized into the following chapters:
Chapter 2, About AWM, describes Advanced Warehouse Management functions

and features.
Chapter 3, Getting Started, describes the features and steps you need to perform
for setting up the Advanced Warehouse Management module.
Chapter 4, Inbound Processing, explains how to maintain receipts, generate and

process inbound data, locate a product using locating rule sets, and perform
putaway confirmation.
Chapter 5, Outbound Processing, describes how to perform pick planning

activities, independent replenishment, and shipping activities.
Chapter 6, Lot Control, describes lot query and maintenance functions. Lot
tracking includes a user-defined section which enables you to define, print and
select lot information in any order you choose.
Chapter 7, Warehouse Administration, explains how to perform most

administrative functions of Advanced Warehouse Management.
Chapter 8, RF Processing, explains how to perform directed and non-directed RF

Processing for receiving, putaway, pick confirmation, floor spot confirmation,
cycle counting, inventory location loads, and printing shipping labels.
Appendix A, Packing Algorithms, describes the significant configuration functions

and associated fields followed by an overview of the packing logic.
Appendix B, Pick Resource Detail Components, describes the various pick

components including pallet pick type, case pick type, piece pick type, and other
labor components.
Appendix C, AWM Rejected Order Messages from Generate Outbound Advice,

lists the rejected order messages from AWM generate outbound advice.
1–2 MK Advanced Warehouse Management, Volume 2, User Guide

Using MK Documentation
Using MK Documentation
This guide describes how to perform important activities associated with this
MK module. It is intended to be used in conjunction with the online Help
system. For an in-depth description of a field or a list of values related to a field,
use online Help. Instructions for using online Help are provided later in this
guide.
The MK documentation set includes a separate User Guide for each major
business function. The business functions aggregate related MK modules; for
example, Project Control System (PCS) includes the Project Budgeting, Project
Control, and Project Network Planning, and Link PCS to Finance modules. The
guides are listed below:
■ Cost User Guide
■ Engineering User Guide
■ Finance User Guide
■ Inventory Management and DRP User Guide
■ Planning User Guide
■ Product Configurator User Guide
■ Production User Guide
■ Project Management User Guide
■ Purchasing User Guide
■ Quality Assurance User Guide
■ Sales User Guide
■ Service Management User Guide
For a description of the contents of each guide, refer to Getting Started.
Welcome to MK Advanced Warehouse Management 1–3

What You Need To Know
What You Need To Know

In addition to an understanding of basic manufacturing concepts, this guide
assumes that you are familiar with either the Microsoft Windows NT or UNIX
operating system terminology and navigational techniques. If you are
unfamiliar with operating system you are using, please refer to your Windows
NT or UNIX documentation before using MK.
Note: In general, when this guide indicates a procedure using buttons or mouse
actions, it takes for granted that you know the alternative procedure, using only
the keyboard. For example, you will be directed in most cases to “select Close,”
rather than “choose the File End command” or “press Alt+F, E.”

Chapter
About AWM
2
Using MK to Manage Your Warehouse Needs ................................................... 2–1

AWM Features ............................................................................... 2–2
About AWM 2–i

Chapter
About AWM
2
Using MK to Manage Your Warehouse Needs

The Advanced Warehouse Management (AWM) module is an application
intended to fully automate the operations of a large warehousing operation. It is
the complete solution for warehouse management. AWM increases the
efficiency and performance of your business through this automation.
AWM automates seven major operations:

■ Receiving—Receipt documents are matched immediately to goods received.
Labels and worksheets assist in counting, control checking, putaway, and
auditing. Bar codes are an option on putaway labels.
■ Reporting Manufacturing Production—Receipt documents are matched
immediately to goods received. Labels and worksheets assist in counting,
control checking, putaway, and auditing. Bar codes are an option on
putaway labels.
■ Locating with Confirmation—Optimum locations are calculated, labels confirm
receipts, radio frequency (RF) terminals direct stocking, and check digits
ensure placement. Paper putaway verification is also supported.
■ Pick Planning and Confirmation—Picking plans are developed based on
standards, available resources, and orders. AWM ensures that these plans
are executed accurately with the use of bar codes and optional RF terminals.
Reports of standard versus actual labor utilization help the warehouse
manager achieve high employee productivity.
■ Packing and Shipping—AWM selects appropriate shipping parcels
automatically, and customer-defined logic consolidates parcels.
■ Production Packing and Staging—AWM selects appropriate shipping parcels
automatically, and customer-defined logic consolidates parcels.
■ Replenishment—Picking areas are replenished based on customer-defined
rules, orders, equipment, and pick frequency with the minimum use of
labor.
About AWM 2–1

AWM Features
AWM Features
The advanced features of AWM include:
Pick Planning Proposed pick plans are analyzed and picking activity is optimized based on
Optimizer user-defined pick rates, available equipment, human resources and available
inventory. Managers can model and control the day’s shift’s work based on
resource allocations that break down the shift’s work by zone, teams, and
workers. This allows management to identify and react to potential bottlenecks
before they occur.
Replenishment Detailed output from the pick planning process is analyzed to provide batching
Optimizer or loose and case picks. Item locations for replenishment within the warehouse
is optimized based on the movement of the item and the type of item (seasonal,
cyclical, promotional). Replenishment activity is calculated to suggest which
piece of equipment is appropriate and how much stock to replenish based on
management criteria. The result is unique; there is no need for physical
inventories, because the system counts as you pick. There is no need to reslot
items because the item is in the best spot available as defined within your rule
sets.
Dynamic Parceling This alternate parceling method enables MK to pick for an order and to pack
the items until the carton is full. The operator indicates that the carton is
closed, and MK assigns the remaining pieces to be picked to the next carton.
This process is repeated until all items for the order are picked. Dynamic
parceling enables the use of carton packing lists and assignment of cartons
based on carrier consideration (weight and size) and customer packing
requirements.
Directed Radio Radio Frequency (RF) terminals and bar coding equipment is used to direct
Frequency warehouse personnel to the next task they are to perform. For example, as
warehouse personnel complete a task (item pick, putaway, or replenishment)
another task is automatically assigned. Directed RF allows for interleaved
picking and putaway. This allows warehouse personnel performing RF
picking to be informed of a pending putaway near the location of the next pick
assignment, which reduces “deadheading.” The system selects the task based
on established rules. It considers the task priorities, type of material handling
equipment, location and types of activities you want each operator to perform.
Operators can be assigned to pick, putaway, replenish, or any combination of
these activities.
Advanced Pick and Additional locating rules allow the random selection of locations based on an
Putaway Rule Sets item’s ABC classification or equipment needs. “Hot ship” items can go directly
to cross docking areas for fast turnaround. Shipping and replenishment rules
take into account personnel available, equipment needed, and picking rates per
hour. Rush orders are also flagged for cross-docking.

AWM Features
Additional functional enhancements include cross-docking, the ability to direct

non-stock items, location control of the shipping dock, and association of
carriers-to-dock doors. All of these new features combine to provide the most
advanced warehouse management system in the industry.
The key benefits of using MK AWM are as follows:

■ Lowering Costs—AWM lowers cost by increasing staff productivity. Staffing
needs decrease and employees work more efficiently. The work planning
capabilities of AWM ensure that work is coordinated to use employees’ time
effectively. The software generates work plans that consider factors such as
the distance traveled within the warehouse and sequence of the tasks. The
software supports workload planning, using standards for each operation.
AWM also highlights potential bottlenecks, allowing the manager to respond
before committing resources. The use of optional RF terminals eliminates
the need for paper processing.
■ Improving Customer Service—Improved customer service results from faster
throughput and accurate inventory information. AWM combines automatic
parcel picking and location logic, the ability to pick by zone, and automated
parcel consolidation processing to accelerate the order processing cycle.
■ Improving Inventory Accuracy—AWM improves inventory accuracy.
Inventory balances of all stock locations are accessible in online, real-time
mode.
About AWM 2–3

Chapter
Getting Started
3
Introduction .................................................................................. 3–1

Features ..................................................................................... 3–2
General Features .......................................................................... 3–2
Administrative Features ................................................................... 3–6
Receiving Features ........................................................................ 3–8
Locating Features ........................................................................ 3–10
Pick Planning Features ................................................................... 3–12
Picking Features ......................................................................... 3–13
Packing Features ......................................................................... 3–15
Replenishment Features .................................................................. 3–16
Shipping Features ........................................................................ 3–17
Setting Up MK Advanced Warehouse Management ............................................. 3–19
Warehouse Setup Procedures ............................................................. 3–19
Item Setup Procedures.................................................................... 3–19
Receiving Setup Procedures ............................................................... 3–21
Shipping Setup Procedures ............................................................... 3–21
Getting Started 3–i

Chapter
Getting Started
3
Introduction
The Advanced Warehouse Management (AWM) module is an application
intended to fully automate the operations of a large warehousing operation. It is
the complete solution for warehouse management. AWM increases the
efficiency and performance of your business through this automation.
AWM offers complete flexibility, which allows customers to tailor MK to meet

individual requirements without modifications. Considerations at a site might
include product attributes, storage equipment, characteristics and capacity,
volume, inventory turns, and special storage requirements such as refrigeration.
AWM supports multiple levels of warehousing, including multiple zones within

a site and multiple site operations. The customer defines each zone, warehouse,
or site as a functional entity, yet an overall view of inventory for the entire
operation is available.
The new Advanced Warehouse Management module contains several additional

features for MK as described in the following pages.
Getting Started 3–1

Features
Features
General Features
Advanced Pick and Putaway Rules
Multiple locating rules for putaway enable the random selection of locations
based on an item’s ABC classification or equipment needs. Hot Ship items can
go directly to cross docking areas for fast turnaround. Shipping and
replenishment rules take into account personnel available, equipment needed,
and picking rates per hour. Rush orders can also be flagged for priority picking
or cross docking.
Warehouse Zoning
Warehouse zone definitions, used for picking, putaway, and allocation

processes, are a valuable asset to AWM. Warehouse locations are assigned to a
specific zone within a process. Zones are created to handle different storage
areas or equipment requirements. Each zone can have unique rule sets assigned
to handle the picking, putaway, and allocation requirements of each.
Storage Locations
Storage locations are assigned to zones for putaway, picking, and locating.
Multiple items and lots can be stored in a single location. Indicators can block
transactions from a location. Infinite capacity can be specified for locations such
as the initial receiving location.
In addition, dimension and weight determine maximum capacity. Location

definition is keyed by warehouse ID and location ID. Each location is further
defined by height, width, depth, and weight capacity by storage type definition.
An item can be assigned to one or more permanent or fixed locations by
associating the item code to a warehouse ID and location ID.
Item Characteristics
Locating, picking, replenishment, handling, and packing categories have been

added to the Item Master data. These categories help in the rule set selection.
Item length, width, and height enhance the storage unit of measure for location
determination. The length, height, and width (and the other units of measure
that apply for the item) need to be added for each, innerpack, case, mastercase,
pallet.

Features
Labor Standards
Standards for pallet, master case, case, inner pack, and piece are set by each
warehouse. Travel time requires each pick type to also be set. Standards are
also set for time to replenish a case, time to fabricate a loose pick carton, average
number of items per loose pick, average number of visits per case pick location,
and indirect labor percentage. These standards are then used in determining the
resource requirements of a pick plan. Setting a standard to zero eliminates it
from the resource requirement’s calculation. Actual times are captured during
RF processing. The start and ending times for each pick is placed into the RF
transaction file when the pick is completed via the RF device input. The start
and end time only reflect the total pick time and are not broken down into
categories used to create standards.
Labor Reporting
In outbound processing, resource requirement reports can be generated during

the pick planning process. Warehouse labor standards are used in determining
the resource requirements of a pick plan. Pick plans can be limited to the
available resources or just report a time estimate of the hours required to pick all
orders in the pick plan. Setting a standard to zero eliminates it from the process.
The resource reports summarize manpower requirements by pick wave and
team or team and pick wave. Each report provides type of picks (eaches, cases,
pallets) to be done, hours per team member, and total hours.
ABC Analysis
Items are assigned an ABC movement class. System parameters specify

boundaries. Items can be classified by using average annual issues times the sell
price, average annual issues times the cost price or just average annual issues.
Storage locations have an ABC class movement assigned also. Matching the
location’s ABC classification to the item’s ABC classification occurs when
selecting a location to store the item.
Carton Definitions
Cartons are added by defining the height, length, width, carton weight and
carton weight capacity. Status and downsizing indicators are also required
fields. The user sets the status indicator to show availability of a carton type.
The user also manually sets the downsizing indicator. Downsizing looks for a
smaller carton when the current carton is not filled.

Features
Directed Radio Frequency (RF)
Radio frequency terminal and bar coding equipment directs warehouse

personnel to the next task to perform. For example, as warehouse personnel
complete a task (item pick, putaway, or replenishment), another task is
automatically assigned. Directed RF enables interleaved picking and putaway.
This enables warehouse personnel performing RF picking to be informed of a
pending putaway near the location of the next pick assignment, which reduces
deadheading. MK selects the task based on established rules; it considers task
priorities, type of material handling equipment, location, and the type of
activities you want each operator to perform. Operators can be assigned to pick,
putaway, replenish, or any combination of these activities.
Radio Frequency Definitions
Radio frequency (RF) definitions are broken down into two areas: rule set
definition and assignment of operators to RF rule sets. RF rule definitions
specify a warehouse and the pick zone, and/or dock group to be associated with
the rules. For each rule, the user can specify whether pallets, cases, or other
units of measure can be picked. The user can also specify if the dock confirms
picks and whether to minimize dead heading when selecting tasks. The last rule
set definition requirement is the assignment of warehouse personnel using RF
equipment to an RF rule set.
Radio Frequency Task Management
Each RF task to be performed is placed in a queue. Tasks are displayed in

sequence by priority, date, and time. This sequence is used when selecting tasks.
Each task can be held or released individually. The priority of task selection can
also be changed. A detail inquiry is also available. The inquiry displays source
and destination of items invoiced in a task.

Features
Product Kitting
Product kitting is supported in two ways. The first is termed “issue

components.” Once a line item has been entered into a sales order, the issue
status of the line is changed to Issue Components. This causes the top level
components to be allocated and issued from stock. Component order quantities
reflect the necessary amounts to satisfy the kit item’s quantity ordered.
Allocations of component items only occur in quantities that relate to a whole
kit. Additionally, the lowest common denominator is used in allocating the
components. If a single component item has only enough availability to ship one
kit, then allocations for all components are for one kit. The second type of kitting
enables the components from a bill of material to be copied into the order as
individual lines. Once this is done, component lines are processed as normal
order lines. Order quantities and allocations are managed at the order line level.
A packing category can be used to package all items of a kit into a single carton.
Serial Number Tracking
Serial number (S/N) tracking is accomplished through the use of lot control. An
item definition calls for a single lot number to be assigned to each item unit.
Lots are tracked from raw material through the sale of a finished good. Multiple
S/Ns can be stored in a single location. A single lot number is assigned to a
single item when the Lot Control indicator “by unit” is specified in the item
master.

Features
Administrative Features
Query Inventory and Locations
Inventory and locations can be queried in a variety of ways. Several different

inquiries are available on the Stock Reports Inquiries menu. Each session either
displays or allows zoom capability down to the location level. Information
varies from session to session, but can include quantity on hand, lot ID, storage
unit of measure, allocation quantity, blocked quantity, on-order quantity, and
non-nettable quantity. Net inventory quantities can also be checked at the item
and warehouse levels. Display Stock History by Location (tdilc3510m000) and
Display Stock Transaction by Item (tdilc1521m000) sessions are available from
other menus. These last two sessions track an item from receipt to shipment.
Inventory Adjustments
There are nine predefined transaction types: purchase order, sales order,
production issue, production receipt, stock adjustment, stock transfer, scrap from
inventory, miscellaneous issue, and miscellaneous receipts. Each requires some
different information to be supplied, for example, a sales order adjustment
would require the customer number. An inventory transaction may have
user-entered text associated to it and a user-defined reason code can also be tied
to the transaction. Optional labeling requirements are available.
Transaction Log
Any combination of the following data elements browses the transaction log:
warehouse, location, control number, source type, company, item, date, and lot.
The result may be sorted by location, control number, item, transaction, source
type, or by date and time. Detail transaction information available includes the
date and time the transaction was completed, who the operator was and other
pertinent information belonging to the transactions.
Lot Query and Maintenance
Lots are queried by using any combination of the following: item, lot, expiration
date, number of days within expiration, and current status. Lots can be added,
changed, or deleted. Purchased lots reference the supplier’s code and lot. A
certificate code, two user-defined selection codes and text are also maintained.
Lot expiration is termed shelf life and is maintained along with the item master
data. By means of another session, lots can be placed on hold by assigning
user-defined block codes. Lot processing also contains a feature called Variable
Lot Features. Variable lot features are user defined. These features are tied to
items; values can then be tied to each feature for each lot.

Features
Lot History Query and Reporting
Four sessions are available for querying lot history. These sessions can be found
on the Lot Tracking menu. The four sessions are Display Lots by Supplier’s
Code (tdltc1531m000), Display Where-Used Lots (tdltc1510m000), Display
Origin by Lot (tdltc1520m000), and Display Origin by Order (tdltc1530m000).
None of these sessions can give a complete picture of transactions involving a
single lot. There are three predefined reports: Print Where-Used Lots
(tdltc1410m000), Print Origin by Lot (tdltc1420m000), and Print Origin by Order
(tdltc1430m000). These reports offer more detail, enabling lots to be traced to
their origin. Lot tracking also contains a user-defined section which enables the
end user to define, print, and select lot information in any order he or she
chooses.
Cycle Counting
Cycle counts (stocktaking orders) are generated by specifying warehouse and

locations to be counted. Item locations are selected for counting based on the last
count date and counting interval. The counting interval is tied to the item’s ABC
classification. Selected locations can optionally be blocked based on Inventory
Location Control parameters. These blocks are released when running either the
Process Stocktaking Data (tdilc5211m000) or Delete Stocktaking Orders
(tdilc5212m000) sessions.
Block Items and Lots
Items are blocked through the use of location blocking. Individual lots are
blocked through the use of lot blocking. The picking of items and lots can also
be controlled by user-defined status and rule sets.
Query Outstanding Radio Frequency Tasks
Outstanding tasks can be queried via RF sessions. Radio Frequency Queue

Management provides this function.
Operators of RF equipment are assigned to directed RF rules. RF rules assign

zones and functions to be done. Work can be managed further through the use
of RF Queue Management.

Features
Receiving Features
Material Disposition and Locating
Disposition codes are user defined. A disposition code can be entered on the
Maintain Receipts Disposition (tdawm1110m000) form. Each detailed receiving
line can be assigned a disposition code if the product is damaged or warrants a
disposition code other than Available. Locating a product is accomplished
through a rule set. A parameter is set in the Maintain Purchase Order
Parameters (tdpur4100m000) session to specify the automatic locating of an item.
Locating rules are selected by a combination of locating category, receipt
warehouse, receipt type, and disposition code. Items are located by the Generate
Inbound Advice (tdilc4203m000) session during the following receipt.
Receipt Status Inquiry
Inquire about purchase order receipt status using the Display Receipts
(tdpur4531m000) session. The Display Order Line Status session also displays
the next step. Production order status is available in the Display Production
Order session. Repetitive order status is available in the Display Production
Schedules by Day session. Return Material Authorization status can be viewed
in several different sessions in the Inquiry menu. Distributed Requirements
Planning (DRP) order status can also be viewed in several different sessions on
the Material Requisition menu.
Unexpected Receipt Capability
Purchase order receipts and return material receipts can zoom to their respective
line item maintenance sessions. DRP receipts are handled by the Material
Requisition Stock Transfer (tdilc9190m000) session. Unexpected items can be
added through the maintenance sessions. Production and repetitive orders do
not have unexpected receipt capability.

Features
Pre-Receiving Documents
Goods Received notes are printed (optionally, based on order type) by selecting
a combination of delivery dates, order numbers, and suppliers. The report lists
goods to be received or expected items, quantities, supplier information, buyer,
warehouse, delivery date, and order line text.
Control Over and Under Receipts
Over and under receipts can both be received. Lines can be added if the user is
authorized to the zoom session allowing maintenance to the current receipt type
(purchase order, RMA, etc.). Set up tolerance codes to control over and under
quantities. The tolerance can either warn or block the transactions. Tolerance
codes are tied to the purchase orders. Line items are verified during receiving.
User-Defined Fields
The label on any existing field can be modified. However, there are no fields
reserved for end user definition.
Cross Docking
Cross docking is activated by naming a location in the warehouse as the cross

dock location. This enables items on the receiving dock to be located to the cross
dock location for shipping.
Radio Frequency Receiving
RF is available for receipt confirmation and the putaway confirmation process.

Features
Locating Features
Locating Logic
Two separate subsystems use locating rules to assign storage locations to

inventory: Receiving and Replenishment. Rule sets are linked to a combination
of warehouse, locating category and receipt, adjustment, or order type. There is
no limit to the number of locating rule sets that can be defined. Minimum and
maximum quantities are used to select a rule within a set. Different quantities
can be declared for each set.
Within each sequence of a rule set, quantities can also be specified for received,
expected, and original amounts. Flags indicate if the user can mix pallet sizes,
whether cases that do not qualify as full pallets can be mixed with pallets, and if
partial cases can be assigned to locations as partial pallets. A rule can also
specify the type of label to print, and if the user is allowed to consolidate
quantities (accumulate odd pieces to a case). Location status, bay sequence for
locating, putaway zone, storage type (for a location) and requalifying of
minimum or maximum quantities can all be specified at the rule level.
Paper Confirmation
You can use paper confirmation in lieu of RF confirmation. Putaway

confirmation worksheets are created.
Location Capacity
Location capacity is checked by storage unit of measure. Additionally, the size

and weight of items being stored are also taken into account. A location can be
declared as having infinite capacity.

Features
Alternative Locations
Through the use of locating rules, any number of alternative locations can be
searched. If an item is assigned one or more permanent or fixed locations, these
locations are searched first. During the locating process, the item’s ABC
classification is matched to a location with the same or less ABC classification
(for example, an A item can go into a C location, but a C item cannot go into an
A location). Through the use of an RF device or the Maintain Inbound Data
(tdilc4103m000) session, an alternate location can be assigned manually by the
user.
Radio Frequency Putaway
RF putaway confirmation is supported.
Optional Confirmation
When RF is used, confirmation is part of the transaction. A manual process to

verify the completion is not required. The addition of directed and non-directed
RF offers an extra layer of verification without forcing a manual confirmation
pass.

Features
Pick Planning Features
Pick Planning Optimizer
Proposed pick plans are analyzed, and picking activity is optimized based on
user-defined pick rates, available equipment, human resources, and available
inventory. Managers model and control the day’s or shift’s work based on
resource allocations that break down the shift’s work by zone, teams, and
workers. This enables management to identify and react to potential bottlenecks
before they occur.
Group Orders for Picking
Orders are grouped and selected using the Generate Outbound Advice
(tdilc4201m000) session. Order groupings can be created by using any
combination of the following search criteria: type of order (sales order, service
order, etc.), customer, order/batch ID, operation, production date, delivery date,
project, item, warehouse, route, schedule number, manufacture item,
manufacture warehouse, operation route, region, order type, order priority, site,
and carrier. Most of the fields allow entry of from and to ranges.
For pick plan simulation, totals are displayed by warehouse. The information
includes: number of orders, number of order lines, number of cases, total cubic
measurement, and total weight. By warehouse, order detail information is
available for this pick plan. This information includes: order number, customer
name, order type, company, and if partial shipment of the order is allowed.
Wave Pick Management
All orders are placed in a run, resulting from the Generate Outbound Advice
(tdilc4201m000) session. The size of the run is controlled using the selection
criteria parameters available when executing the Generate Outbound Advice
session. An entire pick plan can be limited to the resources available and the
time allotted for picking. Several different kinds of reports can also be generated
to help analyze requirements. These reports contain information about resource
requirements, product staging, and product loading. The following options have
been added to the Generate Outbound Advice session: pick plan method,
labeling options, bill of lading print, and packing list print.
Resource Allocation Reports
The resource allocation reports are optionally provided during the pick planning
process. The reports are Resource Allocation Summary by Wave and Resource
Allocation Summary by Team for All Waves Report. These reports show the
total manpower needed for the plan and where the manpower is scheduled.

Features
Picking Features
Split Picks by Zone
Each warehouse is broken down into allocation zones. These zones are assigned
specific locations in a warehouse. Picking rules are assigned to specific
allocation zones. The same picking rules are also assigned to pick types (pallet,
case, each). Within each rule set, different allocation zones can be assigned to
different pick types. The user could, in fact, define a different allocation zone for
pallet pick, case pick, and piece pick. Within this process, the warehouse can
also be broken down into pick zones. Pick zones are assigned to warehouse
locations and picking teams. Different teams are assigned to different pick
zones. Conceivably different pick teams could be assigned to pallets, cases, and
pieces.
Pick by Travel Zones
All picks on paper documents are listed by zone and pick address (location ID).
The user is required to name the locations in an order that would cause the picks
to occur by travel sequence. RF picks are controlled by priority, but the sequence
eventually resorts to the pick address. The user can pick by travel zones if
locations are addressed in a sequence that would facilitate this process.
Pick Confirmation
You can achieve exceptional picking accuracy without sacrificing productivity

by having AWM require proof that the product is picked correctly, and proof
that it arrived at the correct dock. Picking can be radio frequency and/or paper
controlled by location in each warehouse, and planned picking parcel records
can be made available for quality control scales and fixed scanner checkoffs and
diverters. Interleaved picking and putaway lets you perform RF picking to keep
informed of a pending putaway in the aisle of the next pick assignment,
reducing deadheading.
Pick confirmation is accomplished using RF pick verification or using the Pick

Confirmation (tdawm4210m000) session. RF picks are verified as they occur for
both the pickup and drop-off process. The Pick Confirmation session records the
results from a paper-driven picking process. The results of the pick process are
recorded when the pick information is updated through the online session. Both
types of confirmation enable the verification of pick data.

Features
Paperless Picking
Paperless picking is accomplished through the use of direct RF processing. Once

the operator signs on, the RF device directs the operator to the location and
transactions to be done.
Flexible Picking Rules
Pick rules are completely user-defined. Rules can be as simple or as complex as

needed. Rules can be created for individual warehouses and zones. Rules can
be based on storage type, or pick type (pallets, cases, pieces). A picking rule can
also identify a replenishment rule. The number of rules per rule set is 9,999.
Rule sets can then be tied to any combination of warehouse, order type, and
locating category. This combination of warehouse, order type, and locating
category can specify different rule sets for standard orders, lot specific orders,
and single lot orders.

Features
Packing Features
Dynamic Parceling
This alternate parceling method used in conjunction with RF, enables MK to pick
for an order and to pack the items until the carton is full. The operator indicates
that the carton is closed, and MK assigns the remaining pieces to be picked to the
next carton. This process is repeated until all items for the order are picked.
Dynamic parceling enables the use of carton packing lists and assignment of
cartons based on carrier consideration (weight and size) and customer packing
requirements.
Carton Selection
Packing Category Definition defines codes that are assigned to each item to
describe the various sized cartons each into which each item can be packed.
Cartons are added by defining height, length, width, carton weight, and carton
weight capacity.
Packing Requirements
Packing Category Definition defines codes that are assigned to each item to
describe the various sized cartons into which each item can be packed. The
carton’s volume, percentage to consider full, and maximum fill percentage are all
contained in the packing category definition.
Carton Packing List
Packing lists are associated with each order being shipped. The warehouse
address is used as the shipped-from location and the ship-to information comes
from the shipping order ship-to information. All items, item descriptions, ship
quantities, and associated lots are listed on the packing list. A user can request
to print a packing list from the Generate Outbound Advice session or the
Maintain Carrier Manifest (tdawm4105m000) session.
Carrier Guidelines
Carrier guidelines are considered in carton selection through parcel maximum

fields for weight, height, length, and by width from the Carrier Definition Detail
form. These maximums do not apply to case quantity shipments of a single
item, but only to loose picked items for which a shipping carton size must be
selected.

Features
Replenishment Features
Replenishment Optimizer
Detailed output from the pick planing process is analyzed to provide batching or
loose and case picks. Item locations for replenishment within the warehouse are
optimized based on the movement of the item and the type of item (seasonal,
cyclical, promotional, etc.). Replenishment activity is calculated to suggest
which piece of equipment is appropriate and how much stock to replenish based
on management criteria. The result is unique; there is no need for physical
inventories because
MK counts as you pick. There is no need to re-slot items because the item is in
the best spot available as defined within your rule sets.
Track Bulk versus Pick Stock
AWM has the ability to recognize both pick locations and bulk storage locations
(full location visibility). Products are picked from bulk storage areas and
putaway products in pick locations.
Fixed Locations
Besides the random locations where any item is located, fixed locations may be
defined per item. For each location, you can specify aisles, bays, and levels.
Fixed locations are also selected first, before random locations, by priority
sequence.
Replenish Based On Demand
The pick planning process is used to schedule shipments of merchandise from

the warehouse (demand). Orders originate from the pick plan, and pick
planning processes these orders for shipping. From the shipping orders,
replenishments are determined optionally, if needed, after checking the
appropriate rules sets and finding the need to replenish. For replenishment, one
rule set is used to identify where to pick the inventory from, and another rule set
to is used to put away inventory into the appropriate location (pallet, case,
piece).
Location Fill
Bins are optionally and additionally rounded up to a full case or pallet to make
work more productive.
Replenishment Calculations
Replenishments are supported by demand and recent days history.

Features
Shipping Features
Shipping Documentation
Loading and staging worksheets are supported for the dock floor, as well as
picking lists, dispatch notes, packing lists, bills of lading, sales order deliveries,
and shipping manifests for outbound.
Change Carrier
A carrier can be entered or changed in the Maintain Sales Orders

(tdsls4101m000) session. The carrier is validated. A shipment’s change of carrier
is allowed in two different ways.
■ Modify the carrier through Maintain Sales Orders. This causes the carrier to
be changed for all shipments selected for outbound processing after the
change occurs.
■ Change the carrier when the shipment has already been selected for
outbound processing via the Maintain Carrier Manifest (tdawm4105m000)
session.
Change Order Manifest
Through the order entry module, you can change specific customer and item
data by order prior to outbound advice.
Once pick planned, a new manifest can be created and populated with orders
transferred from another carrier manifest. The ability to add order lines to a
manifest is limited to order lines existing in the Sales Order database.
Display Unconfirmed Picks
Inquiry into unpicked items is provided in two ways—either by unconfirmed

pick query or RF queue management. Unconfirmed pick query is used to view
picks that are currently pending. RF queue management provides an interface to
query and manage the RF transaction queue. Transactions are displayed in
sequence by priority, date and time, and status. Status indicates if the item has
been picked or not. Unpicked items can also be displayed through the Display
Order Line Status session.

Features
Emergency Picks
Through the use of order types, sessions and steps can be selected or omitted
from the order process to perform emergency picks. The order type can specify
documents to print and the sequence and selection of steps to be performed for
that order. By designating an order type as collect, direct stock update and a
limited amount of order steps are used to process an emergency or rush order.
EDI Support
The Electronic Data Interchange (EDI) module can be used to exchange sales
orders inbound, and sales order acknowledgments, purchase orders, and
invoices outbound to trading partners.
Shipment Confirmation
There are two confirmation steps: dock floor spot confirmation and shipping
confirmation (after parcels are loaded on the truck). Dock floor spot
confirmation is performed through an RF terminal or an online session.
Shipping confirmation is performed only through an online session.
Location Control of Shipping Dock/Area
Location control is handled by using dock floor spots. A dock floor area is
distinguished from a location in that an area has no specific item dimensions
associated with it. A dock floor area has a total maximum volume of items only
and can be as large or small as you want.
Associate Carrier to Dock Floor/Area
Carrier definition detail allows the entry of a dock floor area, which is where the
parcels for this carrier should be staged at shipping time. Entries are validated
against the dock floor areas previously entered in dock floor area definition.
Reverse Stop Sequence for Routes
Route can be specified on the sales order. When the route is supplied, loading
and staging worksheets are formatted specifically to aid in the truck loading
process. This information is then used for printing various delivery documents.

Setting Up MK Advanced Warehouse Management

To use MK Advanced Warehouse Management, you must first perform setup
procedures:
■ Warehouse
■ Item
■ Receiving
■ Shipping
Warehouse Setup Procedures
The following steps are necessary to establish operations for any site and
warehouse combination using MK. You must first define the following:
■ Sites
■ Warehouses
■ Carton Types
■ Packing Cartons
■ Storage Equipment Types
■ Locating Rule Sets
■ Locations
■ Directed RF Rules
■ Directed RF Terminal
Item Setup Procedures
You must perform the following steps to establish items that are shipped
through AWM. With the first section, you must define categories of information
for each item. During the second section, you must assign specific rules,
definitions, and detail to each category.
Section 1
■ Locating Category
■ Picking Category
■ Handling Category
■ Replenishment Category
■ Packing Category

■ Freight Class
■ Inventory Status
■ Lot Status
■ Item Maintenance
■ Customized Item Maintenance
■ Lot Maintenance
Section 2
■ Handling Standards
■ Storage Handling Standards
■ Putaway Zone
■ Pick Zone
■ Allocation Zone
■ Locating Rule
■ Picking Rules
■ Replenishment Rules
– Replenishment Rule Override
– Replenish Order Types
– Replenish Store Type Exception
■ Locating Assignment
■ Picking Assignment
■ Replenishment Assignment
■ Independent Replenishment Assignment

Receiving Setup Procedures
You must establish disposition codes and any reasons for rejection prior to
receiving inventory in MK.
Shipping Setup Procedures
These steps are required for setting up shipping information in MK. The
following information must be established:
■ Picking teams
■ Picking team assignments
■ Dock groups
■ Dock floor area
■ Carrier codes
■ Shipping waves
For detailed information on these steps and Advanced Warehouse Management

Configuration, refer to Advanced Warehouse Management, Volume 1, Getting
Started.

Chapter
Inbound Processing
4
Introduction .................................................................................. 4–1

Inbound Data ................................................................................ 4–2
Maintaining Receipts ...................................................................... 4–3
Generating Inbound Advice................................................................ 4–6
Maintaining Inbound Data ................................................................ 4–11
Displaying Inbound Data ................................................................. 4–14
Printing Data ................................................................................ 4–16
Printing Inbound Data.................................................................... 4–16
Printing Inbound Advice Steps ............................................................ 4–18
Locating Rule Sets ........................................................................... 4–20
Using Locating Rule Sets in Receipt Processing ............................................. 4–23
Displaying Locating Rule ................................................................. 4–23
Locating Rule Set Checklist ............................................................... 4–25
Putaway Operations ......................................................................... 4–27
Printing Putaway Labels .................................................................. 4–29
Error Labels ............................................................................. 4–30
Putaway Control Sheets .................................................................. 4–31
Putaway Confirmation ................................................................... 4–32
Determining Why Items Were Not Located ................................................. 4–34
How Variable Pallets Are Handled ............................................................ 4–35
Inbound Processing 4–i

Chapter
Inbound Processing
4
Introduction
MK contains a comprehensive module used to process supplier purchase orders.
Receipts against purchase orders are performed for AWM warehouses based on
ILC and AWM parameters.
Inbound processing determines the appropriate location to store items based on

space, storage conditions, and item data. This location data (inbound advice) is
typically generated by MK.
This chapter describes how to perform the following operations:
■ Maintain receipts for AWM warehouses

■ Generate inbound advice
■ Process inbound data
■ Locate product by locating rule
■ Perform putaway confirmation
Inbound Processing 4–1

Inbound Data
Inbound Data
Maintain Purchase
Orders
(tdpur4101m000)
Maintain Receipts Display Inbound

(AWM) Data
(tdpur4120m000) (tdilc4599m000)
Generate Inbound Maintain Inbound

Advice Data
(tdilc4203m000) (tdilc4103m000)
Print Inbound Data

(tdilc4403m000)
Print Putaway Print (reprint)

Control Sheets Putaway Labels
(tdawm2404m000) (tdawm2403m000)
Putaway
Confirmation
(tdawm2107m000)
Required Optional

Inbound Data
Maintaining Receipts
The Maintain Receipts (tdpur4120m000) session is used to record the receipt of

goods that have been purchased. The items received (purchase order lines) are
related to a receipt number and a dispatch note number, that is, a supplier’s
packing list.
The goods are posted to stock online, unless they are cost items or items on an
expensed purchase order line. These items are never included in the inventory.
If the goods have to be inspected, the quantity that has arrived will be blocked.
If fewer items are received than were ordered, a back-order can be created for
the remaining quantity. If the warehouse is location-controlled (ILC) and is an
AWM warehouse, the receipts must be posted to stock in the Maintain Receipts
(AWM) (tdawm4113s000) session.
Rose Stump works in the dock area of the warehouse. Rose begins the
receipt/putaway process by running the Maintain Receipts (tdpur4120m000)
Scenario session for goods that have been purchased by Starcom. Here is how she does
it:
Before You Begin Before you can enter receipts in this session, one of the following sessions
should have been carried out, depending on the origin of the receipt (purchase,
production, etc.):
■ Maintain Purchase Order (tdpur4101m000)

■ Maintain Purchase Order Lines (tdpur4102s000) (for collect orders)
■ Report Production Orders Completed (tisfc0202m000)
■ Maintain Planned PRP Warehouse Orders (tipcs5130m000) (for warehouse
orders)
■ Maintain RMA Receipts (tsrma3160m000) (for RMA orders)

Inbound Data
Session Procedure 1. Access the Maintain Receipts (tdpur4120m000) session.
2. Select a receipt number.

3. Enter the dispatch note number, if applicable, and press Enter.
4. Select Post Receipts to Work In Progress. The Post Receipts to Work In
Progress menu appears.
5. Change the receipt data or quantity received in the Disp. Note quantity field.
The Maintain Receipts (AWM) pop-up form appears.

Inbound Data
6. Change the quantity and pieces received. Explanations of the required and
any other important fields follow:
■ Quantity—indicates the number of units in the standard unit of measure
being received. You can zoom to the Line Item Dimensions
(tdawm2104s000) session.
■ Pieces—indicates the pieces being received. Options are:
EA—eaches
IP—inner pack
CS—case
MC—master case
PL—pallet
Note: MK lets you enter quantities for a receipt line item in units of pallets,
cases, or eaches. After each entry, MK recalculates the total receive quantity
based on the entries you made and the pallet or case pack value currently
assigned to the receipt line (either from the AWM Item Master File or from
operator input via the Line Item Dimensions window).
The unit of measure you use to indicate the total quantity to be received has
no effect on the locating rule set selected or the type of putaway schedule by
the locator system. The locating rule set selected determines the type of
putaway transaction scheduled by MK.
This form now displays the Dispatch and Received quantities in the upper
right corner.
Note: The received field will show quantity in eaches. For example, if you
receive 2 cases with 12 eaches to a case, then 24 eaches displays in the
Received field.

Inbound Data
Generating Inbound Advice
In this session you can generate inbound advice for items which have been
registered at a receipt location of a warehouse. This is done through the
Maintain Receipts (tdpur4120m000) session (for standard production, repetitive
production, or Advanced Warehouse Management warehouses).
Inbound advice is only generated for those items that have been specified in the
Maintain Item Data (tdinv0101m000) or Maintain Customized Item Data
(tipcs9102m000) sessions.
The receipts may be the result of a purchase order, production order, rework
production order, PRP warehouse order, repetitive production, or RMA. You
cannot generate inbound advice for an expensed item on a purchase order.
The advice signifies that items are assigned to locations as follows:

■ For Inventory Location Control (ILC) warehouses, MK takes into account the
storage conditions and the priority sequence of fixed and free locations, as
well as the available capacity of a location.
■ For AWM warehouses, a locating rule set determines the correct putaway
zone and location for an item receipt based on a sequence of rules defined
for the item’s location category.
Once Rose has recorded the receipt information, she runs the Generates
Inbound Advice (tdawm4113s000) session. This session determines where the
Scenario inventory should be stored based upon predefined rule sets.
Before You Begin Enter the ranges for which you want to generate inbound advice. By specifying
the relevant ranges, you can select on the basis of which receipts the advice has
to be given. You can advise and maintain inbound advice after any of the
following sessions:
■ Maintain Purchase Order Lines (tdpur4102s000)
■ Maintain Receipts (tdpur4120m000)
■ Report Repetitive Completions (tisfc9202m000)
■ Maintain Planned PRP Warehouse Orders (tipcs5130m000)
■ Maintain RMA Receipts (tsrma3160m000)
Performing a System The Generate Inbound Advice (tdawm4113s000) session uses the following
Check procedure for advising receipts. For AWM warehouses, the Locating Rule
Detail determines the putaway zone and storage type, and the location status
for the location. Also, the following ILC edits are performed:

Inbound Data
For AWM warehouses, the Locating Rule Detail determines the putaway zone
and storage type, and the location status for the location. Also, the following ILC
edits are performed:
System check on Advice restrictions

Total blocking If a location is blocked through a blocking reason, the location is not
advised.
Inbound location If a location is not defined as an inbound location, (refer to the Maintain
Locations (tdilc0110m000) session), the location is not advised.
Inbound blocking If a location is blocked for the inbound transaction type, the location is
not advised.
Location type If a location is the same as the location from where the advice is given, a
receipt location, the location is not advised.
Multi-item location yes/no If a parameter is No and the advised item has a different item code than
parameter that of the item already stored in that location, the location is not
advised.
Multi-lot by item location If a parameter is No and a different lot is already stored at the location
yes/no parameter than that of the advised item, you are not allowed to store another lot in
that location.
Advice on unoccupied location If a parameter is No and a quantity is in that location, the location is not
yes/no parameter advised.
Minimum percentage free If the percentage free of a location is smaller than the percentage free as
recorded by warehouse, the location is not advised. MK checks the
available capacity of a location in this step.
Conversion factor unit When no conversion factor has been defined between the capacity unit
of a location and an entered alternative unit of an item, the location is
not advised.
Storage conditions by item If the Test Storage Conditions for Items parameter is Yes and the
condition of the item does not match the condition by location or
warehouse, the location is not advised.
Storage conditions by item If the Test Storage Conditions for Item Groups parameter is Yes and the
group condition of the item group does not match the condition by location or
by warehouse, the location is not advised.
Storage conditions by location If the Test Storage Conditions for Locations parameter is Yes and the
condition of the location does not match the condition of the item or
item group, the location is not advised.
Storage conditions by If the Test Storage Conditions for Warehouses parameter is Yes and the
warehouse condition of the warehouse does not match that of the item or item
group, the location is not advised.

Inbound Data
Session Procedure Note: A prompt is available in this session to automatically run inbound advice
steps when creating inbound advice.
1. Access the Generate Inbound Advice (tdilc4203m000) session:
2. Enter the run number. You can also select Zoom in the Run Number field.
Enter 1 to display and select an existing run number or enter 2 to maintain
run numbers.
3. Select Close to return to the main form.
4. Enter data in all the required fields. Explanations of the required fields
follow:
■ Run Number—links to the inbound lines when advising and maintaining
inbound data. For example, if you must execute the whole procedure for
a range of items, orders and delivery dates, it is not necessary to record
the same selection each time for each selection.
■ Order Type—indicates the order type that begins or ends the range.
Purchase Order—the order is a purchase order.
Production Order—the order is a production order.
RMA—the order is an RMA.
■ Warehouse Type—indicates the type of warehouse. Valid entries are:
ILC Warehouse—this is an ILC warehouse.
AWM Warehouse—this is an AWM warehouse.

Inbound Data
Other important fields are as follows:

■ P.O. Receipt Number—provides the purchase order receipt number that
begins or ends the range.
■ Warehouse—provides the code of the warehouse where the items must be
stored.
■ Supplier—indicates the supplier that begins or ends the range.
■ Project—provides the project code that begins or ends the range.
■ Item Code—indicates the item code that begins or ends the range.
■ Order/Batch ID—indicates the order or batch ID number that begins or
ends the range.
■ Schedule No—provides the schedule number that begins or ends the
range.
■ Operation Route—provides the operation route number that begins or
ends the range.
■ Delivery Date—indicates the delivery date that begins or ends the range.
5. After entering all key information on the first form, advance to Form 2.

Inbound Data
follow:
■ RMA Receipt Number—indicates the RMA receipt number that begins or
ends the range.
■ Customer—indicates the customer code that begins or ends the range.
■ Region—indicates the region code that begins or ends the range.
■ Print Advice—indicates whether to print advice. Inbound data can be
printed after generating advice through the Print Inbound Data
(tdilc4403m000) session.
■ Include Non-net Location—indicates whether to include non-nettable
items. Non-nettable items are unavailable for material planning.
7. Select Execute to generate inbound advice.
8. Display or print your output.
After MK generates advice, one of the following steps is possible:

■ Maintain Inbound Data (tdilc4103m000 or tdilc4104s000)
■ Print Inbound Data (tdilc4403m000)
■ Delete Inbound Data (tdilc4213m000)

Inbound Data
Maintaining Inbound Data
You can enter or maintain inbound item data advised into a receipt location or
an inspection location of a non-AWM warehouse. These items may originate
from purchase orders, production orders, batches, production schedule
quantities, rework orders, PRP warehouse orders, or RMAs.
Before you begin maintaining inbound data through this session, you can first
generate inbound advice through the Generate Inbound Advise (tdilc4203m000)
session discussed previously. You can advise and maintain inbound data after
items have been booked to a receipt or an inspection location of the warehouse.
Items are received to an inspection location when a purchase order indicates
they must be inspected and the order type has the Maintain Approvals
(tdilc4123s000) session as an order step. You can record a receipt location and an
inspection location for a warehouse through the Maintain Warehouses
(tcmcs0103m000) session.
Before You Begin One of the following sessions may precede this session depending on the origin
(order type) of the items:
■ Maintain Purchase Order Lines (tdpur4102s000)
■ Maintain Receipts (tdpur4120m000)
■ Report Repetitive Completions (tisfc9202m000)
■ Maintain Planned PRP Warehouse Orders (tipcs5130m000)
■ Maintain RMA Receipts (tsrma3160m000)

Inbound Data
Session Procedure To maintain inbound data:

1. Access the Maintain Inbound Data (tdilc4103m000) session.
2. Enter data in all required fields. Explanations of the required and any other
important fields follow.
a range of items, orders/batches/production schedule quantities, and
delivery dates, it is not necessary to record the same selection each time
for each session.
■ Order Type (Purchase order, Production order, PRP warehouse order,
Rework production order, Repetitive production, RMA order, Material
requisition)—searches for the relevant order by entering the order type
when maintaining inbound lines already recorded.
■ Order/Batch ID—searches for the relevant order batch ID by entering the
number when maintaining inbound lines already recorded.
■ Operation Route—provides the item’s sequence of operations.

Inbound Data
3. Select Execute to maintain inbound data.
4. Select the correct order/batch ID, position, or serial number you want to
change.
5. Enter data in all required fields. Explanations of the required and any other
■ Order/ Batch ID—searches for the relevant order/batch which applies to
the inbound. If you are not maintaining batch IDs for repetitive
production, the production/schedule/item/warehouse/operation/
route/delivery date combination is used to maintain inbound data.
■ Position—indicates the position number of the order/batch for which the
inbound lines are recorded.
■ SrNr.—denotes the partial delivery relevant to the inbound. This
number is needed to register many storage lines for the same partial
delivery.

Inbound Data
Displaying Inbound Data
This session allows you to display detailed inbound data (tdilc4599m000) for a
particular purchase order, production order, PRP warehouse order or repetitive
production. If inbound data exists for a particular order, batch or production
schedule quantity, you can mark and zoom to display detailed information
about it.
Before You Begin If you want to view inbound data, you must run the following sessions in this
order:
1. Maintain Receipts (ILC) (tdilc4113s000)
2. Maintain Receipts (ILC for repetitive production) (tdilc9113s000)
3. Generate Inbound Advice (tdilc4203m000)
Session Procedure To display inbound data:

1. Access the Display Inbound Data (tdilc4599m000) session.

Inbound Data
2. Select what type of orders you want to display.

3. Enter data in all the required fields. Explanations of the required and any
other important fields follow.
■ Order Type (Purchase order, Production order, Repetitive production,
PRP Warehouse order, RMA order)—searches for the relevant order by
entering the order type when maintaining inbound lines already
recorded.
■ Order Bat. ID—provides the number of the order/batch which applies to
the inbound.
■ Pos.—identifies the position number of the order/batch for which the
inbound lines are recorded.
4. Select Next or Prev to display the next or previous orders or batches.
5. Information can be selected from one of the following sorts:
■ Warehouse/Order Type/Order Number/Position Number/Serial
Number 1/Serial Number 2
■ Warehouse/Location/Order Type/Order Number/Position/Serial
Number 1/Serial Number
■ Run Number/Order Type/Order Number/Position Number/Serial
Number 1/Serial Number 2
■ Order Type/Schedule/Item/Warehouse/Operation Route/Delivery
Date/Position/Serial Number 1/Serial Number 2
6. To display details, mark the order you want.
7. Select Confirm to confirm the selection and then select Zoom to display the
details.

Printing Data
Printing Data
There are a number of useful reports you can use to help keep track of inbound
data, including printing of inbound data or inbound advice steps. The following
procedures provide information on using these sessions.
Printing Inbound Data
The Printing Inbound Data (tdilc4403m000) session allows you to print the
locations advised for inbound purchase orders, production orders, batches,
production schedule quantities, PRP warehouse orders and RMAs. This report
can be used as a storage list. This list indicates the items receipt or inspection
location and the location where the item must be stored.
Before You Begin You must run the Generate Inbound Advice (tdilc4203m000) session, before
you can report inbound data.
Session Procedure To print inbound data:

1. Access the Print Inbound Data (tdilc4403m000) session.

Printing Data
2. Enter the range of data you want to report. Explanations of the required or
important fields follow:
■ Run Number—provides the run number that begins or ends the range.
■ Order Type—provides the order type that begins or ends the range.
■ P.O. Receipt Number—includes the purchase order receipt number that
■ RMA Receipt Number—indicates the RMA receipt number that begins or
ends the range.
■ Project—provides the project number that begins or ends the range.
3. Select Execute and select one of the following options:
■ Report 1 reports inbound data by run number.
■ Report 2 reports inbound data by order or batch ID.
■ Report 3 reports inbound data by schedule.

Printing Data
Printing Inbound Advice Steps
Before You Begin To report inbound advice steps, the Log Inbound Advice Steps for Report
parameter must be set to Yes in the Maintain Location Control Parameters
(tdilc0100m000) session. You must also have run the Generate Inbound Advice
Session Procedure To print inbound advice steps:

1. Access the Print Inbound Advice Steps (tdilc4404m000) session.

Printing Data
2. Enter the range of data you want to report. Explanations of the required
fields and any other important fields follow.
a range of items, orders/batches/production schedule quantities, and
delivery dates, it is not necessary to record the same selection each time
for each session.
■ Order Type (Purchase order, Production order, Repetitive production,
PRP Warehouse order, RMA order)—searches for the relevant order by
entering the order type when maintaining inbound lines already
recorded.
■ Order/Batch ID—indicates the order or batch number that begins or ends
the range.
■ Position Number—indicates the position number that begins or ends the
range.
■ Schedule No—gives the schedule number that begins or ends the range.
■ Warehouse—indicates the warehouse that begins or ends the range.
■ Delivery Date—provides the delivery date that begins or ends the range.
3. Select Execute to print data.

Locating Rule Sets
Locating Rule Sets

How Rules Sets Are When you request assignment of storage locations to products from a receiving
Selected session, MK selects a locating rule set based on the purchase order line item’s
warehouse, the locating category assigned to the line item, the receipt type
from the receiving document, and an optional receipt disposition. This criteria
also points to the inventory status (see Maintain Inventory Status
(tdawm3101m000)) and lot status codes MK uses to assign product to a location
or area for storage.
The warehouses, receipt type, and locating category are fixed criteria not under
the operator’s control during an active receiving session. However, the receipt
disposition is a dynamic facility which allows the operator to specify that a
quantity of product is assigned locations using a specially selected rule set.
The rule sets that are used in receipt processing are maintained by Jay Strange.
The following section discusses the logic that MK uses to apply those rules.
Scenario
MK uses groups of individual rules called rule sets to locate inventory in a

warehouse. The following describes the relationship between items, rule sets,
and locations within the warehouse.
■ Item/quantity—From the expected receipt record, MK determines the item
and quantity that needs to be put away, based on the predefined unit of
measure from the Item Master.
■ Rule Set—For each unique item in the warehouse, a separate rule set can be
defined. A rule set consists of two parts:
– Quantity/location—A group of individual rules that specify the location
for a specific quantity of inventory. You can define rules for specific
quantities of pallets, unit of measure 2, cases, unit of measure 1, and
eaches per item.
– Putaway sequence—Within the pallet, UOM2, case, UOM1, and each
quantities, each rule has a sequence number. MK executes the rules in
the sequence order. This enables you to define alternative locations so
that the product is always put away.
■ Zones—Each rule points to a specific zone and storage type combination of
the warehouse in which to put inventory. For example, you may put pallets
in the pallet storage type of the general putaway zone and cases in the carton
flow storage type of the general putaway zone.

Locating Rule Sets
How Rule Sets Work After determining the total quantity of an item to put away from the receipt
entry, MK sequences through the rule set and puts away the product in
available locations. The following is an example of how rule sets work:
1. If the total quantity of a product that must be put away equals one full
pallet, MK checks the first pallet rule in the rule set.
If space is available in the location(s) in the first rule, then the one full pallet
is put away there.
2. After locating the pallet quantity, MK checks for case and/or each rules if
less than a pallet remains to be put away.
Rule Set Factors Factors affecting rule sets are as follows:

■ Space requirements/equipment capacities. If a rule points to a storage type
within a putaway zone that is available, MK will make sure that:
– The total cubic dimensions of the product to be put away is equal to or
less than the available cubic dimensions of the specified storage type.
– The weight capacity of the product is less than the weight capacity of the
storage type.
■ User-defined sequences. Each rule within a sequence of rules is set up for a
unique combination of the following:
– Quantity
– Zone
– Equipment criteria
– Location status
Search Sequence MK uses the following search sequence to obtain the proper locating rule set
assignment record. The assignment record then points to the appropriate
locating rule set to use.
Locating Receipt Receipt Type Disposition

Category Warehouse Receipt
Specific Specific Specific Specific
Specific Specific BLANK Specific
BLANK Specific Specific Specific
BLANK Specific BLANK Specific

Locating Rule Sets
Also considered is the following:

■ ABC classification (only A items can be stored in A locations)
■ Inventory status
Search Sequence 1 When first processing a receipt, MK searches through the assignment records
for one that has the specific locating category, receipt warehouse, and receipt
type that matches the receipt. This is Sequence 1 (specific, specific, and
specific). To use Sequence 1, you must assign a separate locating rule set for
each valid combination of locating category, receipt warehouse, and receipt
type and disposition.
Search Sequence 2 Using any other sequence (2 through 4) eliminates the need to define a separate
assignment record for each unique combination of locating category, receipt
warehouse, and receipt type. Sequences 2 through 4 enable you to use a single
locating rule set for multiple receipt types. The sequence works as follows: If
MK does not find the specific assignment record, it uses Sequence 2. In
Sequence 2, MK searches for an assignment record with a specific locating
category and receipt warehouse, but BLANK receipt type.
BLANK Designator BLANK means the corresponding field is not filled in MK searches for this
exact combination in the list of assignment records. For example, in Sequence
2, MK searches for the assignment record in which the Receipt Type field has
not been filled in. If such an assignment record is found, it is selected and the
corresponding locating rule set is used. If an assignment record is not found
after Sequence 4, the order is rejected and not processed.
BLANK for Receipt Disposition means Blank only; it does not mean All.
Note: Specifying the receipt warehouse is required because each receipt is

received into a specific receipt warehouse.

Locating Rule Sets
Using Locating Rule Sets in Receipt Processing
Receipt processing uses locating rule sets in the following manner:

■ Reads the item master. Using the item number from the receipt, MK reads
the item master and obtains the locating category.
■ Obtains assignment record. Using the receipt type and receipt warehouse
from the receipt, disposition, and the locating category from the Item Master,
MK obtains the appropriate receipt locating rule set assignment record.
■ Obtains the rule set. From the rule set assignment record, the appropriate
rule set is obtained.
■ Uses the specific rule. Using the quantity from the receipt, MK uses the
appropriate rule.
■ Locates inventory to specified putaway zone/storage type or area. Using
the rule, MK locates the inventory to the specified putaway zone/storage
type in the warehouse.
Displaying Locating Rule
Session Procedure To display a locating rule:

1. Access the Display Locating Rule (tdawm4114m000) session.

Locating Rule Sets
2. Enter the project and item number for locating rules you want displayed.
For project or item detail select Zoom.
■ Project—indicates the number of the project you want to display.
■ Item—indicates the item code for the locating rule you want to display.
The locating rules for that project and item are displayed.
3. Advance to Form 2.

Locating Rule Sets
Locating Rule Set Checklist
If you encounter problems locating an inbound item (resulting in an error label),

perform the following checks. (This assumes ILC module parameters are set to
Yes, AWM module parameters indicate that the AWM is set to Yes, and the
warehouse is set as an AWM warehouse and a Receiving Warehouse.)
1. Determine where you think the item should be located. (It also helps to have
extra locations where the item can be located in the case of an excess
quantity or volume problem which is preventing an advice.)
2. Determine if the ABC code of the location matches the ABC code from the
item master. The location’s ABC code can be less than the item’s ABC code,
but MK looks for matches on the ABC code first.
3. Track the locating category from the item to the locating rule assignment.
On the locating rule detail Form 2, ensure that the warehouse, putaway
zone, and storage type match that of the location.
■ Ensure you have a locating rule assignment sequence with a blank
disposition code to match the receipts of line items where no disposition
code is entered during receiving, that is, the disposition code for the line
item is blank.
■ Ensure that in the location rule detail, you have specified a label type (on
Form 2) which corresponds to the pick type (PL, CS, or EA). Also,
within the location rule detail, the minimum and maximum for Expected
and Original values typically are set to zero, if the quantities are not in
use by the ordering system.
4. Check the location status. The location status must equal a status specified
in the location rule detail:
E = Empty
S = Storage
P = Picking
5. Ensure the quantity and volume of the item to be located fits into the
minimum and maximum values specified on the location rule and the
storage type.

Locating Rule Sets
6. Once a locating rule is selected, the locating logic is as follows:

■ Check for permanent (fixed) locations of the item. Fixed locations have
priority over free locations.
■ If the locating rule’s location status is Storage, than look for a location
that already contains the item. The location’s status must also be
Storage.
■ If the locating rule’s location status is Empty, then look for a location
with an Empty status. The sequence of looking for Empty or Storage
status locations is determined by the sequence number of the location
rule detail.
■ Finally, look for multi-item locations, assuming ILC parameters are set
to allow multi-items in a location.
ILC Checks Once an AWM location is selected, all ILC checks are performed, including
block conditions, storage conditions, and quantity restrictions, which can
prohibit inbounding an item.
These checks include:

■ The location is blocked for all transactions
■ The location is blocked for inbound
■ The location is not set as an inbound location
■ Stock of different items is not allowed (check ILC parameters)
■ Stock of different lots is not allowed (check ILC parameters)
■ Only allowed to inbound for free locations (check ILC parameters)
■ Unit of measure for the purchase order line item and the location do not
match, and no conversion factor is established
■ ILC storage conditions have been loaded which do not match for the item
and location
Note: On the Purchase Order Header, ensure that the Delivery Address Code, if
specified, is one which is established in the rule sets. Ensure at the line item
level that the warehouse code is one which is established in the rule sets in case it
was overridden on the line. Also, check the order line status to ensure it has
been received properly and is not on hold, awaiting some other order step.

Putaway Operations
Putaway Operations
Putaway operations involve performing one of the following tasks:
■ Paper putaway confirmation
– Uses putaway control sheets and labels
– Uses the putaway confirmation session
■ Radio frequency terminal receipt confirm and putaway confirmation.
Note: This chapter assumes a Paper Putaway process is in place. For RF flow,
refer to Chapter 8, “RF Processing.”
You can add all receive quantities to inventory and print the Putaway Control
Sheets. Putaway labels can be reprinted, if necessary, from receiving any time
after initial locating and prior to the Confirm process.
Purpose of Putaway Putaway labels serve two purposes: they list information needed to put away
Labels the merchandise in the warehouse, based on the locating rules contained within
MK, and they provide a physical count of the merchandise when applied.
If there are not enough labels to place on all the received merchandise, or if
there are labels left over, it indicates that AWM used incorrect information
when calculating the quantities to be received. If there are not enough labels,
the quantity received was too low. If there are too many labels for the
merchandise, the quantity received was too high. In either case, the error may
have been caused by an incorrect quantity entered by the operator, or by
incorrect information contained in the Item Master File.

Putaway Operations
Types of Putaway The following are the types of putaway labels you can produce:
Labels
■ CASE CONSOL – Case Consolidation. MK produces a case consolidation
putaway label when the locating rules specify that the received pieces
should be added to an existing case location if possible. Directly under the
location address, MK indicates the number of pieces that should be in the
case once the consolidation is complete.
■ FULL CASE – Full Case. MK produces a full case putaway label when the
locating rules specify storage in a case location, and the number of items to
be put away at the location is equal to the case pack specification used by the
operator when the product was received.
■ FULL PALLET – Full Pallet. MK produces a full pallet putaway label when
the locating rules specify storage in a full pallet location, and the number of
cases to be put away at the location is equal to the pallet specification used
by the operator when the product was received.
■ PALLET CONS – Pallet Consolidation. MK produces a pallet consolidation
putaway label when the locating rules specify that the received cases should
be added to an existing pallet location if possible. Directly under the
location address, MK indicates the number of cases that should be present on
the pallet once the consolidation process is completed.
■ PART CASE – Partial Case. MK produces a piece putaway label when
receiving less than a full case quantity (determined by the standard case
pack for the item), the locating rules specify storage in a case location, and a
case label is requested in those rules.
■ PART PALLET – Partial Pallet. MK produces a partial pallet putaway label
when the locating rules specify that the product should be stored in a pallet
location, and the number of cases to be stored in that location is less than the
cases per pallet specification used by the operator when the product was
received.
■ PIECES – Pieces. MK produces a piece putaway label when the receipt
quantity is less than the case pack quantity used by the operator during the
receiving process, and the locating rules specify that a piece putaway label
should be produced.

Putaway Operations
Printing Putaway Labels
Sonja Matichuk begins the putaway process by printing putaway labels. These
labels identify where the product is to be put.
Scenario
Session Procedure To print putaway labels:

1. Access the Print Putaway Label (tdawm2403m000) session.
2. Enter the range of information for which you want to print putaway labels.
Explanations of the required fields and any other important fields follow.
■ Control Number—provides the range of control numbers for which you
want to print putaway labels.
■ Warehouse—indicates the range of warehouse codes for which you want
to print the location data of items.
■ Location—indicates the location data to be printed using the location
code.
■ Sequence—provides the range of sequence numbers for which you want
to print putaway labels.
3. Select Execute to print putaway labels.
4. Select the appropriate device for printing the labels.

Putaway Operations
Error Labels
Error labels indicate that MK was unable to determine a putaway location for
some or all of the item quantity. An error label is produced if there is not
enough information available to complete the locating process, or the
information it has is ambiguous.
For example, if the item master does not indicate a quantity for the number of
cases that should be on a pallet, and the locating rule indicates that a pallet
quantity has been received, MK will produce an error label requesting the
additional information required.
Error Description To indicate the error that has occurred, MK prints the literal *ERROR*NNN
where NNN indicates the three-digit error code which identifies the cause of
the problem. The remaining fields along the bottom of the label are used for
the same purpose as on the putaway label format: to indicate the product
quantity and configuration information.
MK prints all of the information that it has for the product. Any fields that do
not have an entry print as zero. At times, the lack of information printing in
these fields will be a direct indication of the problem that MK found.
Error Label Codes The following lists error label codes and their meanings:
■ 000—Count not assigned putaway area sequence number.
■ 001—No locating rule found.
■ 002—Two line items with the same SKU number were selected or received.
Each contains different case pack or cases per pallet information.
■ 003—No locating rules left in sequence, partial quantity not yet located.
■ 004—Failure when computing pieces per location.
■ 006—Warehouse not found for indirect SKU.
■ 007—No item record is found.
■ 008—No lot master record is found.
■ 009—Movement class for items is invalid.
■ 010—P label requested by locating rule.

Putaway Operations
Putaway Control Sheets
MK produces two separate types of putaway control sheets: the master copy is
used by the supervisor and contains the check digit for each location. The
working copy is used by the putaway worker, and contains blanks for entry of the
check digit found at each location.
The putaway worker takes the items to the specified location and marks the
check digit on the working copy of the putaway control sheet.
The control sheet can use bar-coded control sheets used with keyboard wedge
bar-code scanners for AWM confirmation. If bar-code scanners are used, the
Print Pick Control Sheet (tdawm4467m000) and Print Putaway Control Sheet
(tdawm2404m000) reports include the bar code at the bottom of each sheet, and
the Bar Code Control Sheets option in the Maintain Warehouses
(tcmcs0103m000) session is set to Yes, as described in Advanced Warehouse
Management, Volume 1, Getting Started. The bar-code scanner configuration
allows AWM confirmation with less re-entry of required information.
After putaway, the supervisor compares the check digits on the master copy
with those entered on the working copy.
Discrepancies between the master and the working copy must be corrected
before confirming the putaway.

Putaway Operations
Putaway Confirmation
You can maintain exceptional inventory accuracy without sacrificing

productivity by requiring proof that a product was in transit and proof that it
arrived correctly. Putaway can be radio frequency or paper controlled.
Interleaved picking and putaway lets you perform RF picking to be informed of
a pending putaway in the aisle of the next pick assignment.
Putaway confirmation is used to provide positive acknowledgment that a

predetermined quantity of inventory was put away as instructed by the locating
logic used by MK. There are three methods you can use to perform putaway
verification: a paper-driven system, Directed RF (Radio Frequency), and Non-
Directed RF.
Note: Refer to Chapter 8, “RF Processing,” for the steps you should follow if
you are performing putaway confirmation from an RF Terminal system.
The Putaway Confirmation (tdawm2107m000) session is used to record the

results of the paper-driven putaway process, including the employee who
performed the stocking function, and the number of errors made in the process.
Unlike RF putaway verification, the paper process does not immediately release
stock into its predefined inventory status when the physical putaway is
complete. MK does not know the results of the planned putaways until the
information contained on the putaway control sheet is input into the
confirmation form.
Once the items have been put away, Sonja runs the Putaway Confirmation
(tdawm2107m000) session to confirm the putaway.
Scenario

Putaway Operations
Session Procedure To confirm a putaway:

1. Access the Putaway Confirmation (tdawm2107m000) session.
2. To access the appropriate putaway sheet, enter the Warehouse and Locate
Control Number from the Putaway Control Sheet Working Copy and press
Enter. You can also select Zoom on the Warehouse or Locate Control
Number field to select the appropriate information.
3. Enter a receipt number if confirming an individual receipt against a
purchase order.
4. If all items have been put away correctly, select Confirm All. This will
putaway confirm all detail lines for the displayed location control number
and receipt number. After confirming all lines, MK deletes all putaway lines
on the form.
5. If there are items which have not been put away as advised by the Inbound
Advice worksheets, select individual detail lines by selecting Execute to
mark a line, then select Confirm All to confirm.
Note: The Location Control Number on the Putaway Confirmation form is
the same as the Putaway Control Number on the Unconfirmed Putaway
form, presented in “Warehouse Administration.”

Putaway Operations
Determining Why Items Were Not Located
The Item Location Simulation Report (tdawm3203m000) session or the

procedures listed in Chapter 8, “RF Processing,” allow you to confirm which
items were not located, but do not give the reason(s) why. Use the Print Item
Location Simulation Reports to determine why putaway items were not located.
After Sonja runs the Putaway Confirmation (tdawm2107m000) session to

confirm the putaway, she notices that some items were not located. She runs
Scenario the Item Location Simulation Report (tdawm3203m000) session to find out why
not.
Session Procedure To determine why items were not located:

1. Access the Item Location Simulation Report (tdawm3203m000) session.
2. Enter the locating rule ID or zoom to the Display Locating Rule

(tdawm0515s000) menu, mark the locating rule and description, and select
Execute to return to the Item Location Simulation Report.
3. Enter the project, item number, inventory status, source type, lot number,
and quantity.
4. Select Execute to display the Select Device (ttstplopen) form.
5. Enter the desired device name, or zoom to the Display Device Data
(ttaad3500s000) form and select the target report device.
6. If desired, change the print parameters.
7. Select Execute to print the Item Location Simulation Report.

How Variable Pallets Are Handled

Some times product can arrive on the receiving dock pre-stacked on pallets, but
the number of cases per pallet may not conform to the standard number of cases
per pallet configured on the AWM Item Master. To allow this product to be
handled as full pallet quantities by the locator system, MK offers the Line Item
Dimensions function.
The Line Item Dimensions function allows the operator to tell MK that a single
line on the receipt has variable configurations. For each variable pallet
configuration entered, the operator indicates the number of cases per pallet, and
the number of pallets containing that quantity.
When the receiving system processes a receipt line, it first looks to see if variable
pallet information was entered. If variable pallet information exists, a call to
locator is made for each variable pallet configuration found. Before the call is
made, the expected quantity is set to the greater of the quantity of cases specified
on the variable pallet record, or the remaining quantity from the receipt line.
Using the Line Item Dimensions function does not guarantee that the putaway
transaction scheduled by locator will be for a pallet. It does guarantee that when
the locating rule set is scanned, any rule conditioned by a full pallet quantity will
be used if the quantities match. Therefore, the rule set must contain rules that
can be fired by a pallet quantity to produce the desired results.
Accessing Line Item Perform the following steps to access the Line Item Dimensions function:
Dimension
1. Access the Maintain Receipts (tdpur4120m000) session.

2. Select a receipt number. If necessary, you can also click Zoom to select the
Display Receipts or Display First Free Receipt Number sessions.
3. Enter the dispatch note number and press Enter.
4. Change the quantity received in the Disp Note field. The Line Item
Dimensions pop-up form appears.

Chapter
Outbound Processing
5
Introduction .................................................................................. 5–1

Pick Planning ................................................................................ 5–3
Generating Outbound Advice .............................................................. 5–3
Simulating Outbound Advice ............................................................. 5–12
Maintaining Outbound Data (ILC) ......................................................... 5–13
Releasing Outbound Data (ILC) ........................................................... 5–13
Deleting Outbound Data (ILC) ............................................................ 5–14
Displaying Outbound Data (ILC) .......................................................... 5–14
Printing Outbound Data (ILC)............................................................. 5–15
Reversing Sales Delivery (ILC) ............................................................ 5–15
Releasing Planned AWM Material Requisition Orders ....................................... 5–16
Displaying Rejected Orders ............................................................... 5–16
Building Batch/Cart...................................................................... 5–17
Deleting Batch/Cart ...................................................................... 5–17
Deleting AWM Pick Plan ................................................................. 5–18
Pick Confirmation........................................................................ 5–19
Picking Rule Set Checklist ................................................................ 5–22
Shipping .................................................................................... 5–24
Maintaining Carrier Manifest ............................................................. 5–25
Confirming Dock Floor Spot .............................................................. 5–27
Maintaining Parcels ...................................................................... 5–29
Maintaining Ship Confirm Manifest ....................................................... 5–31
Ordering Shipment Reprints .............................................................. 5–32
Creating Independent Replenishments ..................................................... 5–33
Production .................................................................................. 5–35
Confirming Staging Areas ................................................................ 5–35
Confirming Work Order Manifests ........................................................ 5–36
Outbound Processing 5–i

Chapter
Outbound Processing
5
Introduction
This chapter explains the AWM process of selecting the most efficient locations
from which to pick a product for a customer order as part of a pick plan. This
process must be completed before you can actually deliver goods. The following
information is discussed:
■ Pick planning activities including:
– Generating advice and associated documents and labels
– Pick confirmation
– Deleting an AWM pick plan
■ Independent replenishments
■ Shipping activities including:
– Maintaining carrier manifest
– Dock floor confirmation
– Shipment confirmation
– Displaying parcels
– Order shipment reprints
Outbound Processing 5–1

Introduction
The following figure depicts AWM outbound processing:
Maintain Sales
Orders
(tdsls4101m000)
Generate Outbound
Advice
(tdilc4201m000)
Pick Planning Pick Plan

Process Simulation
Yes
Determine Quantity Select Locations to
Replenish?
to Replenish Pick
No
Print Picking Find Locations to

Labels/Sheets Putaway
Pick
(Wave 0 Replen)
(Wave 1-999 Pick)
Pick Confirmation
(tdawm4210m000)
Shipping Process
Maintain Carrier
Manifest
(tdawm4105m000)
Dock Floor
Shipment
Confirmation
Confirmation
(tdawm4135m000)
By Panel and In Truck

Manifest Off Manifest

Pick Planning
Pick Planning
The Pick Planning process schedules shipments of merchandise from the
warehouse based on customer orders for a site and warehouse.
Proposed order pools are analyzed and picking activity is optimized based on
user-defined pick rates, available equipment, human resources, and available
inventory. You can model and control the day’s or shift’s work based on
resource allocations that break down the work by zone, teams, and workers.
This lets you identify and react to potential bottlenecks before they occur.
Generating Outbound Advice
You can generate outbound advice (tdilc4201m000) for sales orders, service
orders, and RMAs. When generating outbound advice, stock is allocated at
location and lot level. Outbound can be advised for items stored at the receipt
location of the warehouse (if not blocked for outbound) or at noninspection
locations.
Outbound takes place on the basis of the outbound system (FIFO or location
sequence) defined for the item. If the item must be retrieved in components, the
advised quantity for the main item is calculated on the basis of its “weakest”
component. For example, often the components on a sales order dependent bill
of material must be issued instead of the main item. In this case, the components
are retrieved from the warehouse specified on the bill of material line for the
component.
Outbound is advised for each item that must be delivered. The following steps
must be performed for advising items that have to be delivered.

Pick Planning
For ILC and AWM Warehouses:

■ Check on the item type—if the item is not a purchased or manufactured
part, it will not be advised.
■ Check on stock—if an item has no location stock in the warehouse stated on
the sales order, the item will not be advised.
■ Check on outbound location—if a location is not defined as an outbound
location, the item will not be advised.
■ Check on outbound blocking—if a location is blocked for the outbound
transaction type, the item will not be advised.
■ Check on blocking—if the stock on location (total) is blocked, the item will
not be advised.
For AWM Warehouses Only:

■ Check on Picking Rule Assignment and Pick Rules—rules are employed in
determining the best locations from which to pick products for a selected
Pick Plan order.
The advised quantities from a location are stored under a run number, accessed
by selecting Zoom on the run number. By specifying the relevant ranges, you
can select on the basis of which deliveries the advice must be given.
Jan Ronald is the first shift supervisor for Starcom. The first thing that she does
every day is run Generate Outbound Advice (tdilc4201m000) session. This
Scenario session assigns inventory to orders and generates the pick plan for the
warehouse.
Before You Begin You can advice outbound when one of the following sessions has been run:
■ Maintain Sales Order Lines (tdsls4102s000)
■ Maintain Service Orders (tssma3101m000)
■ Maintain Return Material Authorizations (tsrma3101m000)

Pick Planning
Session Procedure To generate outbound advice:

1. Access the Generate Outbound Advice (tdilc4201m000) session.
2. Enter the run number. You can also select Zoom in the Run Number field.
Select Display Run Numbers or Maintain Run Numbers.
3. If using the Display or Maintain Run Numbers sessions, Select Close to
return to the Generate Outbound Advice form.
follow:
■ Run Number—links to the outbound lines when advising and
maintaining outbound data. For example, if you must execute the whole
procedure for a range of items, orders and delivery dates, it is not
necessary to record the same selection each time for each selection.
■ Order Type—indicates the order type that begins or ends the range.
Valid order types are:
Purchase Order—the order is a purchase order.
Production Order—the order is a production order.
Sales Order—the order is a sales order.
RMA—the order is an RMA.

Pick Planning
Other important fields are as follows:

■ Customer—indicates the customer that begins or ends the range.
■ Order/Batch ID—indicates the order or batch ID number that begins or
ends the range.
■ Operation—indicates the operation number that begins or ends the range.
■ Prd Dt/Prd. Yr-Wk-Dy—indicates the product date that begins or ends
the range. The information you enter here is converted into Year-Week-
Day information in the next field.
■ Delivery Date—provides the delivery date in the range you want to
select.
■ Warehouse—provides the code of the warehouse where the items must be
stored.
■ Process AWM Data?—prompts you whether you want to process AWM
data.
Note: The default for this field is determined by the warehouse. If you
enter Yes in this field, Form 3 of this session is enabled. Form 2 is
provided for Manufacturing operations and the carrier.
5. After entering key information on the first form, proceed to Form 2.

Pick Planning
6. Enter data in all the required fields. Explanations of the required or any
■ Route—indicates the range of routes you want to select. This field is only
important for sales orders.
■ Schedule No—provides the schedule number that begins or ends the
range.
■ Mfgr. Item—includes the manufactured item that begins or ends the
range.
■ Man. Item’s Whse.—indicates the manufactured item’s warehouse that
■ Operation Route—indicates the operation route that begins or ends the
range.
■ Region—provides the region number that begins or ends the range.
■ Carrier—provides the carrier code that begins or ends the range. To see a
list of all carriers defined in MK, zoom to the Display Shipping Carrier
(tdawm0509s000) session from this field.
Note: This field is available only if AWM warehouses are selected to be
included in the outbound advice.
■ Print Advice—indicates whether you want to print outbound advice.
Note: The same data can be printed through the Print Outbound Data
(tdilc4401m000) session after MK has generated outbound advice.
■ Include Non-net Location—indicates whether you want to include non-
nettable items. Non-nettable items are unavailable for material
planning.
■ Alter. Wrh. on Exception—determines whether to include information
about potential locations in other warehouses on the exception report.
Yes—include other warehouse locations. MK searches every warehouse
for potential locations.
No—do not include other warehouse locations in the exception report.
Note: This field is not used for AWM warehouses. Also, if you enter
Yes, you may significantly slow down this session if there are numerous
exceptions and numerous warehouses in which to search.

Pick Planning
7. Access Form 3.
8. Enter the site for this outbound advice. Select the order type and priority
range, if applicable.
9. Enter data in all the required fields. Explanations of the required or any
■ Plan Method—enables you to select the methodology used for this pick
plan. Valid options are:
Batch Plan Method—MK schedules one pick per location per wave for
case picking. For example, if full cases for three different customer
orders are to be picked from location A in wave 1, pick planning
schedules one stop at the location to pick all the cases. The cases can
then be sorted by their respective orders at the shipping dock by labeling
and delivering them to the dock floor spot identified on the label. In
addition, if a single pallet location is to be emptied by case picking for a
particular wave and that item’s handling category allows batch pallet
picking, the picks for that wave are converted to one batch pallet pick.
This provides prior notification, through the label, that there is a
physical pallet to be moved with the cases. When the batch picking
method is selected, pick control sheets for pallet and case picking are
generated by location. One pick control sheet will include picks for
multiple orders from proximate locations within a pick zone.

Pick Planning
Order Plan Method—schedules one pick per location per order for case
picking, and case picks are not converted to batch pallet picks. Since
there can be more than one pick per location per wave, MK cannot
predict which case will empty the pallet and location. An operational
procedure must be established to ensure removal of empty pallets from
locations. Pick control sheets are generated by order within pick type:
one pick sheet will encompass all pallet picks for a single order, a
different control sheet will include all case picks for the order, and a
third sheet will contain all piece picks.
■ Replenish—specifies if MK should allow and plan for the Replenishment
function. Replenishment is the act of moving a product to satisfy
customer orders when no merchandise is available in the correct
locations for allocating.
Yes—prepares replenishment transfer transactions whenever inventory
is depleted and there is available product in the bulk locations.
Movement of product for the replenishment function uses a portion of
the manpower specified as Wave 0 of the pick plan.
No—rejects line items (and possibly entire orders) when inventory is
depleted in the regular pick locations.
Note: If you select the Order plan method in the Plan Method field, it
does not affect replenishment. Replenishment continues to use batch
picking regardless of the plan method selected.
■ Limit by Resource—indicates if you want manpower resources to be a
limiting factor for this pick plan run.
Yes—manpower resources are a limiting factor. You must make an
entry in the Hours to Pick field.
No—manpower resources are not a limiting factor. You do not need to
make an entry in the Hours to Pick field.
■ Hours to Pick—provides the resources limited for this pick plan run.
■ Batch Picks—If individual pick orders should allow multiple lines
containing the same item, enter No. If AWM is to put all identical items
on the same line of each pick order, enter Yes.
■ Resource Reports—indicates if resource reports by team and wave should
automatically print at the end of the pick plan run for the outbound
advice.
■ Pick Multiple Parcel—Use this field to override the warehouse default
when generating pick sheets. Select Yes to allow warehouse workers to
pick multiple orders and/or parcels using the same pick sheet. Select
No to disallow this.

Pick Planning
■ Reject Order Rept—Use this field to select the report generated by the
Display Rejected Orders (tdawm3102m000) session described later in
this chapter.
− Select By Order to sort the Display Rejected Orders report by pick
plan number, order type, order number, line number, sequence
number, project number, item number, reject reason, and rejected
quantity.
− Select By Item to sort the Display Rejected Orders report by pick
plan number, project number, item number, order number, line
number, sequence number, and rejected quantity.
− Select By Reject Reason to sort the Display Rejected Orders report
by pick plan number, project number, item number, and total
rejected quantity.
− Select Summary by Item to sort the Display Rejected Orders report
by pick plan number, reject reason, order number, line number,
sequence number, item number, rejected quantity, and reject reason.
− Select None to prevent Display Rejected Orders reports. This is the
default selection.
■ Staging Reports—indicates if staging reports should automatically print
at the end of the pick plan run.
■ Loading Reports—indicates if loading reports should automatically print
at the end of the pick plan run for the outbound advice.
■ Labels by Zone—determines the order in which labels are printed. You
can choose from the following:
Yes—print labels by zone and order sequence.
No—print labels by order.
Note: This field defaults to Yes if you entered Batch Plan method in the
Plan Method field.
■ Bill of Lading—indicates if a bill of lading should be printed when the
pick plan for the outbound advice has finished processing. A bill of
lading is a legal document containing freight information.
Note: If you print a bill of lading at this point, changes may occur
during the pick process. The Display Manifest Detail (tdawm4110m000)
session enables you to print a bill of lading for items actually shipped,
regardless of the entry.

Pick Planning
■ Packing List—indicates if a packing list should be printed when the pick

plan for the outbound advice has finished processing.
Note: If you print a packing list at this point, changes may occur during
the pick process. The Display Manifest Detail (tdawm4110m000) session
enables you to print a list of items actually packed in the shipment.
Tip: You have two options at this point in the procedure. You can either
simulate the generation of outbound advice or proceed with the actual
generation. Although the Simulate Outbound Processing procedure is
optional, MK recommends that you follow these steps first. See Simulating
Outbound Advice following this session procedure for more information.
■ #Parcels/Sheet—You can use this field to override the warehouse default

when generating pick sheets. Enter the number of orders and/or parcels
to appear on each pick sheet. Select 1 to print one order or parcel per
pick sheet.
10. Select Execute to Generate Outbound Advice.
Note: The Pick Plan Number displays only after you have selected Execute
to run the pick plan, and once you have addressed the document prints on
the Generate Outbound Advice form.
Note: MK displays an outbound exception report if there are sales orders
with quantities not yet advised.

Pick Planning
Simulating Outbound Advice
Session Procedure You can simulate outbound advice by following the procedures for the
Generate Outbound Advice (tdilc4201m000) session:
1. Access the Generate Outbound Advice session.
2. Follow steps 2 through 9 from the previous session procedure.
3. To simulate the generation of an outbound advice, select 1 on third Generate
Outbound Advice form. The Display Warehouse Orders Totals form
appears:
This form is used to view the total number of orders and line items that were
selected for each warehouse, based on the selection criteria you entered. It
displays the total number of cases, cubes, and weight for the orders selected
in each warehouse. This helps control the size of your pick plan.
4. If you want to view detail information about orders at a particular
warehouse, double-click the warehouse whose information you want to
display. The Display Warehouse Orders form appears, based on the data
entered for run criteria.
5. Select Close to return to outbound Form 3.
6. Proceed with steps 10 and 11 of the Generate Outbound Advice session
procedure.

Pick Planning
Maintaining Outbound Data (ILC)
Note: For ILC warehouses only, not applicable for AWM warehouses.
In this session you can change or enter information within a run number. The
run number can be accessed by selecting Zoom in the run number.
You can create a new outbound movement, as well as change an existing

outbound movement created through an outbound advice. You can indicate
which items, in which location (with quantities), are included in the outbound
movement for each order type and order number. With manual outbound, MK
checks whether stock exist on the selected date; items which must be delivered
with the Maintain Sales Order (tdsls4101m000) session are checked on stock
present by stock point.
Access the Maintain Outbound Data (ILC) (tdilc4101m000) session by selecting

Outbound Processing from the AWM Configuration menu, and selecting
Maintain Outbound Data (ILC) from the Outbound Processing Pick Planning
menu.
Releasing Outbound Data (ILC)
The Release Outbound Data (tdilc4202m000) session releases outbound items

which have been advised by MK or manually created. Allocated quantities are
issued from stock through this session. Outbound items can be released for sales
orders, issues to production orders, repetitive production, PRP warehouse
orders, material requests for service orders and RMAs, and exchanges for RMAs.
Access the Release Outbound Data session by selecting Outbound Processing

from the AWM Configuration menu, and selecting Release Outbound Data (ILC)
from the Outbound Processing Pick Planning menu.

Pick Planning
Deleting Outbound Data (ILC)
The Delete Outbound Data (tdilc4211m000) session is not intended to remove an

outbound advice or a released manual outbound movement. It can be used to
globally delete one or more outbound recommendations or manual outbound
movements that have not yet been released.
You can delete outbound data after the items have been allocated for outbound
through one of the following sessions:
■ Generate Outbound Advice (tdilc4201m000)
■ Maintain Outbound Data (tdilc4101m000)
You can only do this if items have not yet been issued through the session
Release Outbound Data (tdilc4202m000). After deleting the outbound data, you
can again generate new advice and/or manually create outbound lines through
the following sessions:
■ Generate Outbound Advice (tdilc4201m000)
■ Maintain Outbound Data (tdilc4101m000)
Access the Delete Outbound Data session by selecting Outbound Processing

from the AWM Configuration menu, and selecting Delete Outbound Data (ILC)
from the Outbound Processing Pick Planning menu.
Displaying Outbound Data (ILC)
You can display outbound data for sales orders, production orders, repetitive
production, PRP warehouse orders, or service orders. If outbound data exists for
a particular order, batch or production schedule quantity, you can mark and
zoom to display detailed information about it.
Access the Display Outbound Data (tdilc4597m000) session by selecting

Outbound Processing from the AWM Configuration menu, and selecting
Display Outbound Data (ILC) from the Outbound Processing Pick Planning
menu.

Pick Planning
Printing Outbound Data (ILC)
You can report the quantities allocated for sales orders, issues to production
orders, batches, productions schedule quantities, PRP warehouse orders and/or
service orders.
Access the Print Outbound Data (tdilc4401m000) session by selecting Outbound

Processing from the AWM Configuration menu, and selecting Print Outbound
Data (ILC) from the Outbound Processing Pick Planning menu.
Reversing Sales Delivery (ILC)
Use the Reverse Sales Delivery (ILC) (tdilc4127m000) session to reverse a sales
delivery incorrectly released by the location control outbound process.
Access the Reverse Sales Delivery (ILC) session by selecting Outbound

Processing from the Advanced Warehouse Management menu, and selecting
Reverse Sales Delivery (ILC) from the Outbound Processing Pick Planning
menu.
This session prompts the user for:

■ sales order number
■ position number
■ delivery serial numbers
When these values are entered, the session displays:

■ customer
■ project
■ manufactured item
■ items ordered
■ items delivered
■ items to be delivered
■ component
■ warehouse
■ lot
■ date

Pick Planning
■ location
■ stock unit quantity
■ storage unit quantity
■ delivery date
After verifying the displayed data, select D to delete the outbound record and
adjust the inventory.
Releasing Planned AWM Material Requisition Orders
Use the AWM Release Planned Material Requisition Orders (tdawm9230m000)

session to process all DRP orders for all AWM warehouses at the selected site.
This session consists of two forms.
Access the AWM Release Planned Material Requisition Orders session by

selecting Outbound Processing from the AWM Configuration menu, and
selecting AWM Release Mat. Req. Orders from the Outbound Processing Pick
Planning menu.
Displaying Rejected Orders
Use the Display Rejected Orders (tdawm3102m000) session to create a report of

rejected (unprocessed) pick plan orders and order lines. Note that the report
type is determined by the Reject Order Rept field in the Generate Outbound
Advice (tdilc4201m000) session described earlier in this chapter.
Access the Display Rejected Orders session by selecting Outbound Processing

from the AWM Configuration menu, and selecting Display Rejected Orders from
the Outbound Processing Pick Planning menu.
Enter the desired pick plan number, and press Enter until MK displays the
desired rejected order report.

Pick Planning
Building Batch/Cart
Use the Build Batch (tdawm6144m000) session to create batch picks of multiple
parcels. To set up a batch pick:
1. Access the Build Batch session.
2. Enter the warehouse code and batch ID.
3. Select Execute to display the Build Batch (tdawm6145s000) session.
4. Enter the parcel and cart positions.
5. Repeat the previous two steps for all items you are adding to the batch.
6. Select Execute to store the new batch.
Access the Build Batch session by selecting Outbound Processing from the AWM
Configuration menu, and selecting Build Batch/Cart from the Outbound
Processing Pick Planning menu.
Deleting Batch/Cart
Use the Delete Batch/Cart (tdawm6146m000) session to delete pick batches. The
Delete Batch/Cart session contains two forms. Zoom to the Display Batch/Cart
(tdawm0539s000) menu to see current batches. Select the batch to be deleted and
select Execute to delete the selected record.
Access the Delete Batch/Cart session by selecting Outbound Processing from the
AWM Configuration menu, and selecting Delete Batch/Cart from the Outbound
Processing Pick Planning menu.

Pick Planning
Deleting AWM Pick Plan
The Delete AWM Pick Plan (tdawm4211m000) session is used to cancel the
execution of a pick plan which was created in the Generate Outbound Advice
(tdilc4201m000) session. Deleting a pick plan reverses any hard allocations that
AWM has made to that point, removes all data pertaining to the canceled plan,
and puts the orders back to their state prior to outbound advice.
Before You Begin The Delete AWM Pick Plan session can only be run after the generation of an
outbound advice pick plan and prior to running pick confirmation.
Session Procedure To delete an AWM pick plan:

1. Access the Delete AWM Pick Plan (tdawm4211m000) session.
2. Enter the pick plan number you want to delete. This number can be
accessed from the Pick Plan Worksheet.
3. Select Execute to delete the selected pick plan.

Pick Planning
Pick Confirmation
AWM requires proof that a product is picked correctly, and proof that it arrived
at the correct dock. Picking can be radio frequency and/or paper controlled by
location in each warehouse, and planned picking parcel records can be made
available for quality control scales and fixed scanner checkoffs and diverters.
Interleaved picking and putaway lets you perform RF picking to keep informed
of a pending putaway in the aisle of the next pick assignment, reducing
deadheading.
MK creates a separate picking control sheet for each wave, aisle, pick team, pick
group, and pick method contained in the pick plan. Each pick sheet consists of
all planned picks which have been grouped together under one pick sheet
number.
There are two separate types of picking control sheets: the Master Copy used by
the checker which contains the check digit for each location, and the Working
Copy used by the stocker, which contains blanks for entry of the check digit
found at each location.
■ For the batch method of pick planning: For pallet, UOM2, and case picking, a
new pick sheet is generated for each unique combination of warehouse,
wave, team, picking assignment, pick type, and work group within team,
ordered by pick location zone. For UOM1 and piece picks which are
parceled, a new pick sheet is generated for each unique combination of
parcel number, tote number, and picking assignment, ordered by pick
address within zone.
■ For order pick method of pick planning: For pallet, UOM2, and case picking, a
new pick sheet is generated for each unique combination of warehouse,
wave, order type and number, pick type, ordered by pick location. For
UOM1 and piece picks which are parceled, one pick sheet is generated for
each order which includes all piece picks, ordered by parcel number and
pick location, with a page break for each new parcel or tote. The effect is to
produce three pick sheets per order: one for pallets, one for cases, and one
for all loose picked parcels.
■ If the item is lot controlled, the lot number and status appears. This is
important because you may contain multiple lots for the same item.
How to Use Pick The stocker picks the items from the specified location and marks the location’s
Sheets check digit on the working copy of the picking control sheet. After picking is
done, the checker compares the check digits on the Master copy with those on
the Working copy.
Resolving Discrepancies between the Master and Working copies must be corrected
Discrepancies before confirming the pick. For example, the checker could contact the
supervisor in order to solve the pick problem, perhaps the wrong check digit
was entered on the working copy.

Pick Planning
you are performing picking confirmation from an RF Terminal system.
The Pick Confirmation session is used to record the results of the paper-driven
process, including the employee who performed the stocking function and the
number of errors that were made in the process. Unlike RF pick verification, the
paper process does not immediately record the picking activity as removal of
product from the location. It moves from allocated to no longer in the location.
For those items that are picked without using RF, Shirley Andrews (the
checker) compares the working pick control sheet to the master. If there are no
Scenario discrepancies, she runs the Pick Confirmation (tdawm4210m000) session.
Session Procedure To record the results of the paper confirmation process for picks:
1. Access the Pick Confirmation (tdawm4210m000) session.
2. Enter a valid pick sheet control number or select Zoom to select a number
and press Enter. The form lists the items to be picked by location and area,
and also lists the cart and order and parcel numbers.
3. Enter the ID of the employee who performed the picks in the Employee field.
4. If errors occurred, enter the total number in the Errors field.

Pick Planning
5. Proceed to Form 2.
6. Mark the items that were picked by entering 2 to select the Confirm Marked
Picks option and then selecting Execute to process. If all items were picked
correctly, select 1 to select the Confirm All Picks option.
Note: After confirming all items on a pick sheet, MK deletes the pick sheet
lines.
7. Select 3 if you want to reprint control sheets.

Pick Planning
Picking Rule Set Checklist
If you encounter problems generating outbound advice for picking items,

perform the following checks:
1. Determine from what locations you think the item should be picked. Ensure
that there is ample inventory stored in the locations from which to pick the
quantity ordered. The best method of confirming inventory in locations is
by displaying the Display Stocks by Item/Lot/Warehouse/Location
2. Verify that the location has an allocation zone and storage type that matches
what has been defined on the picking rule detail. Also, verify that the
picking rule detail has a warehouse which corresponds to the
warehouse/location.
3. To pick from a location, verify that the location status is either S for Storage
or P for Picking and that ILC blocking of the location is not set.
4. Verify that the warehouse specified on the order header and/or line item
corresponds to a warehouse specified in the picking rule assignment. Order
type and locating category on the assignment can be blank, but if not blank,
it must correspond to the location category from the item and the order type
from the order header. The order type must be Sales or Service on the Order
Type Master.

Pick Planning
5. Item status on the pick rule assignment records must match the item status
of the inventory at the location, as well as lot status if lot controlled items are
being picked. This can be verified in the Warehouse Administration session
Maintain Inventory Status by Item (tdawm3101m000). For lot controlled
items with outbound priority equal to LIFO or FIFO, also check the stock
date on the lot master to ensure that the Best Before Date is greater than
today’s date.
6. If standard units or nonstandard units are defined on the picking rule detail,
they must also match what has been defined at the location inventory level.
If Both Allowed is specified on the picking rule detail, there is no need to
check these units.
7. Ensure that the Sales Order line status is not on hold or awaiting another
step like Print Acknowledgments or some other step from the order type that
precedes picking.

Shipping
Shipping
Characteristics of the shipping function include the following:
■ Dock Floor Consolidation—Because orders are associated with carriers and
dock floor spots are also associated with carriers, MK consolidates orders to
dock floor spots.
■ Confirmation—There are two confirmation steps: dock floor spot and
shipping (after parcels are loaded onto the truck). You can choose to
perform floor spot confirmation through an RF terminal or paper. Shipping
confirmation is performed through an online AWM session only, not an RF
terminal. Accuracy is improved through the use of these confirmation steps.
■ Truck Loading Documents—A loading worksheet is available which lists all
orders and parcels assigned to a manifest and formatted specifically to aid in
the truck loading process.
■ Carrier Manifests—A carrier manifest is available which contains a
collection of orders assembled by MK during the pick planning process that
are all scheduled to ship on the same truck of a particular carrier.
■ Parcel Tracking—You can track a parcel on a manifest and view various
levels of detail information about the parcel, such as weight and volume,
and specific items in the parcel.
■ Total Flexibility Within Rules—Rule sets can be set up to work in any
situation, whether it be putaway, picking, or adjustments.
The MK Shipping Menu provides access to the shipping and dock floor area
confirmation process. From this menu you can perform the following
operations:
■ Select and maintain a carrier manifest for processing
■ Confirm the dock floor spot
■ Confirm the shipped order
■ Display parcels on an order
■ Order shipment reprints

Shipping
Maintaining Carrier Manifest
A carrier manifest is a collection of orders that are assembled by MK during the

pick planning process, and that are scheduled to ship on the same truck of a
particular carrier.
To view a list of all carrier manifests for a warehouse, use the Maintain Carrier
Manifest session. You can create a manifest manually through this session, or
MK can automatically create one through pick planning.
Mark McDonald works in the packing area of the warehouse. He runs the
Maintain Carrier Manifest (tdawm4105m000) session to dock floor confirm the
Scenario pick as well as to ship confirm manifest.
Session Procedure To maintain the carrier manifest for a warehouse:

1. Access the Maintain Carrier Manifest (tdawm4105m000) session.

Shipping
2. When this form is first displayed, all open manifests are listed, along with
the following information:
■ Manifest number
■ Warehouse
■ Wave
■ Carrier
■ Truck, if entered on the Sales Order
■ Created by (either the pick plan number or the user ID if the manifest is
manually added by selecting 1)
■ Total orders for manifest
■ Total parcels
■ Total weight
If you do not enter any selection criteria prior to pressing Enter, MK retrieves
and displays all carrier manifests currently on file. The manifests are
displayed in ascending order, depending on the contents of the manifest
field.
Note: The suspense manifest, is always present within
MK and cannot be deleted or ship confirmed. The manifest number of the
suspense manifest is always 0, and the Created By field contains the literal
Suspense. The suspense manifest is a convenient place to hold orders
temporarily.
3. Mark a selected manifest, then select Execute to access the Display Manifest
Detail (tdawm4110m000) session. This form displays all line items for an
order.
4. You can display other forms by entering the following information:
■ Select 2 for Dock Floor Confirmation. This form lists all parcels by the
selection criteria including: parcel number, manifest number, wave, floor
area, or floor spot.
■ Select 3 to Print Load Worksheets. This form lists all orders and parcels
assigned to a manifest. The worksheet is formatted specifically to aid in
the truck loading process.
■ Select 4 for Ship Confirm Manifest. Through this session, you can
confirm that all parcels for the manifest are on the truck. This is the final
shipping step. After ship confirming a manifest, the manifest no longer
appears on this form.

Shipping
Confirming Dock Floor Spot
The purpose of Dock Floor Spot Confirmation is to provide positive

acknowledgment that a shipping parcel has arrived on the shipping dock as
instructed by the pick plan
MK created. Ship confirmation cannot be performed for a truck of product being
shipped on a carrier until all parcels listed on the carrier manifest for the truck
have been floor spot confirmed. There are three methods of dock floor spot
confirmation: a paper-driven two step system, Non-directed RF, and Directed
RF. The use of a Radio Frequency terminal enables you to automatically verify
correct putaway.
you are performing dock floor confirmation from an RF Terminal system.
The Dock Floor Confirmation (tdawm4135m000) session is used to record the

results of the paper-driven floor spot confirmation process. Unlike RF
confirmation, the paper process does not immediately make a parcel eligible to
be ship confirmed when it is placed on the floor spot. MK does not know the
results of the paper-driven process until information contained on the floor spot
confirmation reports is input on the confirmation form.
If the Dock Floor Confirmation session is accessed from the shipping menu, all
header type fields are blank since no selection criteria is passed and all records
are displayed. You can also access Dock Floor Confirmation from within the
Maintain Carrier Manifest (tdawm4105m000) session, by selecting Option 2.
Session Procedure To confirm the parcels assigned to each dock floor spot:
1. Access the Dock Floor Confirmation (tdawm4135m000) session.

Shipping
2. When this form is first displayed, all fields contain blanks. You can enter the
manifest number or select Zoom to access the data relating to a particular
wave manifest or floor spot you want to display. If you do not enter a
manifest number as the selection criteria, all currently active manifests are
displayed. The following information is also displayed:
■ Pick wave number
■ Dock floor area ID and floor spot number
■ Parcel number and carton type
■ Confirmation date and time (once dock floor confirmed)
■ Order number and order type
■ Carrier ID
3. You can select another option by entering one of the following:
■ Select 1 to Confirm All Parcels. Use this option when you want to
confirm all of the parcels for a manifest number. The confirmation date
and time is updated for all of the parcels in the manifest. This
information remains until the manifest is ship confirmed.
■ Select 2 to Confirm All Marked Parcels. Use this option when you want
to confirm only the parcels that have been marked. The confirmation
date and time are updated for the selected parcels. This information
remains until the manifest is ship confirmed.
■ Select 3 to Print Staging Worksheet. Use this option when you want to
print the staging worksheet, which is a layout of all the parcels and floor
spots. This worksheet is used in confirming the dock floor spots.

Shipping
Maintaining Parcels
To display all parcels on a manifest for an order use the Maintain Parcels
(tdawm4118m000) session. This session is also used to maintain parcels. The
Display Parcels form displays the following information by manifest and order
number:
■ Parcel number and carton type
■ Dock floor confirmation time and date
■ Parcel weight and volume
■ Floor spot, ship spur, and consolidation area, if applicable
Option 1, the Parcel Detail session, is used to display all of the items in a parcel
and to make adjustments to the quantities. If the parcel is a standard case, the
contents are shown as a single item. If the parcel is a loose pick parcel, it shows
one line item for every pick location that makes up the parcel (although, in many
situations, each pick location is a unique item, it is possible that a single item
would need to be picked from multiple locations to fill the order). If the number
of line items in the parcel exceeds the form’s display capacity, select Next to view
the additional line items.
Session Procedure To select a parcel to view:

1. Access the Maintain Parcels (tdawm4118m000) session.
2. Enter the manifest and order number you want to display.

Shipping
3. To display parcel detail, select 1 to mark the parcel you want to display, and
then select Execute. The Maintain Parcel Detail (tdawm4120s000) form
appears:
4. To cancel a parcel, select 1.

5. To adjust an item (used to change the ship quantity for an item), select 2 to
mark the line you want to adjust. Select the adjustment type and enter the
actual quantity.
6. To reprint a parcel label, select 3.

Shipping
Maintaining Ship Confirm Manifest
Shipment confirmation is performed when all of the orders contained on a

carrier manifest have been loaded onto the truck. MK does not allow a manifest
to be ship confirmed until all of the parcels that make up the orders on the
manifest have been confirmed as being present in the dock floor staging area.
MK does not allow an empty manifest (one that does not contain any orders) to
be confirmed.
You can verify that tasks have been completed by radio frequency CRTs or fixed
scanners.
Session Procedure 1. Access Maintain Carrier Manifest (tdawm4105m000).
2. Select 4 to mark each manifest you want to confirm for shipment and then
select Execute to process.
A report is then generated listing the contents of the manifest at the time it
was confirmed along with the message “Manifest Confirmed Successfully.”
The manifest is then removed from the list of active manifests displayed in
the Maintain Carrier Manifest (tdawm4105m000) session, and can no longer
be viewed online.

Shipping
Ordering Shipment Reprints
This session is used when you need an additional paper copy of a carrier
manifest that has been ship confirmed. You can reprint either the bill of lading
or the packing list.
Session Procedure To order shipment reprints:

1. Access the Order Shipment Reprints (tdawm4130m000) session.
2. Enter the pick plan number of the manifest you want to print.
other important fields follow:
■ Warehouse—identifies the warehouse number.
■ Order Type—identifies the type of order.
■ Order Number—identifies the order number.
4. To reprint the bill of lading, select 1.
5. To reprint the packing list, select 2.

Shipping
Creating Independent Replenishments
The Create Independent Replenishment (tdawm4205m000) session is used to

select specific items within specific locations to be replenished independently of
pick planning.
Unique records are defined by a replenishment:

■ Replenishment category identifies a group of items
■ Item Status identifies the state of inventory in the warehouse
■ Lot Status identifies lot status for items that require lot control
■ Warehouse identifies individual items that require lot control
■ Allocation Zone determines the locations for picking inventory
■ Storage Type identifies the dimensions and the maximum weight capacity of
storage equipment
There are two methods of replenishment rule sets:

■ Plan Method 1 satisfies today’s requirements
■ Plan Method 2 satisfies the most recent day’s history

Shipping
Session Procedure To create independent replenishments:

1. Access the Create Independent Replenishments (tdawm4205m000) session.
The site you are signed on to appears in the Site field.

Note: Two independent replenishment requests for the same
site/warehouse cannot be run at the same time. However, it is possible to
run a pick plan at the same time.
2. Enter data in all required fields. Explanations of the required and any
■ Pick Plan Number—indicates the pick plan number assigned to the
replenishment plan.
■ Resource Report (Y/N)—indicates whether to generate the resource (labor)
allocation reports for the planned replenishment.
3. Select Execute to create independent replenishments.

Production
Production
Confirming Staging Areas
Use the Staging Area Confirmation (tdawm4140m000) session to confirm

inventory transfer to staging areas (locations). This session displays work orders
by production wave, staging area (location), spot, parcel number, parcel type
and order type.
Session Procedure To confirm staging areas:

1. Access the Staging Area Confirmation (tdawm4140m000) session.
2. Select the order(s) to be confirmed or select all orders.

3. Select Execute to confirm the selected orders.
Note: If Auto Confirm Work Order is set to Yes in the Maintain Warehouses
(tcmcs0103m000) session, you automatically zoom to the Display Production
Order Manifests (tdawm4520m000) session. This session displays manifest
numbers, associated warehouse, production wave, carrier, truck number,
and manifest date.

Production
Confirming Work Order Manifests
Use the Confirm Production Order Manifest (tdawm4150m000) session to

confirm AWM work order manifests for production orders.
Session Procedure To confirm AWM production order manifests:

1. Access the Confirm Production Order Manifest (tdawm4150m000) session.
Note: To view work order manifest detail, select 1 to mark the manifest and
then enter Y to go to the Display Work Order Manifest Detail
(tdawm4112s000) session. Notice that each manifest can consist of multiple
work orders. From this session, you can zoom to the Display Work Order
Detail (tdawm4127s000) session.
2. On the Confirm Production Order Manifest session, select the manifest to be
confirmed.
3. Select 3 to Confirm Work Manifest.

Chapter
Lot Control
6
Introduction .................................................................................. 6–1

Maintain Lots ................................................................................ 6–2
Maintaining Lots .......................................................................... 6–2
Maintaining Lot Selection Codes ........................................................... 6–5
Maintain Blockings by Lot and Transaction .................................................. 6–6
Maintain Blockings by Lot ................................................................. 6–9
Releasing Lots ........................................................................... 6–10
Converting Items ............................................................................ 6–12
Displaying and Printing Lot Information ................................................... 6–12
Lot Control 6–i

Chapter
Lot Control
6
Introduction
The Lot Control module provides full lot traceability for both lot and serial
numbers. Lot Control trace features meet ISO-9001 certification standards,
helping you achieve your quality management objectives.
You specify lot control by item and define the types of information that need to
be collected by item. You can specify control by lot or unit; that is, serial
number. Using blocking, you can restrict or prevent the use of material lots for
specific transactions at the lot, item, and location levels. You can also assign
reasons to blocking codes.
Lot Control provides full source traces beginning with the origin, at purchasing,
of component materials. It tracks material through manufacturing operations to
its final use in a sales or service order. You can trace a lot forward from its
source (purchased item) or backward from its destination (shipped item).
Lot Control 6–1

Maintain Lots
Maintain Lots
You can use the following sessions by selecting the Maintain option on the Lot
Control menu.
■ Maintain Lots (tdltc0101m000)
■ Maintain Lot Selection Codes (tdltc0102m000)
■ Maintain Blockings by Lot and Transaction (tdltc0120m000)
■ Maintain Blockings by Lot (tdltc0121m000)
■ Release Lots (tdltc0122m000)
Maintaining Lots
When an item in the item file is defined as subject to lot control by lot (more than
one item), or by unit (one item), you can record lots for that standard item in the
Maintain Lots (tdltc0101m000) session. This may be a standard item, but it may
also be a customized item from the Maintain Customized Item Data
(tipcs2121m000) session.
When lots are recorded from the Purchase module, the lot type is filled with
Purchase and the code of the supplier. The supplier’s lot code can be used in
display and print sessions, and at a later stage in the Lot Control module.
You can define lots, including the values for the general (item-dependent) lot
features for each lot in the Maintain Lots (tdltc0101m000) session.
Before You Begin You can only record lots for lot items. An item is a lot item when it has been
stated that lot control is to be enforced for the item in one of the following
sessions:
■ Maintain Item Data (tiitm0101m000)
■ Maintain Customized Item Data (tipcs2121m000)
You must also run the following sessions:

■ Maintain Suppliers (tccom2101m000)
(for purchase order lots only)
■ Maintain Lot Selection Codes (tdltc0102m000) (optional)
This session consists of two forms of which the second only displays lot data
influenced by other sessions, such as quantities and blocks. The first form shows
all the data to be maintained.

Maintain Lots
Harry Nigh works in the quality control group. He assigns lot numbers to be
used for receipts and production runs in the Maintain Lots (tdltc0101m000)
Scenario session.
Session Procedure To maintain lots:

1. Access the Maintain Lots (tdltc0101m000) session.
2. Enter data in all required fields. Explanations of the required and important
fields follow:
■ Project—provides both standard and customized items to be registered
in the Lot Control. For customized items, the project code indicates for
which project the items are designated.
■ Item Code—provides the description of the item.
■ Lot—indicates whether MK must trace and track lots for an item in the
Maintain Item Data (tiitm0101m000) and Maintain Customized Item
Data (tipcs2121m000) sessions. If so, the manufactured or purchased
items are registered by lot so that the stock on hand can be registered for
each lot individually.
Lot Control 6–3

Maintain Lots
Form 1 shows all data to be maintained. Form 2 is display only. It provides

lot data influenced by other sessions, such as quantities and blocks.
For AWM, Form 3 shows lot status data.
3. Change the current lot status.

Maintain Lots
Maintaining Lot Selection Codes
You can maintain selection codes with corresponding descriptions using the
Maintain Lot Selection Codes (tdltc0102m000) session. With these lot codes, you
can search for lots.
After entering selection codes, you can assign the selection codes to a lot through
the Maintain Lots (tdltc0101m000) session.
To aid the quality control group in sorting through the lots, selection codes
have been entered to group the supplier and product types of the lots. This
Scenario information was entered in the Maintain Lots (tdltc0102m000) session.
Session Procedure To maintain lot selection codes:

1. Access the Maintain Lot Selection Codes (tdltc0102m000) session.
2. Add a selection code.

3. Enter data in all required fields. Explanations of the required and important
fields follow:
■ Code—provides one of the two selection codes recorded in the session
Maintain Lots (tdltc0101m000). These codes may help in searching for
lots.
■ Description—provides a description for the selection code. This
description is printed next to the code on reports.
You can enter and delete selection codes. You can also change the
description corresponding to the code.
Lot Control 6–5

Maintain Lots
Maintain Blockings by Lot and Transaction
You can block lots for each transaction type. You can block the lots for one or
more types of stock transactions. The consequences of blocking for each stock
transaction are:
■ Inbound—Items from this lot cannot be received in the warehouse (lot is
blocked for receipts and completed production orders).
■ Outbound—Items from this lot cannot be withdrawn from stock for
deliveries in the Sales Control module, for issuing raw materials for a
production order in the Shop Floor Control module or for a service order in
the Service and Maintenance module.
■ Transshipment—Items from this lot cannot be moved.
Blocking Codes After you select the project, item and lot code, you can begin to assign blocking
codes. After these codes have been assigned, the description of the reasons for
blocking is immediately shown. MK also registers your login code for each
blocking reason, as well as the time (both date and time) that the block has been
entered. The date and time are only informative. The login code is retained in
order to prevent a block from being wrongly removed. A blocking code cannot
be deactivated with a login code that is different from the one under which it
was entered. Those who activate a block are the only ones who can make it
inoperative.
Linking a blocking reason to a lot automatically means that this lot is then
blocked. By deleting the line, the block is lifted. When all blocks of a lot are
removed, the lot is automatically released.
You can deactivate all blocks regardless of the login code used when assigning
them through the Release Lots (tdltc0122m000) session.
If a lot is blocked for all transactions, the available stock of the lot item will
decrease (Available Stock = Stock on Hand - Blocked Stock).
The QC group blocks certain items for outbound transactions in the Maintain
Blockings by Lot and Transaction (tdltc0120m000) session until they have
Scenario verified that the items are acceptable.

Maintain Lots
Before You Begin Before you can record a block for a transaction of a lot, you must have already
defined the lot through the Maintain Lots (tdltc0101m000) session.
Session Procedure To maintain blockings by lot and transaction:

1. Access the Maintain Blockings by Lot and Transaction (tdltc0120m000)
session.
For each lot recorded for the item, the following data is shown:
in the Lot Control. For customized items the project code indicates for
■ Item—provides the description of the item.
Maintain Item Data (tiitm0101m000) and Maintain Customized Item
Data (tipcs2121m000) sessions. If so, the manufactured or purchased
items are registered by lot so that the stock on hand can be registered for
each lot individually.
Lot Control 6–7

Maintain Lots
2. For each lot transaction, you can activate or deactivate a block by entering
Yes or No in one of the following fields.
■ Blocked for Inbound—indicates if the lot has been blocked for inbound. If
Yes is entered in this field, receipts (from the Purchase Control module
and completed orders from the Shop Floor Control (SFC) module) are
not possible. The block that was imposed in the session Maintain
Blockings by Lot and Transaction (tdltc0120m000) triggered this block.
■ Blocked for Outbound—indicates if the lot has been blocked for outbound.
If Yes is entered in this field, the following applies:
– No deliveries can be made from this lot for the Sales Control (SLS)
module.
– No stock can be issued for production in the SFC module.
– No stock can be issued for a service order in MK Service.
■ Blocked for Transshipment—indicates if the lot is blocked for
transshipment. If Yes is entered in this field, the lot cannot be
transferred to another warehouse or location.

Maintain Lots
Maintain Blockings by Lot
You can activate or deactivate a block on all transactions for a lot using the
Maintain Blockings by Lot (tdltc0121m000) session. Given that more reasons
may exist to impose a total block on a lot, you can activate many blocks for each
lot. Each block is then supported with a specific reason which has been assigned
as a description to the blocking code.
Before You Begin Before you assign a blocking code to a lot, the following sessions must be run:
■ Maintain Lots (tdltc0101m000)
■ Maintain Reasons for Blocking (tdilc0140m000)
Session Procedure To maintain blockings by lot:

1. Access the Maintain Blockings by Lot (tdltc0121m000) session.
2. Select a valid item number and project number, if applicable.

3. Enter the lot number for which you want to add a blocking.
4. Select Zoom to access the Maintain Reasons for Blocking session. Select the
code and description that describes the reason for blocking.
5. Enter data shown under the blocking code description.
6. Select Close to return to the main form.
7. Enter the reason for blocking code.
Note: Your login code appears on the form.
Lot Control 6–9

Maintain Lots
Releasing Lots
Lots can be released only by the person with the same login code as the one who
initially blocked the lot, through the session Maintain Blockings by Lot
(tdilc0121m000). This may cause problems. With the help of Release Lots
(tdltc0122m000), blocks entered by other employees may be removed also.
Establish strict authorization as to who may use this session to prevent
unauthorized people from running it.
Once QC has approved the lots, Harry uses the Release Lots (tdltc0122m000)
session to release the lots.
Scenario
Session Procedure To release lots:

1. Access the Release Lots (tdltc0122m000) session.
2. Enter a valid item number.

Maintain Lots
3. Enter data in all required fields. Explanations of the required or any other
in the Lot Control. For customized items the project code indicates for
■ Item—provides the description of the item.
Maintain Item Data (titm0101m000) and Maintain Customized Item Data
(tpcs2121m000) sessions. If so, the manufactured or purchased items are
registered by lot so that the stock on hand can be registered for each lot
individually.
The reason for blocking is displayed after you enter this information.
Note: A total block can be deactivated when it has been recorded through
the Maintain Blockings by Lot (tdltc0121m000) session.
4. Mark the lot you want to delete. By removing the line, the block is
deactivated. You cannot add lines through this session.
5. Enter Yes to delete the records. When all blocks for the lot are removed, the
lot is automatically released.
Lot Control 6–11

Converting Items
Converting Items
There are two sessions available from the Lot Control/Lots/Miscell menu to
convert items from a lot item to a non-lot item, and back:
■ Convert Non-Lot Item to Lot Item (tdltc0130m000)
■ Convert Lot Item to Non-Lot Item (tdltc0131m000)
Both sessions change the master data of an item, create or remove a lot, and
process stock data up to lot level or item level. They alter both the master data
and the current data so that the selected item becomes a lot item or reverts to a
normal item again.
Note: These programs do not examine the current locations of the items stored
or whether those locations can contain multiple lots.
Displaying and Printing Lot Information
There are a number of useful reports you can use to help keep track of lot
information. You may want to either display information to the screen or print
out a report. Refer to the following items to display and print lot information.
Displaying Lots
The following display sessions are available for lot control reports:
■ Display Lots (tdltc0501m000)—Access this session from the Lot
Control/Lots/Inquiries menu. This session displays general data about
registered lots. For each lot the data is displayed over two forms. The form
layout is the same as that for the Maintain Lots (tdltc0101m000) session. The
following search sequence is possible:
– Project/item/lot
– Project/item/relation/lot
– Selection code 1/project/item/lot
– Project/item/relation/supplier’s lot code/lot
You can also zoom to a detailed version of this session by selecting Zoom.
■ Display Lots by Item (tdltc0505m000)—Access this session from the Lot
Control/Lots/Inquiries menu. This session displays all lots with their
general lot data by item sequence. After selecting the project and item, all
registered lots are shown and associated lot data. You can also zoom to a
detailed version of this session by selecting Zoom. The data is distributed
over 5 forms.

Converting Items
■ Display Lots by Selection Codes (tdltc0502m000)—Access this session from

the Lot Control/Lots/Inquiries menu. This session displays lots by selection
codes. Before you can display selection codes, define them in the Maintain
Lot Selection Codes (tdltc0102m000) session. When using this session, the
corresponding description for each selection code is displayed. The display
sequence is by selection code.
■ Display Lots by Selection Code (tdltc0503m000)—Access this session from
the Lot Control/Lots/Inquiries menu. This session displays lot data for each
item and each lot. Before you can do this you should define it in the
Maintain Lots (tdltc0101m000) session. The following search sequence is
shown:
– Project/item/lot
■ Display Blockings by Lot (tdltc0521m000)—Access this session from the Lot
Control/Lots/Inquiries menu. This session displays the lots blocked for all
transactions together with the reasons for blocking. Before you can display
blocked lots, you should have blocked them in the Maintain Blockings by
Lot (tdltc0121m000) session. When you display the blocked lots, associated
blocking reasons are shown for each item. For each blocking, the blocking
time (date and time) as well as the login code of the person who activated
the block are shown.
■ Display Where-Used Lots (tdltc1510m000)—Access this session from the Lot
Control/Lot Tracking menu. This session displays the orders in which a
specific lot has been used. This session shows lot use, specified by order
number. The help information shows all possible destinations of a lot.
■ Display Origin by Lot (tdltc1520m000)—Access this session from the Lot
Control/Lot Tracking menu. This session displays registered lots of an item
including the data of the order from which the lot has originated. For each
project and item, all registered lots are shown. For each lot, the following
data is displayed: Order type, order, position, date, quantity, and relation.
■ Display Origin by Order (tdltc1530m000)—Access this session from the Lot
Control/Lot Tracking menu. This session displays orders in which lots of a
certain item have been used or from which they have originated. For each
order type, project and item, all registered order lines are displayed. For
each order line, MK indicates which lot has been used, the date of the stock
entry, the quantity, the unit used for the stock entry, and the relation/project
associated with the order type.
Lot Control 6–13

Converting Items
Printing Lots
The following printing sessions are available for lot control reports:
■ Print Lots (tdltc0401m000)—Access this session from the Lot
Control/Lots/Reports menu. This session allows you to print fixed lot data.
Before you can use this session, you must first define the lots through the
Maintain Lots (tdltc0101m000) session.
After you specify a range of projects, items, supplier, and lot types, you can
specify a detailed report. Except for stock data, a detailed report contains
less relevant information such as certificate code, blocking data and selection
codes. You can also determine whether text blocks linked to lots must be
printed. After entering the above mentioned data, you can still decide on the
sequence of the print report: by item or by item/supplier.
■ Print Lot Selection Codes (tdltc0402m000)—Access this session from the Lot
Control/Lots/Reports menu. This session allows you to print selection
codes which can be assigned to lots. Before you can do this, you must define
them through the Maintain Lot Selection Codes (tdltc0102m000) session.
After you specify a range of selection codes, you can start the printer. For
each selection code, the corresponding description is printed.
■ Print Blockings by Lot (tdltc0421m000)—Access this session from the Lot
Control/Lots/Reports menu. This session allows you to print the lots
blocked for all transactions together with the reasons for the blocking.
Before you can print this report, you should block the lots in the Maintain
Blockings by Lot (tdltc0121m000) session.
You can select the data to be printed by specifying a range of projects, item
codes, lot codes, and blocking reasons. The blocked lots with their
corresponding blocking reasons are printed for each item. The blocking time
(date and time) and the login code of the person who activated the block are
also printed for each block.
■ Print Lot Price Structure by Cost Price Component (tdltc0407m000)—Access
this session from the Lot Control/Lots/Reports menu. This session allows
you to print the lot structure for each item/lot. The price is constructed from
cost price components. The data needed for this report is saved when
purchase receipts are processed through the Maintain Receipts (ILC)
(tdilc4113s000) session.
You can specify a range of item codes, lot codes and cost price components.
For each cost price component of a lot item, the number of units (number of
hours for operations or the number of units from the bill of material) and the
amount are printed.

Converting Items
■ Print Stock Valuation by Lot Item (tdltc0408m000)—Access this session from

the Lot Control/Lots/Reports menu. This session allows you to print stock
on hand and the stock value based on the lot prices of the lot items. Before
you can do this, you should first run the Maintain Lots (tdltc0101m000)
session.
The data to be printed can be selected by specifying a range of projects,
items, suppliers, lots and lot types. The items printed are sorted by item
group.
■ Print Where-Used Lots (tdltc1410m000)—Access this session from the Lot
Control/Lot Tracking menu. This session allows you to print the orders in
which specific lot has been used.
After specifying a range of order types, order numbers, position numbers,
projects, items, and lots, you should indicate if each lot must begin on a new
page. You can choose from three different report types: single-level, all
levels, or last level.
■ Print Origin by Lot (tdltc1420m000)—Access this session from the Lot
Control/Lot Tracking menu. This session allows you to print lots which
have been used for specific orders. On this report, diverse order types are
printed with the lots which are used for their corresponding orders.
■ Print Origin by Order (tdltc1430m000)—Access this session from the Lot
Control/Lot Tracking menu. This session allows you to print lots which
have been used for specific orders. On this report, diverse order types are
printed with the lots which are used for their corresponding orders.
Lot Control 6–15

Chapter
Warehouse Administration
7
Introduction .................................................................................. 7–1

Maintain Option .............................................................................. 7–2
Entering Stock Transactions ................................................................ 7–2
Entering Stock to Stock Transfers ........................................................... 7–3
Material Requisition Stock Transfer ......................................................... 7–5
Maintaining User Authorizations for Stock Transactions ...................................... 7–7
Maintaining Inventory Status by Item ....................................................... 7–8
Maintaining Directed RF Assignments ...................................................... 7–9
Maintaining RF Queue Management ....................................................... 7–11
Purging the Rejected Order Table .......................................................... 7–14
Purging the Inventory Usage Table ........................................................ 7–15
Displaying and Printing Options .............................................................. 7–16
Displaying Unconfirmed Picks ............................................................ 7–16
Displaying Unconfirmed Parcel ........................................................... 7–18
Displaying Unconfirmed Putaway ......................................................... 7–19
Warehouse Administration 7–i

Chapter
Warehouse Administration
7
Introduction
The Warehouse Administration Menu provides access to all administrative
functions. These functions allow supervisors or operators to input data into the
computer or inquire into the status of operations. In addition, this menu
provides access to the AWM configuration menus.
Warehouse Administration 7–1

Maintain Option
Maintain Option
The Maintain option on the Warehouse Administration menu allows you to
perform the following tasks:
■ Enter stock transactions
■ Enter stock to stock transfers
■ Material requisition stock transfer
■ Maintain user authorizations for stock transactions
■ Maintain inventory status by item
■ Maintain directed RF assignments
■ Maintain RF queue management
Entering Stock Transactions
You can use this session to enter stock transactions by item and warehouse. For
purchase and sales transactions, you must state the trade relation (customer or
supplier). For stock transfers, you must indicate the warehouse where the goods
must be transferred.
In all cases, you enter the stock transaction status. It can be active, a planned
stock transaction, or closed, a technical stock transaction.
When leaving this session, MK automatically links a transaction date and

warehouse order number to each transaction line entered.
Jake Unger is responsible for correcting inventory discrepancies and stock-to-

stock transfers. Jake uses the Enter Stock Transactions (tdilc1120m000) session
Scenario to enter stock adjustments.
Before You Begin The warehouse data should be recorded beforehand through the session
Maintain Item Data by Warehouse (tdinv0101m000). You can only use this
session if you are authorized to do so. You can set up an authorization for each
login code and transaction type in the session Maintain User Authorizations for
Stock Transactions (tdinv1110m000).

Maintain Option
Session Procedure To enter stock transactions:

1. Access the Enter Stock Transactions (tdilc1120m000) session.
2. Enter data in all required fields. Explanations of required and any other
■ Item Code—provides the code that uniquely identifies the item.
■ Warehouse—indicates the warehouse where the item is stored.
■ Serial Number—provides the serial number for each stock transaction in a
warehouse.
Note: Press Enter to accept the default serial number.
3. Select Continue to maintain delivered quantities. The Maintain Stock
Transactions by Lot and Location form appears.
Entering Stock to Stock Transfers
This session allows you to manually enter stock transfers.

Maintain Option
Session Procedure To enter stock-to-stock transfers:

1. Access the Enter Stock to Stock Transfers (tdilc1129m000) session.
■ Item Code—provides the code that uniquely identifies the item.
■ Warehouse—indicates the warehouse where the item is stored.
■ Serial Number—provides the serial number for each stock transaction in a
warehouse.
3. The Trans. Status field indicates whether a transaction line may still be
maintained. If the transaction status is Active, you may still maintain the
transaction line. If it is Closed, you may not make any changes.
4. Select Continue to maintain delivered quantities. The Maintain Stock
Transfers by Lot and Location form appears so you can specify the stock
transfer by location and/or lot level.

Maintain Option
Material Requisition Stock Transfer
This session allows you to transfer stock as a result of a material requisition in an

ILC environment. Material requisitions, whether generated manually with
Maintain Material Requisition (tdinv9130m000) or automatically with Generate
Planned Material Requisitions (tddrp1210m000), are processed as a stock
transaction with this session.
Session Procedure To perform a material requisition stock transfer:

1. Access the Material Requisition Stock Transfer (tdilc9190m000) session.
2. Enter the order number and position number of the material requisition line
for which you would like to transfer materials.
Note: If the requester flag on the material requisition is of type Warehouse
or Region, the transaction is recorded as a stock transfer. You then have the
option of either transferring the material directly from source warehouse to
the requester warehouse, or transferring them first to an intransit warehouse
until the materials are physically received at the requester warehouse, using
the Trans Type field.
3. If the requester flag on the material requisition is of type Warehouse or
Region, enter the transfer type as a direct transfer, intransit issue, or intransit
receipt. The latter two types give you the option of transferring material
from the source warehouse to an intransit warehouse and then from the
intransit warehouse to the requester warehouse, respectively.
If the requester flag on the material requisition is of type Other, the Trans
Type field is automatically set to direct transfer, and the transaction is
recorded as a miscellaneous issue.

Maintain Option
4. Enter desired data in the remaining fields.

5. Select Continue to access the next form.
To aid the receiving warehouse in confirming shipment of a receipt stock
transfer, the To warehouse is printed on the packing list that may optionally
accompany the shipment. Thus, if an intransit warehouse is used, the
receiving warehouse may make the stock transfer from the intransit
warehouse/location into their own stocking warehouse/location.
Note: After transferring the materials and completing the transaction, you
may run the Print Material Requisition Dispatch Notes (tdinv9434m000)
session to create a packing list document to accompany the
materials/shipment.

Maintain Option
Maintaining User Authorizations for Stock Transactions
This session allows you to have different stock transactions performed by

different persons. The user code (login) for each user involved in the inspection
of stocks is linked to the transaction types for which one is authorized.
If a user is not authorized for a particular type of stock transaction, MK reports

when an unauthorized transaction is being entered.
Before Jake could perform any stock transactions, he had to be granted access to
the Enter Stock Transactions (tdilc1120m000) session. Thomas Cook, the
Scenario warehouse manager, controls which users have access to stock transactions
Thomas uses Maintain User Authorizations for Stock Transactions
(tdinv1110m000) to control who can adjust the inventory.
Session Procedure To maintain user authorizations for stock transactions:

1. Access the Maintain User Authorizations for Stock Transactions
(tdinv1110m000) session.
2. Enter the user’s login code.

3. Enter Y or N in the Authorized field, to indicate whether the user is
authorized to enter stock transactions resulting from whatever transaction
type was entered in the Enter Stock Transaction by Items (tdinv1101m000)
session.

Maintain Option
Maintaining Inventory Status by Item
This session is used to define the particular status or state of the items stored in
the warehouse. For example, you may wish to identify damaged, expired, and
newly received items.
Before You Begin You must define the inventory status codes in the Maintain Inventory Status
Codes (tdawm1135m000) session.
Session Procedure To maintain inventory status by item:

1. Access the Maintain Inventory Status by Item (tdawm3101m000) session.
■ Project—indicates which project the items are intended.
■ Item—indicates the code of the item. If this code is filled in it indicates a
customized item. If this code is not filled in it indicates a standard item.
■ Wrh—provides the code under which the warehouse is recognized
within MK. The locations in the warehouse can be linked to this code.
■ Location—indicates the part of a warehouse where items can be stored.
Several locations can be recorded for each warehouse.
■ Lot—indicates whether lot control applies to an item. If it does, the
manufactured and purchased items are supplied with a lot code to
register the stock on hand for each lot.
■ Date—provides the stock date assigned to an item when storing it.
■ St. Un.—indicates the storage unit of the item.

Maintain Option
Maintaining Directed RF Assignments
You can assign an operator to a specific Radio Frequency (RF) rule using the
Maintain Directed RF Assignments (tdawm6196m000) session. When the
operator signs on to the RF system, MK first checks to see if a directed RF
assignment has been defined for the operator. If an RF assignment has been
established, MK starts the directed RF dialogue immediately and begins
selecting transactions for the operator using the assigned rule. If the operator
does not have an assignment, MK displays the RF menu.
Thomas has also assigned a specific rule set to each of his warehouse operators.
These rule sets were defined earlier by Jay Strange.
Scenario
Before You Begin Before you use this session, the operator(s) you want to use must already have
been set up as MK users from the Maintain User Data (ttaad2100m000) session.
Also, you must know the MK user login code of the operator you want to assign
directed RF rules to. To obtain a report which shows the users defined for MK
and their user login codes, run the Print User Data (ttaad2400m000) session.
Additionally, the following sessions must already have been run:

■ Maintain Warehouses (tcmcs0103m000), to define warehouses
■ Maintain Directed RF Rules (tdawm6195m000), to define directed RF rules

Maintain Option
Session Procedure To assign an operator to a specific RF rule:

1. Access the Maintain Directed RF Assignments (tdawm6196m000) session.
2. Enter the MK user ID code for the operator assigned to this rule. An
operator can have only one rule assignment record.
3. Enter the directed RF rule code assigned to the operator. RF rules can have
more than one record.

Maintain Option
Maintaining RF Queue Management
The RF queue management function provides an interface to query and manages

the RF transaction queue. Transactions are displayed in sequence by priority,
date, and time.
Session Procedure To maintain RF queue management:

1. Access the RF Queue Management (tdawm6190m000) session.
2. Select the AWM warehouse whose directed RF transactions you would like
to view and/or manage.
Note: You can scroll through all AWM warehouses by selecting Next or
Prev. This avoids the need to reselect warehouses each time.
3. Specify the selection criteria of the transactions you want to display.
Explanations of required or important fields follow:
■ Pickup Typ—identifies the source or location of the pickup. Valid entries
are:
Z—indicates the pickup is in a zone.
D—indicates the pickup is at a dock.
■ Pickup Src—identifies the source or location of the pickup.
Z—indicates a picking zone.
D—indicates the pickup is at a dock floor area.
■ Status (HLD, REL, ASN, PCK, REC)—indicates the status of the
shipment.

Maintain Option
The following information is then displayed:

■ Trans Pri—displays the value specified for this type of transaction.
Note: The transaction priority comes from either the Sales Order
Priority session or the Maintain Warehouses session (Form 3).
■ Trans Ty—identifies the unit of measure type.
■ Date/Time—identifies the date and time the transaction is first released to
the queue.
■ Source Typ (RCT, PPL, ADJ)—indicates the source type.
■ Source Control Number—further identifies the source of the transaction.
■ Pickup Whs—identifies the warehouse where the transaction is to be
picked up.
■ Wav—displays information for shipment or replenishment transactions
only.
■ Carrier—provides the carrier used for the shipment.
■ Truck—provides the truck used for the shipment.
This form shows the order type and order number of the transactions. The
order fields replace the source type and control numbers and the column
headings change to Order, allowing you to display transactions by order
number.

Maintain Option
This form shows the order type and RF ID number of the transactions. The
RF ID # field replaces the Order Number field. This allows you to display
transaction by RF ID number.
Note: The RF ID # is the same as the RF Control number.
6. To change a transaction’s priority and/or status from Held to Released, enter
C in the Choice field, cursor to the desired transaction, and change the
priority and/or status value.
7. To view detailed putaway, pickup, or replenishment data for a transaction,
select the transaction, press Ctrl+D in the Choice field, cursor to the desired
transaction, and enter Y. You can then access the appropriate subsession,
based on the chosen transaction type.

Maintain Option
Purging the Rejected Order Table
This session allows you to purge the rejected order table.
Session Procedure To purge the rejected order table:

1. Access the Purge Rejected Order Table (tdawm4250m000) session.
2. Enter the range of pick plan numbers to be deleted.
3. Select Continue to delete the selected pick plan numbers.
Note: If the Generate Outbound Advice (tdilc4201m000) session is running, MK

aborts the Purge Rejected Order Table session and displays the error message
“Can not purge the pick plan record because outbound is running.”

Maintain Option
Purging the Inventory Usage Table
This session allows you to purge the inventory usage table.
Session Procedure To purge the inventory usage table:

1. Access the Purge Inventory Usage Table (tdawm4251m000) session.
2. Enter the inventory transaction age (number of days older than) to purge.
3. Enter the target warehouse code.
4. Select Continue to delete the selected inventory transactions.

Displaying and Printing Options

MK provides a number of display and print sessions to help you evaluate
warehouse administration data. You can either display information to the form
or print out a report.
■ Display sessions are available by selecting the Inquiry 1 or Inquiry 2 option
of the Warehouse Administration Menu (within Advanced Warehouse
Management).
■ Print sessions are available by selecting the Reports option of the same
menu.
Displaying Unconfirmed Picks
The Display Unconfirmed Picks (tdawm3117m000) session is used to view picks

that are currently pending. If you do not fill in any of the selection fields, the
form displays all unconfirmed pick records, (that is, pick confirmation has not
been run). MK does not edit for valid entries in the selection fields.
Starcom has a corporate policy to ship everything that has been picked on the
same day. Prior to the carriers arrival, Thomas runs the Display Unconfirmed
Scenario Picks (tdawm3117m000) session to determine which picks are still
unconfirmed.

Session Procedure To display unconfirmed picks:

1. Access the Display Unconfirmed Picks (tdawm3117m000) session.
2. Enter the appropriate data or range of data to display the desired pending
picks. Explanation of the fields follows:
■ Source Cntl #—selects the source or the activity that generated the
record. If this field is left at zero, it is not be used as part of the selection
criteria.
■ Pick Control —selects the pick control number to be used in Pick
Confirmation.
■ Source Type—allows for selection of a specific source type or a range of
source types.
3. The following information is displayed for the pending picks selected:
■ Pick Sheet #—provides the pick sheet number that a pick is assigned to.
■ Wave—indicates the specific shipping wave or a range of shipping
waves.
■ Pick Type—indicates a specific pick type or range of picks.
■ Whs—indicates a specific warehouse or range of warehouses.
■ Location—indicates a specific location or a range of locations. The
location field consists of three fields separated by cases, aisle, bay and
level.

Displaying Unconfirmed Parcel
The Display Unconfirmed Parcel session (tdawm3116m000) allows you to view a

listing of the current parcels that have not been Floor Spot confirmed. MK does
not edit for valid entries. If none of the selection fields are filled in, all
unconfirmed parcel records are be displayed.
Session Procedure To display unconfirmed parcels:

1. Access the Display Unconfirmed Parcels (tdawm3116m000) session.
2. Enter the parcel number to display the desired pending parcel.

3. The following information is displayed for the pending parcel selected.
■ Pick Plan #—indicates a parcel number that has not been Floor Spot
confirmed. If this field is left at zero, it can not be used as part of the
selection criteria.
■ Pcl Typ—indicates a specific parcel type or a range of parcel types.
■ Ord Typ—indicates a specific order type or a range of order types.
■ Order—indicates an order number or range of order numbers.
■ Wave—indicates a specific shipping wave or a range of shipping waves.
■ Manifest—provides the manifest associated with the parcel.
■ Carrier—indicates a specific carrier or range of carriers.
■ Ship Whs—indicates a specific shipping warehouse or range of shipping
warehouses.
■ Fl Spt—indicates the floor spot number where the parcel is to be placed.

Displaying Unconfirmed Putaway
The Display Unconfirmed Putaway (tdawm3115m000) session displays details

on item location putaways which are currently pending (that is, putaway
confirm has not been run). All unconfirmed putaway records are displayed.
In order to maintain warehouse integrity, the third shift supervisor runs the
Display Unconfirmed Putaway (tdawm3115m000) session. He ensures
Scenario warehouse integrity by ensuring that all items are confirmed.
Session Procedure To display unconfirmed putaway:

1. Access the Display Unconfirmed Putaway (tdawm3115m000) session.
2. Enter the appropriate data to display the desired pending putaways.

Explanations of these fields follow:
■ Putawy Cntl #—selects the putaway number which controls the
unconfirmed putaway and is used in putaway confirmation.
■ Whs—indicates the code associated with the warehouse.
3. The following information is displayed for the pending parcel selected:
■ Source Cntl #—indicates the source or the activity that generated the
record.
■ Source Type (RCT or PPL)—indicates a specific source type or a range of
source types.

Additional Inquiry 1 The following display sessions can also be accessed using the Inquiry 1 option
Display Sessions on the Warehouse Administration menu.
■ Display AWM Transaction History by User (Detail) (tdawm4576m000)
This session displays all of the AWM transactions performed by a user for a
period that you can specify. For directed RF transactions, you can enter start
and stop times to determine operator efficiencies within a warehouse. You
can select a summary to view total transaction counts by transaction and
terminal type for the selected user and date or a detailed report listing all of
the transactions.
■ Display Stock History by Location (tdilc3510m000)
This session displays stock transactions by location. You can only display
stock transactions within warehouses furnished with a location system and
which have been specified at location level. The condition is that the
transactions have been logged. This is controlled through the parameter Log
Physical Stock Transactions by Location in the session Maintain Location
Control Parameters (tdilc0100m000).
■ Display Stock Transactions by Item (tdilc1521m000)
This session displays stock transactions by item. Only stock transactions are
shown which do not belong to the transaction type Stock Transfer but have
been specified to the lot and/or stock location.
You can only display stock transactions recorded through the session
Maintain Stock Transactions by Lot and Location (tdilc1121s000). You can
call this subsession from the main session Enter Stock Transactions.
Through the session Display Stock Transfers by Item you can display stock
transactions belonging to the transaction type Stock Transfer.
■ Display Transaction History by Item (tdawm4121m000)
This session displays information about the changes of inventory at locations
in the warehouse.
Whenever there are any changes to the quantity fields at a location, a
Transaction History record is produced. This session is used to review
historical transactions that have been processed in the warehouse. If there is
a problem with a count in a location, this session might prove useful in
reviewing the transactions for that location. The data might be used to
pinpoint the error.

Inquiry 2 Display The following display sessions can also be accessed by selecting the Inquiry 2
Sessions option on the Warehouse Administration menu.
■ Display Stock by Item (Standard) (tdilc1510m000)
The Display Stock History by Location session allows you to display stock
data of all standard items.
■ Display Stock by Item (Customized) (tdilc1520m000)
The Display Stock by Item session allows you to display stock data of all
customized items.
■ Display Stocks by Item and Lot (tdilc1511m000)
The Display Stock by Item and Lot session allows you to display stock data
by item and lot. All lot data present is displayed regardless of the stock
level. For detailed information, mark a line and call the Display Stocks by
Location and Lot (tdilc1514m000) session by selecting Zoom.
■ Display Stocks by Item and Warehouse (tdilc1512m000)
You can display stock data by standard item and warehouse through this
session. All stock data present in
MK is displayed.
For detailed information, mark a line and call the Display Stocks by Location
and Lot (tdilc1518s000) session by selecting Zoom. Since customized items
are not registered at warehouse level, you cannot display these items.
■ Display Stocks by Warehouse and Item (tdilc1513m000)
You can display stock data by warehouse and standard item through this
session. All stock data present in
MK is displayed.
For detailed information, mark a line and call the Display Stocks by Location
and Lot (tdilc1518s000) session by selecting Zoom. You cannot display
customized item stock because it is not registered at warehouse level in the
Inventory Control module.
■ Display Stocks by item/Lot/Warehouse/Location (tdilc1514m000)
You can display stocks by item, lot, warehouse and location (all displayed by
date, storage unit, warehouse, and location).
The stock on hand, as well as the blocked, allocated, and expected stock are
displayed by project, item, lot, date, storage unit, warehouse, and location.
Form 1 shows the stock in the stock unit while Form 2 shows it in the storage
unit (in so far that it applies at all).

■ Display Stocks by Item/Storage Unit/Location (tdilc1515m000)

You can display detailed stock data by item, storage unit, warehouse,
location, lot and date.
Locations, lots and stock which are present in
MK are displayed by project, item, storage unit, and warehouse.
■ Display Stocks by Location/Item/Lot (tdilc1516m000)
You can display a detailed overview of stock data by warehouse, location,
item, lot and date.
The locations with their data (project, item, lot, stock date) and the stock on
hand are shown. Locations without (expected) stock are not shown. For
detailed information, select Zoom to access the Display Stocks by Location
and Lot (tdilc1509s000) session.
■ Display Stocks by Warehouse, Item, and Date (tdilc1505m000)
This session allows you to display a detailed overview of stock data by
warehouse, item and stock date at the most detailed level (by lot and
location).
For each warehouse, project and item, MK shows the stock on hand, as well
as the blocked, allocated, and expected stock level. Form 1 shows the data
expressed in the stock unit; Form 2 shows the same data in the storage unit
(if applicable).
■ Display Component Stocks by Manufactured Item (tdilc1517m000)
This session allows you to display stock data of Bill of Material (BOM)
components on the production BOM of a manufactured item. For each
manufactured item, all BOM components are shown. The stock on hand and
the blocked stock is shown for each component.

Print Sessions The following print sessions can also be accessed using the Report option in the
Warehouse Administration menu.
■ Print AWM Transaction History by User (tdawm4476m000)
You can print all of the AWM transactions performed by a user for a period
that you specify. For directed RF transactions, you can enter start and stop
times to determine operator efficiencies within a warehouse. You can select a
summary report to print total transaction counts by transaction and terminal
type for the selected user and date or a detailed report listing all of the
transactions.
■ Print Stock Transactions by Item (tdilc1421m000)
You can print stock transactions by item using this session. Only such
transactions not belonging to the transaction type Stock Transfer are printed.
You can select by project code, item code and warehouse code. Transactions
are printed in the following order: project/item/warehouse/series
number/serial number.
■ Print Stock Transfers by Item (tdilc1422m000)
You can print stock transactions by item using this session. Only such
transactions not belonging to the transaction type Stock Transfer are printed.
You can select by project code, item code, and warehouse code. Transactions
are printed in the following order: project/item/warehouse/series
number/serial number.
■ Print Blocked Stock (tdilc1441m000)
You can print item quantities blocked for all transactions and you can choose
various reports using this session including Blocked Stock By
Warehouse/Location, Blocked Stock by Item, or Blocked Stock by
Warehouse/Login Code.
You can select by warehouse code, project code, item code, and lot code.
You may also select by the reason for blocking.

Chapter
RF Processing
8
Introduction .................................................................................. 8–1

Directed Versus Non-Directed RF Processing .................................................... 8–2
Paper Versus Paperless .................................................................... 8–2
Replenishment ............................................................................ 8–4
Parcel Numbers for Case Picks ............................................................. 8–5
General RF Menus and Forms .................................................................. 8–6
RF Main Menu ............................................................................ 8–6
Directed RF Rule Selection Form ........................................................... 8–8
RF Processing Form ....................................................................... 8–9
RF Location Assignment Form ............................................................ 8–10
Before You Begin ............................................................................ 8–11
RF Inbound Receipt Confirm.................................................................. 8–12
Receipt Confirm for Non-Directed Inbound Putaway ........................................ 8–12
Directed RF Inbound Receipt Confirm ..................................................... 8–14
RF Inbound Putaway Confirm ................................................................ 8–17
Non-Directed RF Terminal Inbound Putaway Confirmation.................................. 8–17
Directed RF Terminal Inbound Putaway Confirmation ...................................... 8–18
RF Process Receipts and Print Putaway Barcode Labels ...................................... 8–20
RF Stock Transfers ........................................................................... 8–22
Viewing Locations ........................................................................... 8–24
Viewing Stock by Warehouse and Location ................................................. 8–24
Viewing Stock by Item.................................................................... 8–25
Cycle Counts ................................................................................ 8–26
Non-Directed RF Terminal for Cycle Counting .............................................. 8–26
Count Select ............................................................................. 8–27
RF Outbound Picking Confirmation ........................................................... 8–30
Non-Directed RF Terminal Picking Confirmation ........................................... 8–31
RF Outbound Floor Spot ..................................................................... 8–35
Non-Directed RF Dock Floor Spot Confirmation ............................................ 8–35
Directed RF Dock Floor Spot Confirmation ................................................. 8–37
RF Processing 8–i
Maintaining RF Outbound Staging Areas ...................................................... 8–38
Picking RF Outbound Batches ................................................................ 8–39
RF Inventory Location Load .................................................................. 8–40
Printing RF Outbound Shipping Labels........................................................ 8–41
8–ii MK Advanced Warehouse Management, Volume 2, User Guide

Chapter
RF Processing
8
Introduction
Radio Frequency (RF) applications generally use the following keys: A (Exit), Y
(Execute), E (Exit or Skip), and 9 (Help). Movement from field to field on the
terminal form is accomplished by selecting Execute.
Unless otherwise noted, selecting A returns you to the RF Main Menu and Y
causes MK to begin processing the data entered on the current form.
Error messages are displayed on the form, overriding what was on the form.
After pressing Execute, the previous form appears.
RF Processing 8–1
Directed Versus Non-Directed RF Processing

The directed RF feature provides the ability to define rules to direct an RF
terminal operator through a series of inventory movements.
In a non-directed RF environment, the terminal operator decides which function

to perform (pick, putaway confirm, cycle count, etc.) and selects that function
from a menu. Once in the function, MK assumes that documents such as
putaway labels or pick control sheets have been printed, and requires the
operator to select a specific transaction to execute. The operator must enter or
scan, some identifying information for the transaction (for example, a putaway
location and sequence number, or a pick control number), and then executes the
transaction. MK may suggest a subsequent transaction, usually of the same type
(putaway or pick), after the selected transaction has been executed, but the
operator always has the ability to select a different transaction - execution is
quasi-directed after the first transaction.
In the directed RF environment for picking, the RF operator signs on to a

terminal and, depending on system configuration options, selects or is assigned
to a directed RF rule. The rule identifies a group of storage locations and/or a
group of shipping/receiving docks where the operator can pick up transactions,
and identifies the types of transactions (pallets, cases, etc.) that can be picked up.
The RF system selects a transaction from a priority driven queue and directs the
operator to pick it up. Once the operator confirms that the transaction has been
picked up, MK directs him/her to drop it off. If necessary, paperwork (a
shipping label) to accompany the transaction is generated when the transaction
is dropped off. This pick-up and drop-off dialogue continues until the queue has
been emptied.
Paper Versus Paperless
The purpose of directed RF is to direct all inventory movement in the warehouse

without the use of labels, although there are still some situations where labels are
necessary. For example, shipping requires the use of the UCC-128 standard
shipping label. The general approach for directed RF is to pick first and then
stop off on the way to the dock to print and apply the label. This eliminates the
need to have labels printed and divided among the operators before picking.
Directed RF works well for pallet picking (one label per pallet), for case picking
by order when cases are being picked to a pallet for shipping (one label per
pallet), and for piece picking to a carton or tote (one label per carton).

MK continues to generate paper labels to drive the process for case picks by
batch wave and for case picks for UPS type shippers. In both of these situations,
each case must be labeled individually, and stickered with a control number.
Each case would also be pick confirmed individually to reduce the risk of
applying the wrong shipping label.
MK also generates paper labels to drive the process for piece picking with pick-
to-tote and -consolidate parceling options. Again, this is due to the need to
ensure all of the totes meet up with the correct shipping label.
MK uses the following rules to determine which transactions are queued for
directed RF.
Replenishment Queued for directed RF (and a label is NOT printed) if the pick location uses
pick verify = Electronic, and the putaway location uses putaway verify =
Electronic.
If either side of the transaction uses paper confirmation, transfer label(s) is/are
printed and the pick is not queued for directed RF.
Picks for Shipment Placed in the directed RF queue, and shipping label printed AFTER pick
confirmation if all of the following are true:
■ The pick location uses pick verify = Electronic.
■ The pick is not a case (or mastercase) pick or the pick plan uses plan method
= O (pick plan by order)
■ AND the item is NOT a “batch pick only” item
■ AND the carrier allows electronic case pick confirmation (flag set to Y in the
Carrier Manifest Detail)
Putaways From Queued to directed RF if the putaway location uses putaway verify =
Receiving or Electronic.
Adjustments
Paper labels are printed for all other inventory movement transactions.
RF Processing 8–3
Replenishment
Directed RF does not prevent sending an operator to pick from a location before
the location has been replenished. Two methods exist to reduce the chance of
this occurring:
Option 1— Give replenishment transactions a higher priority than picks for

shipment. Note that this does not resolve the issue, as the replenishment
operator may do several picks before beginning to do the putaways. It also does
not work if two different groups of operators (different zones) are doing picks
for replenishment and picks for shipment, and both groups start working
concurrently.
Option 2—Release replenishment transactions to the queue automatically, but

don’t release picks for shipment to the RF queue automatically. The downside of
this option is that manual intervention is required to release the picks for
shipment.
Non-Pallet Putaways from Receiving
Another paper versus paperless issue is whether or not to pre-sort the receipts at
the dock to facilitate the putaway operation for non-pallet putaways from
receiving.
If receipts are not pre-sorted, an operator may be sent to put something away
into a location he cannot physically reach. You can prevent this by defining
directed RF rules such that only RF operators allowed to pick up non-pallet
putaways from a dock have access to all non-pallet putaway locations in the
warehouse. Or, the putaway operator can use the Skip Transaction function to
bypass the impossible transactions, and then drop them off at a dock for pickup
by someone with the proper equipment.
If your installation requires pre-sorting at the dock, you can print putaway labels
at receiving and use the non-directed putaway functions. The labels are much
easier to work with for pre-sorting than attempting to sort by reading putaway
locations from the RF form.

Parcel Numbers for Case Picks
For case (or mastercase) shipments when paper labels are generated by pick
planning, MK assigns one parcel number per case for full case shipment.
When case (or mastercase) picks are queued to directed RF, there is one parcel
per dock floor spot. If one of these parcels is broken during picking by dynamic
parceling all resulting parcels are assigned to the same floor spot.
Only one directed RF operator can work with one of these parcels at a time.
However, as soon as he closes the control number, the remaining picks in the
parcel are queued for the next available operator.
An option, known as the Pier 1 option, will be added to the pick zone record to
allow combining piece (and inner pack) picks into these directed RF case pick
parcels. When the option is selected, one parcel could contain all non-pallet
picks for an order (given a large enough dock floor spot).
A second option, (in the warehouse record) allows breaking these parcels by pick
zone or consolidation zone. Selecting this option and defining large logical dock
floor spots could be used to generate one parcel per order pick zone.
RF Processing 8–5
General RF Menus and Forms

The following menus and sessions are accessed for all directed RF transactions.
RF Main Menu
MK displays this page after you select RF Main Menu from RF Main Menus
under Advanced Warehouse Management:
From RF Main Menu, you can display one of twelve sessions:

■ Batch/Cart
■ Count
■ Directed RF
■ Floor Spot
■ Label
■ Location Load
■ Pick
■ Pick to Cart
■ Putaway Confirm
■ Receipt Confirm
■ RF Count Select
■ Staging Area

From RF Menu 2, you can display one of six sessions:
■ Disp. Stock by Items
■ Display Stock
■ Loc. Assignment
■ Receipt Putaway
■ Stock Adjustment
■ Stock Transfer
RF Processing 8–7
Directed RF Rule Selection Form
MK displays this form after you make one of three selections:

■ Directed RF from the RF Main Menu
■ Directed RF Rule Selection from the RF Outbound Menu
■ Directed RF Rule Selection from the RF Inbound Menu
After you enter an RF rule in the RF Rule Selection form, MK displays the
associated AWM Warehouse on the same form:

RF Processing Form
The following directed RF form appears when MK has processed all work for
your current RF rule:
Note: In a non-directed RF environment, the terminal operator decides which

function to perform and selects that function from a menu. These steps are
included in each of the following non-directed RF procedures. In the directed
environment, the RF system selects a transaction from a priority-driven queue
and directs the operator to pick up or drop off an item. This pick-up and drop-
off dialogue continues until the queue has been emptied. Although the directed
RF environment is not menu-driven, it can be assessed through the RF Main
Menu by selecting Directed RF.
Operators using an RF terminal should be set up to start performing RF

transactions from the RF Main Menu. For those not using an RF terminal, you
can access the RF Main Menu by selecting MK Sales and Purchasing and
Advanced Warehouse Management.
RF Processing 8–9
RF Location Assignment Form
You can assign and de-assign fixed storage locations for items using an RF
terminal. MK will not allow you to assign an item to a fixed location that is
already occupied and warns you if the location is set up as a multi-item location.
Session Procedure To assign fixed storage location:

1. Access the Loc. Assignment (tdawm6072m000) session.
2. For customized items, enter the project code that indicates for which project
the items are designated.
3. Enter an item code for the item for which the warehouse is being assigned or
de-assigned. MK displays the item’s description.
4. Enter the number of the warehouse that you want to assign or de-assign
items. MK displays the name of the warehouse.
5. Enter the number of the location of the warehouse for which you are
assigning or de-assigning items.
MK determines if you are assigning or de-assigning items by locating the
warehouse, location, and item cobination that you entered. If the
combination exists, MK checks if the quantity of the specified item in the
specified location is zero. If the quantity on hand at the loaction is zero, MK
prompts you to confirm the de-assignment. If the combination of
warehouse, location, and item does not exist, MK allows you to finish
entering the rest of the information.
6. Enter the check digit for the item for the warehouse that you are assigning or
de-assigning
7. Enter a number between one and five for the inbound priority for the
warehouse that you are assigning or de-assigning.
8. Enter a number for minimum and maximum stock for the warehouse that
you are assigning or de-assigning.
9. Indicate whether you want to include nettable items for the warehouse that
you are assigning or de-assigning.
10. Click Execute to start the assigning process.

Before You Begin
Before You Begin

For all directed RF transactions, you must first run the Maintain Directed RF
Rules and Maintain Directed RF Assignments sessions. Advanced Warehouse
Management, Volume 1, Getting Started describes the Maintain Directed RF Rules
(tdawm6195m000) and Maintain Directed RF Assignments (tdawm6196m000)
sessions in the “Directed RF Setup” chapter.
For non-directed RF, there are no preliminary sessions required.
RF Processing 8–11
RF Inbound Receipt Confirm
Receipt Confirm for Non-Directed Inbound Putaway
If non-directed confirm for putaway was selected in the Warehouse Definition

program, after you enter information on the first RF Receiving Confirmation
form, the Putaway Control form appears. This function enables you to process
inventory from receiving through putaway as it comes into the warehouse. This
processing can be accomplished without any staging activity.
Session Procedure To perform receipt confirm for non-directed putaway:

1. Access the RF Receipt Confirm (Non-directed) (tdawm6114m000) session.
2. Enter the warehouse identification and select Y to display the Receipt

Confirm (tdawm6108m000) form.
3. Enter the dock identification and select Y. If the transaction is valid, the
following form appears:
This form enables you to verify the item is packed as configured by

receiving, and to verify the quantity being confirmed.

4. Enter the quantity, unit of measure, and piece quantity. If the information
displayed is correct, select Continue to begin the confirmation process. MK
performs the following activities:
■ Performs a validation process.
■ Checks for a location assignment within the warehouse for this location
and the corresponding sequence number.
■ Processes the receipt confirmation request.
5. Select Continue or press Ctrl+G to activate the RF Putaway Confirmation
form and permit putaway confirmation of the received inventory. The
following system activities occur:
■ Validates your entries.
■ Checks Location Assignments for a record indicating putaway
confirmation for this warehouse by location or area and sequence
number.
■ This type of receipt confirmation only applies to the single Location
assignment selected by the operator, and is not the same as global
receipt confirmation when requested from the Edit form.
■ Determines if receipt session for the receipt control number has
confirmed all items. If so, the following Close Receipt message
automatically appears.
6. Select Continue to close receipt or A to continue processing.

Note: If you do not set the flag to Label in the Maintain Warehouses
session, the following form will appear when you begin the Receipt Confirm
session. This form allows you to switch to receipt confirm for non-directed
putaway.
Directed RF Inbound Receipt Confirm
The Advanced Warehouse Management module provides an RF facility that will

facilitate the receiving confirmation of inventory, as it comes into the warehouse,
without having to receive confirm the entire receipt activity, and allow for
queuing for Directed RF putaway.
Ken Cameron is a warehouse employees who uses the RF terminals and

Directed RF functionality. Ken runs the RF Receipt Confirm (Non-directed)
Scenario (tdawm6114m000) session to confirm the receipt of goods into the warehouse.
Session Procedure To perform directed RF Receipt Confirmation:

1. Access the RF Receipt Confirm (Directed) (tdawm6110m000) session.
2. Enter the Warehouse identification and select Y.
3. Enter the dock and receipt number and then select Continue. The following
form appears:

4. Scan or enter the item number and project number to confirm, and enter a
control number to attach the confirmed transactions to. A control number is
used only when using directed RF confirm for putaway and is assigned to
each full pallet. Less than pallet quantities combined and assigned a
putaway control number. Select Continue. The following form appears.
5. Enter the unit of measure quantity and the each quantity. Select Continue.
MK then begins the following validation:
■ Validates that one or more unconfirmed receipts exist for the item/lot
number, and that the total unconfirmed quantity is at least as much as
the quantity being confirmed.
■ Confirms receipt of location assignments (pending putaway
transactions) for the item/lot number that have not yet been receipt
confirmed. MK selects transactions to confirm by first looking for a
transaction with a quantity equal to the quantity entered. If none is
found, MK confirms smaller quantity transactions until the entire
quantity has been confirmed. If there are no unconfirmed transactions
with quantity less than or equal to the quantity to confirm, MK confirms
part of a larger transaction.
■ If all of a pallet putaway transaction was confirmed (the confirmed
quantity was greater than or equal to an entire pallet putaway
transaction) the control number is automatically closed and queued for
pickup by a putaway operator. You are not able to attach more putaway
transactions to the control number. If no pallet putaway transaction was
confirmed, the control number is left open until you purposely close it.
■ Determines if receipt session for the receipt control number has
confirmed all items. If so, the following Close Receipt message
automatically appears.
6. To close the control number:

■ Scan the control number
■ Select 2 on Form 3 to close the control number and queue it for pickup
by a putaway operator.

RF Inbound Putaway Confirm

The purpose of putaway confirmation is to provide positive acknowledgment
that a predetermined quantity of inventory was put away as instructed by the
locating logic used by Advanced Warehouse Management. There are three
methods you can use to perform putaway verification: a paper-driven system,
Non-directed RF and Directed RF. This section will discuss both RF methods.
Refer to Chapter 4, “Inbound Processing,” for information on the paper-driven
method.
Non-Directed RF Terminal Inbound Putaway Confirmation
For immediate updating, perform the following steps using an RF terminal:
Session Procedure To perform non-directed putaway confirmation:

1. Deliver the item to the location.
2. Access the RF Putaway Confirmation (tdawm6120m000) session.
3. Enter the location check digit and quantity then select 1. MK verifies that the
check digit matches the location.
4. If the check digit is correct, the transaction is complete and the inventory
moves from Expected to On-hand for the location.
If the check digit is incorrect, you should address the error immediately with
the warehouse supervisor and make the correction. In general, to maintain
the integrity of the warehouse, all errors must be corrected.
Multiple Putaway Multiple putaway transactions are created for a single putaway control number
Transactions when an item from a single receipt is put away in multiple locations within the
same aisle. Multiple putaway transactions for a single putaway control
number are identified by the sequence number that appears on the right-hand
portion of the label.
Directed RF Terminal Inbound Putaway Confirmation
For immediate updating, perform the following steps using an RF terminal:
After items have been put away, based upon the information generated
through running Inbound Advice, Ken needs to confirm that he has put the
Scenario items in their correct locations. He does that using the following session.
Session Procedure To perform directed RF putaway confirmation:

1. Access the RF Putaway Confirmation (tdawm6176s000) session.
2. Enter the AWM Warehouse code.
3. Select Y.
The RF system selects a transaction from a priority-driven queue. The
following form appears, displaying the warehouse, dock area, and control
number of the pick transaction.
4. After you find and pick up the item, select Continue. The Putaway
(tdawm6174s000) form appears:
This form directs you to the “first” putaway location. It identifies the
location to deliver the item to, which item to put away, and how much to put
away.

5. Go to the destination location and scan or enter its check digit to verify that
you are in the correct location. If entering the check digit, you must first
select C in the Choice field. Select Continue to verify the check digit.
6. Scan or enter the item to verify that you are dropping off the correct item.
There may be more than one item under that pallet. Enter the lot (if lot
controlled) and the project (if a customized item). Select Continue to confirm
putaway of the transaction. MK performs the following tasks:
■ Verifies that the scanned item and lot numbers are the same as those that
were directed to putaway
■ Posts the putaway confirm transaction
■ Directs you to the “next” putaway location or the next transaction in the
queue
7. Use the Drop Transaction command key for situations where you need to
drop your current transaction for completion by another RF operator.
Note: “First” and “next” are enclosed in quotes in this description because
MK determines the order in which transactions are processed.
If the control number references both pallet and less-than-pallet putaway
transactions, all of the less-than-pallet transactions are processed first
regardless of location address. The assumption is that you are not able to
drop the pallet until all other transactions have been dropped off.
Note: To display other available options on this form, select 9 for online
help.
RF Process Receipts and Print Putaway Barcode Labels
You can use MK to process receipts and print putaway barcode labels.
Session Procedure To receive product and print putaway barcode labels:

1. Access Form 1 of the Receipt Putaway RF (tdawm6145m000) session.
2. Enter the warehouse, receiving dock, receipt number (existing or new), and
dispatch note for which you want to record receipts. MK displays the project
and item numbers.
3. Click Execute to access Form 2 of the Receipt Putaway RF (tdawm6145m000)
session.
4. Enter the receipt, purchase order, item, position, dispatch note, and quantity
for which you want to record receipts.
5. Select Prepaid or Collect for the type of freight charges and enter the freight
charge amount associated with the receipt.
6. If you use lot control, enter a lot number for which you want to record
receipts. You can use the Maintain Lot Status (tdawm1120m000) session to
view and modify lot control.
7. Click Execute to process the receiving transaction. MK updates the receipt
record for the current purchase order line and records the receipt of goods.
If you set the Streamline Inbound Process During Receipt option to Yes in
the Maintan Purchase Order Parameters (tdpur4100m000) session, MK
generates inbound advices.
8. Select a device from the list of devices that you entered in the Print Location
Assignment (tdawm1154m000) session from which you want to print
putaway barcode labels.

9. Click Execute to print putaway barcode labels.

Note: You can reprint putaway barcode labels using the Print Putaway
Label (tdawm2403m000) session.
If you generate a pending RF receipt record with either electronic or paper
putaway verification for the advised location, MK zooms to the Receipt
Confirm (tdawm6115s000) subsession.
10. Insert the received item in a pallet from the RF Queue.
11. Click Execute to continue to record receipts or select to save and end. MK
updates backorder quantities.
RF Stock Transfers
RF Stock Transfers
You can perform stock-to-stock transfers using an RF terminal. Transfering
stock is a two-step process. First you select items to transfer and then you put
the transferred items away.
Session Procedure To pick the stock to transfer:

1. Access the Stock Transfer (tdawm6070m000) session.
2. Enter the item number of the stock you want to transfer.

3. Enter the warehouse from which you want to transfer stock. MK displays the
next available serial number for the transfer. You may change it. MK
displays the warehouse order number.
To view the warehouse and location stock information for the item, click
Application and then select the Display Stock Data by Location and Item
(tdawm6061s000) subsession.
4. Enter the number of the warehouse to which you want to transfer stock.
5. Enter the number of stock items that you want to transfer. MK displays the
type of unit for the stock item that you want to transfer.
6. Click Execute to go to the Stock Transfer (tdawm6071s000) subsession to put
away the transferred stock. You can perform multiple putaways for a single
pick.
MK displays the item and serial number for the item to be transferred.

RF Stock Transfers
7. Enter a serial number for the picked items that you want to put away. MK
displays the numbers of the warehouses that you are transfering stock from
and to.
To view stock data at the location and the warehouse stock data pertaining
to the item, select L to go to the Display Stock Data by Location and Item
(tdawm6061s000) subsession and press the right arrow key (→ ).
8. Enter the location from which you want to transfer stock. Enter the location’s
check digit.
9. If you are using lot control, enter the lot control number for the transferred
stock.
10. Enter the quantity of stock that you want to transfer. MK displays the type of
unit for the stock items.
11. Enter the location that you want to use to put away the transferred stock.
Enter the location’s check digit.
12. Click Execute to print a stock transfer ticket. The transfer ticket includes the
item code, description, transfer from warehouse location and its serial
number, and the transfer to warehouse locations and their serial numbers.
13. The status of the picked item does not change when it is in transit. The stock
transfer ticket indicates that the item has been picked. The item picked for
transfer remains in its original location with an allocation so no other process
can reserve it. When the item is confirmed to its new location, the inventory
is transferred to its new location.
You can continue to put transferred stock away or click End to exit.
Viewing Locations
Viewing Locations
You can view location status, storage type, and range of locations utilizing an RF
device using the following two sessions:
■ Display Stock (tdawm6060m000)
■ Disp. Stock by Items (tdawm6062m000)
Viewing Stock by Warehouse and Location
To view AWM locations by location code, location status, or storage type, use the
Display Stock (tdawm6060m000) session.
Session Procedure To view AWM locations:

1. Access the Display Stock (tdawm6060m000) session.
2. Select the warehouse and location for which you want to view details.
3. Click Application and then choose on of the following sorts to view stock
information:
■ Sort by location
■ Sort by storate type, location, item

Viewing Locations
Viewing Stock by Item
To view and search stock data by item, use the Disp. Stock by Items
(tdawm6062m000) session.
Session Procedure To view and search stock data by item:

1. Access the Disp. Stock by Items (tdawm6062m000) session:
2. Enter the stock data for the item that you want to view.
Cycle Counts
Cycle Counts
You can perform cycle counts by running the following three separate sessions:
■ Generate Stocktaking Orders (tdilc5210m000)
■ Print Stocktaking Orders (tdilc5410m000)
■ RF Count (tdawm6131m000)
Or, you can use the RF Count Select (tdawm6211m000) session to streamline the
cycle counting process.
Non-Directed RF Terminal for Cycle Counting
Before you can perform non-directed cycle counting from an RF terminal, you
must first run the Generate Stocktaking Orders (tdilc5210m000) session to create
inventory orders for counting warehouse stock at the location level. You must
also run the Print Stocktaking Orders (tdilc5410m000) session before counted
quantities can be entered.
For random spot check, perform the following steps using an RF terminal.
Session Procedure To perform non-directed RF terminal cycle counting:

1. Access the RF Count (tdawm6131m000) session.
Note: MK AWM RF cycle count uses existing cycle count (stocktaking) logic
obtained from the Enter Stocktaking Data (tdilc5110m000) session. MK RF
only displays one location/item and includes the check digit field.
2. The first order is auto-displayed. To find an order, press Ctrl+F. Enter the
order and warehouse.
3. Select C in the Choice field and then a valid check digit for the location. The
quantity defaults to the system count.
4. Go to the location to be counted and count the product in the location.
5. Enter the counted quantity in stock unit of measure and the counted
quantity in storage unit of measures.
6. Select 9 to display available options.

Cycle Counts
Count Select
Use the RF Count Select (tdawm6211m000) session to select the appropriate

order for cycle counting. You can pick orders by order type and order number.
From this session, you can run the following sessions:

■ Generate RF Count List (tawm6200m000)
■ RF Process Data (tdilc5411s000)
■ RF Count Report (tdilc5211s001)
Before You Begin If you want MK to ignore the ABC code and percent annual cycle count for cycle
counts by product code, range or location, and stocktaking order, select No in
the Use ABC Code and % Annual Cycle Count to Generate Cycle Count List field
in the Maintain Advanced Warehouse Management Parameters
(tdawm0100m000) session.
Session Procedure To select orders for cycle counting:

1. Execute the RF Count Select (tdawm6211m000) session. The Generate Stock
Taking Orders (tdilc5210m000) session displays.
2. To generate stocktaking orders by item, select Item for the count type and
enter the range of items that you want to count.
To generate stocktaking orders for a range of locations, select Range for the
count type and enter the range of warehouses and locations from which you
want to count items.
Click Execute to go to the MK RF Count Select (tdawm6211m000) session.
Cycle Counts
3. Select a count type for cycle counting from the following choices:
■ Item. To perform a cycle count by item.
■ Range. To perform a cycle count based on the range of warehouses and
locations that you selected in the Generate Stocktaking Orders
4. MK displays the number of your first warehouse order and the name of the
individual that created the order. You can zoom to select from a list of
warehouse orders.
5. To generate a count list, click Execute to go to form 2.
6. Enter the Count type for which you want to generate a list of stocktaking.
MK displays the orders, login codes, and status for the items selected.
7. To view the count list, click to go to the Display Stocktaking Orders List
(tdilc5500s000) subsession.
8. Enter a check digit and quantity counted for the item. Click Close to save the
count and return to the RF Count Select Session. MK changes the status of
the counted item to Count Completed.

Cycle Counts
9. To generate a report of the discrepancies found during cycle counting, click

Application and choose RF Count Report to go to the Count Check Report
(tdilc5211s001) session.
10. Enter the device to which you want to print the discrepancy report. The
report includes the location, ISBN, description, physical quantity, system
quantity, and location of the discrepancies sorted by location.
11. To process the stocktaking data, click Application and then choose select RF
Process Data.
12. Click Close. MK checks if all of the items for the selected order are counted
and updates the status of the order. When you perform a sales or
replenishment pick that results in a zero bin count, MK frees the bin location.
If the bin is not empty, MK prompts you for the current quantity on hand
and displays the item code, description, and unit of measure.
RF Outbound Picking Confirmation

AWM offers three methods of Pick Confirmation; a paper-based system, non-
directed RF, and directed RF. The RF terminal system is preferred because it
confirms the pick to be confirmed at the actual time the product is removed from
the storage location. Also, warehouse personnel using RF terminals are
provided with a mechanism to correctly link their picking and putaway
activities. This mechanism is known as Interleave Picking/Putaway. The paper-
based system accomplishes the same purpose, though in a time-delayed fashion.
In practice, the RF and paper method can be used interchangeably since the pick
transaction is assigned an identifying control number, and control numbers are
grouped into pick sheets. For example, a pick sheet can contain all the case picks
that are to be made on shipping wave 1, in aisle 6; or contain all individual piece
picks that make up one shipping parcel. After you have indicated the initial
control number to use, MK leads you through all subsequent picks that make up
the pick sheet that contained the starting control number.
This section discusses both RF methods in detail. For information about the
paper-based system, refer to Chapter 5, “Outbound Processing.”

Non-Directed RF Terminal Picking Confirmation
Session Procedure To perform non-directed picking confirmation:

1. Access the RF Picking Confirmation (non-directed) (tdawm6140s000)
session.
2. Enter the warehouse identification and select Continue. The following form
(tdawm6140m000) appears:
3. In the Ctl# field, enter the pick sheet control number for the first pick from
either the pick sheet or the label. Select Continue to redisplay the form with
more information:
Explanation of the information displayed on this form follows:

■ Loc—displays the first pick for the control sheet. The location or area
nickname is also displayed.
■ Pcln—displays the parcel number.
■ Item—displays the 15-character item number.
■ Lot—displays the 15-character lot number if the item is lot controlled.
■ Qty—shows the pick quantity in the item’s default unit of measure.
4. In the CkDg field enter the location check digit. Select Continue. MK
verifies that the check digit matches the location.
Note: For other Pick Confirmation options, select 9 for help.
5. If the check digit is correct, the transaction is complete. Pick the product
from the location. If the check digit is incorrect, you can have the worker
make a correction.
6. Apply labels, if required.
7. After indicating picks are completed, deliver the product to the To location
(for adjustments or replenishment) or the dock floor spot (for shipping
orders) on the label.
Note: To maintain the integrity of the warehouse, all errors must be corrected.
Interleave The Interleave Picking/Putaway option provides an RF facility with the means
Picking/Putaway to minimize dead-heading (that is, truck movement without materials) without
Option sacrificing existing system productivity and throughput advantages. Once the
pick is confirmed, the Interleave Picking/Putaway program evaluates the next
pick with the same control number. If it is a pallet pick, the program searches
for pending pallet putaways from receiving in the aisle as the next pick. If a
pending pallet putaway is found for this aisle, the program presents the RF
Putaway Confirmation form, which allows only one pending record; for
example, the control number, aisle, bay, level, and putaway sequence number
fields.

Directed RF Terminal Picking Confirmation
For immediate confirmation of picks, use the RF terminal.
Ken uses the interleave functionality to save time. After his terminal directs
him to pick products, he uses the following session to confirm that he has
Scenario picked the correct product from the correct location.
Session Procedure To perform directed RF Picking Confirmation:

1. The RF system selects a transaction from a priority-driven queue.
2. Go to the location displayed and scan (or enter) the control number and the
check digit. Select Continue to pick by location. MK performs the following
tasks:
■ Validates the check digit
■ Confirms the pick transaction
■ Associates the picked inventory with the control number
3. Select 2 to close the control number. This is only valid when the quantity
picked is less that a pallet.
After the pick transaction is confirmed and the control number is closed, you
can perform one of two options. Option 1 assumes label printing and floor
spot confirmation occur independently of picking. Option 2 assumes the
same operator that did the picking is to apply the label and drop the goods
off at the dock floor spot.
4. For Option 1, enter the warehouse, dock, and spot information, and select
Execute to display the following message:
5. Select Execute to print shipping labels.

6. To continue this drop-off using Option 2, refer to Directed RF Floor Spot
Confirmation.
Directed RF Piece Picking
Perform the following steps if you want to perform Directed RF Piece Picking.
1. Any time a directed RF rule directs you to begin picking a new each parcel,
MK displays the Directed RF Piece Picking form.
2. After you select the carton and press Execute, MK directs you to the first
pick for the parcel.
3. The directed RF picking dialogue continues the same as discussed earlier.

RF Outbound Floor Spot

Dock Floor Spot Confirmation provides positive acknowledge that a shipping
parcel has arrived on the shipping dock as instructed by the pick plan created.
Ship confirmation cannot be performed for a truck of product being shipped on a
carrier until all parcels listed on the carrier manifest for the truck have been floor
spot confirmed. There are three methods of floor spot confirmation: a paper-
driven two step system, non-directed RF and directed RF. The use of a Radio
Frequency terminal enables you to automatically verify correct putaway. This
section discusses both RF methods in detail. For information about the paper-
driven system refer to Chapter 5, “Outbound Processing.”
Non-Directed RF Dock Floor Spot Confirmation
Session Procedure To perform non-directed RF dock floor spot confirmation:

1. Access the RF Dock Floor Spot Confirmation (non-directed)
(tdawm6150m000) session by choosing the following:
■ RF Main Menu (AWM)
■ RF Outbound
■ Floor Spot
MK displays the tdawm6150m000 form:
2. Scan (or enter) the dock floor spot check digit, and the UCC-128 container
ID. Select Continue to execute. This validates and confirms a parcel/control
number.
MK performs the following activities:
■ Verifies that the check digit is correct for the floor spot, and confirms the
parcel by placing the current system time and date, along with your user
ID, into its control files.
You do NOT need to indicate the floor area on the floor spot number
where the parcel is placed. MK can identify the spots and areas based
on the check digit value alone.
■ If pick verification is required and the parcel contains items which have
not been pick confirmed, an error message appears notifying you of the
condition. Other validations are performed for things such as correct
warehouse, parcel number, and whether the parcel has been previously
confirmed.
■ Validates the check digit and if an error is found, issues an error
message or locks the RF terminal.
■ Verifies that the parcel shipping label has been printed. This is always
true for any parcel picked with non-directed RF (the label was printed
during pick planning). For parcels picked with directed RF, the label
must have been printed by the RF shipping function.
■ Verifies this is a parcel to be picked by directed RF. If yes, then it checks
if it has been released by the directed RF operator. If it has not been
released, an error message is displayed.

Directed RF Dock Floor Spot Confirmation
Use Directed RF floor spot confirmation when you want the same operator that
performed picking to apply the label and drop the goods off at the dock floor
spot. Directed dock floor spot confirmation enables you to confirm only those
parcel/control numbers that you have picked.
At Starcom, the same operator who picks the product, applies the shipping
labels. Ken uses the following session to confirm that the items are in the
Scenario correct floor spot and print the shipping labels.
Session Procedure To perform directed RF dock floor spot confirmation:1. If the same operator
that performed picking is dropping the goods off at the dock floor spot the
following form appears:
2. Go to the label printing station and scan (or enter) the parcel number, control
number, and check digit number associated with your pick.
Note: Part of the parcel number is the parcel prefix from the AWM
parameters.
3. Go to the floor spot and scan (or enter) the floor spot check digits, the UCC-
128 parcel number, and the control number originally associated with the
pick. Select Continue to execute. This validates and confirms a
parcel/control number.
Note: It is best to use a scanner from the labeling station to request the
shipping label. This prevents you from requesting the label before arriving
at the label printer, and lessens the chances of picking up the wrong
shipping labels.
Maintaining RF Outbound Staging Areas
Maintaining RF Outbound Staging Areas

Use the RF Outbound Staging Area (tdawm6151m000) session to maintain RF
outbound staging areas. Display this form by selecting:
■ RF Main Menu
■ RF Outbound
■ Staging Area
Enter the parcel number and select Continue to execute. This validates and
confirms the staging area. MK performs the following activities:
■ Verifies that the check digit is correct for the staging area, and confirms the
parcel by placing the current system time and date, along with your user ID,
into its control files.
■ You do NOT need to indicate the floor area on the staging area number
where the parcel is placed. MK can identify the spots and areas based on the
check digit value alone.
■ If pick verification is required and the parcel contains items which have not
been pick confirmed, an error message appears notifying you of the
condition. Other validations are performed for things such as correct
warehouse, parcel number, and whether the parcel has been previously
confirmed.
■ Validates the check digit and if an error is found, issues an error message or
locks the RF terminal.
■ Verifies that the parcel shipping label has been printed. This is always true
for any parcel picked with non-directed RF (the label was printed during
pick planning). For parcels picked with directed RF, the label must have
been printed by the RF shipping function.
■ Verifies this is a parcel to be picked by directed RF. If yes, then it checks if it
has been released by the directed RF operator. If it has not been released, an
error message is displayed.

Picking RF Outbound Batches
Picking RF Outbound Batches

Use the RF Outbound Pick Batch (tdawm6141m000) session to pick RF outbound
batches.
Session Procedure To perform RF outbound batch picks:
1. Display the Pick Batch (tdawm6141m000) form by selecting:

■ RF Main Menu
■ RF Outbound
■ Pick to Cart
2. Enter the target warehouse code.
3. Enter the target batch ID code. If you do not know the target batch ID code,
zoom to the Display Batch/Cart (tdawm0539s000) menu to display a list of
batch ID codes.
4. Select Continue to display the tdawm6142s000 form, which displays the first
pick for the selected batch.
5. Select exit to skip this pick and display the next pick in the batch, or select
Continue to verify this pick.
6. When you have verified a pick, MK displays the Item Confirmation

(tdawm6175s000) form. Reverify the pick, and MK displays the Parcel
Verification (tdawm6143s000) session.
7. In the Parcel Verification form, enter the parcel number and position. When
the parcel number and position are correct, MK deletes the pick assignment,
and marks the associated pick assignment records as Pick Confirmed.
Once all the picks in a batch are confirmed, MK deletes the batch record.
Once all the batch picks associated with a cart are confirmed, MK deletes the
cart record.
RF Inventory Location Load
RF Inventory Location Load

Session Procedure To perform non-directed RF inventory location load:
1. Access Location Load (non-directed) (tdawm6160m000).
2. If you are processing by location, enter a starting location and an ending

location (vary by aisle, bay, and level information). Select Continue to
execute. The secondary inventory load processing form appears:
other important fields follow:
■ Ck—indicates the item check digit number.
■ Itm—indicates the 15-character item number.
■ Status—indicates the status of the item.
■ Qty—shows the pick quantity in the item’s default unit of measure.
■ Lot —displays the 15-character lot number if the item is lot controlled.
■ Stock Date—indicates the current date.
4. Press Ctrl+N to skip or N to execute.

Printing RF Outbound Shipping Labels
Printing RF Outbound Shipping Labels

The Print RF shipping label function is used to print shipping labels for
shipments picked by the directed RF functions. In this instance, the label must
be printed after picking and before dock spot confirmation.
Session Procedure To print shipping labels:

1. Access the RF Non-Directed Label (tdawm6180m000) session by choosing
the following:
■ RF Main Menu (AWM)
■ RF Outbound
■ Label
2. Enter data in all required fields. Explanations of the required and any
important text boxes follow.
■ Ctrl—indicates the control number associated with the picks. This is the
control number applied during the directed picking process.
■ Prtr—indicates the name of the printer where the label is to be printed.
The initial default is the default shipping label printer for the warehouse.
If you specify a different printer, the new printer is used as the default
for subsequent labels until you press A to exit or E to return.
■ #Cop—indicates the number of copies of the label you want printed. The
value you enter here is used as a default for subsequent labels until you
select A or E.
3. Select Continue to process the shipping labels.
Appendix
Packing Algorithms
A
Configuration Functions ...................................................................... A–2

Warehouse Definition Form ............................................................... A–2
Carrier Definition Form .................................................................. A–5
Picking Zone Definition Form ............................................................. A–5
Carton Type Definition Form.............................................................. A–5
Packing Category Definition Form ......................................................... A–6
Packing Cartons Definition Form .......................................................... A–7
Packing Logic Overview...................................................................... A–8
Packing Algorithm 1 – Virtual Dimensions ................................................ A–11
Packing Algorithm 2 – Total Packed Volume .............................................. A–15
Packing Algorithms A–i

Appendix
Packing Algorithms
A
Packing algorithms includes the program that is loosely referred to as “loose
pick,” “parceling,” or “packing,” and all the supporting configuration functions.
Presented in this document is a brief description of the significant configuration
functions and associated fields followed by an overview of the packing logic.
Packing Algorithms A–1

Configuration Functions
The Carrier Definition, Carton Type Definition, and Picking Zone Definition
form formats are included only to document the source of some of the
configuration data that affects the parcel packing programs. For all of the
configuration functions, only the fields pertinent to packing algorithms are being
described here.
Warehouse Definition Form
The significant fields in the Warehouse Definition form that support packing
algorithms are listed below, accompanied by a usage definition.
Field Content/Action
Ship Label Lines Specifies the maximum number of line items (picks) that can be printed on a
single label.
Create New Parcel Determines whether the packing program creates a new parcel when the
When Ship Label maximum ship label lines (see above) is exceeded. If yes, no parcel picked from
Lines Exceeded the warehouse ever contains more picks than the number of ship label lines
specified. If no, parcels can contain more picks than can be printed on a label,
and the label is printed in multiple pages.
Packing Sequence The order in which individual picks are processed by the packing algorithm can
affect carton selection and/or which picks are packaged together. This field
allows each picking warehouse to determine the order in which items picked in
the warehouse are processed. Option 1 processes picks in order by picking
location. Option 2 processes picks in descending order by item packing
dimensions (see next paragraph) with length being more significant than width,
and width more significant than height. Option 3 processes picks in descending
order by item volume (length times width times height). Option 1 can produce
the packing plan with the most efficient use of picking labor, while either option
2 or 3 can produce a packing plan with more efficient parceling (size and
number of physical cartons).
For option 2 only, the Rotate flag in the packing category record affects the order
in which items are processed. If items can be rotated, the packing length is the
largest of the three dimensions, width is the next largest, and height is the
smallest. If rotation is not allowed, the packing length is the larger of the item
length and width, the packing width is the smaller of length and width, and the
packing height is always the item’s height. Note that for packing method 1
(virtual dimensions), the item can again be re-oriented (rotated) during packing
to obtain the best use of space in the carton.
A–2 MK Advanced Warehouse Management, Volume 2, User Guide

Split Picks A Yes/No flag indicating whether a single pick can be split across multiple
parcels. If this value is yes, picking labor efficiency can be sacrificed (that is,
multiple picks is made from one location for one order) in order to pack cartons
more efficiently.
Note that any time a single pick cannot fit in a single carton, the pick is split
regardless of the value of this field. This assumes that a carton has been
associated with the item’s packing category that is large enough to hold at least
one piece of the item.
Maximum Splits This field has no impact if picks are not being split (Split Picks = No). However,
if picks are to be split, this field determines the maximum number of times a
particular pick can be split. A low value in this field, for example, one, allows a
particular pick to be split in order to finish off one parcel and start the next. A
higher value could be used to allow a proportionately small item (when
compared to other items in the order) to be used as filler for several parcels.
Downsize Parcels Downsizing is the process of selecting the smallest possible carton for a given
parcel. In general, MK selects a starting carton from a list when processing the
first pick for a packing category/order/pick zone combination. This carton
normally is larger than is necessary for that single item, and
MK attempts to pack other items for the order into it. After the order has been
packed, the downsizing process determines whether there are physically smaller
cartons that could contain the same items and, if so, selects the smaller carton.
This field contains a Yes/No flag that determines whether the packing programs
attempt to downsize parcels. If yes, after parcel consolidation is complete, the
packing program attempts to use the smallest possible cartons without
increasing the number of parcels being shipped. If no, items are packed in the
first carton selected, which can be larger than necessary.

Consolidate Parcels Consolidation takes place when picks from multiple pick zones are combined
into a single parcel. MK generates a “tote” label for the picks from each
component pick zone. The totes are then forwarded to a consolidation area,
where they are packed into the shipping carton.
This field determines how the packing programs treat picks for a single order
from multiple pick zones. Possible options for this field are:
Option 1 – Separate parcels are created for each pick zone. That is, parcels do not
cross pick zone boundaries.
Option 2 – The programs first pack working parcels by pick zone, and then
attempt to consolidate these parcels across the pick zones that are associated
with a common consolidation area. When parcels are consolidated, tote labels
are generated for each consolidated working parcel, along with a consolidation
label for the finished parcel.
Option 3 – The packing programs ignore pick zones. In other words, MK acts as
if Option 1 had been chosen and all picks are from a single picking zone. Tote
labels are not generated.
Option 4 – MK creates separate parcels for each consolidation area, but does not
create tote labels when a parcel spans pick zones within the consolidation area.
This option is similar to option 2, but does not generate tote labels.

Carrier Definition Form
Field Content/Area
Use Parcel If this field is set to Y (Yes), the packing programs ensure that parcels packed for
Maximums the carrier do not exceed these limits. Items that exceed the carrier’s limits, or
that cannot be packed in a carton that does not exceed the limits, are packed in
the Error carton.
Picking Zone Definition Form
Consolidation Area This field is used to tie the picking zone to a consolidation area. If the warehouse
uses parcel consolidation option 2 or 4, picks from the picking zone can be
included in parcels with picks from other picking zones that are associated with
the same consolidation.
Carton Type Definition Form
Note that in the Carton Type Definition form, the carton dimensions are INSIDE
dimensions, not the external dimensions of the carton. The dimensions are use
by the packing programs to determine available space inside the carton.
The carton weight is added to the weight of the items packed in the carton to
arrive at a total parcel weight.
Downsize This field (heading DN Sz), determines whether or not the carton is available for
downsizing. That is, if N (No) is entered in the field, the downsizing routines
bypasses the carton.
Status This field (S T) indicates whether the carton is available for packing. This allows
the AWM customer to disable an out-of-stock carton temporarily without having
to re-work other configuration data (packing category cartons).

Packing Category Definition Form
The packing method fields allow a choice of packing algorithms by packing

category.
Rotate Yes/No flag indicating whether items in this category can be turned on end (yes)
for more efficient packing. A No value means that items in this category must
remain upright. Value has no impact if method 2 is selected.
Packing Method Specifies the packing algorithm to be used for items in the packing category.
Option 1 is the existing virtual dimensions method, and option 2 is the new total
packed volume method. The descriptions, VIRT DIMS or TOTAL VOL are
displayed upon entry.
Using the virtual dimensions method, all items packed in a parcel have the same
logical dimensions. These dimensions are the largest length, width, and height
of all items packed in the carton. This ensures that all items packed in the parcel
physically fit in the parcel, but can waste an excessive amount of space in the
carton if the items packed in the carton do not have similar dimensions.
The total packed volume method ensures that each item packed in the container
fit in the container if packed individually. The program s adding items to the
carton until the total volume of the packed items reaches the threshold set for the
carton by the Maximum Fill Pct field on the Packing Cartons Definition form.
This method does not guarantee that all items packed in the carton can
physically fit in the carton, but can provide better space utilization when items of
different sizes and shapes must be packaged together.
Optimize For packing method 2 only, this field determines whether the program attempts
to optimize packing when all items in the container have the same dimensions.
In this case, space is not wasted due to packing different sized items, and packing
method 1 can be used to determine the exact capacity of the carton. If the packing
method is 2, this field can be Y or N. This field has no impact on packing method
1, however, the field must be set to N.

Packing Cartons Definition Form
Seq A five-digit field that determines the sequence in which the carton selection and
downsizing logic processes the cartons for this packing category. This field
allows AWM users to place odd-size cartons at the end of the list rather than
selecting cartons strictly by descending volume. For example, if the packing
category consisted primarily of video cassettes, but also included baseball bats
that are being shipped as part of a special promotion, a carton large enough to
hold the bat plus some number of cassettes could be placed at the end of the list.
In this case, the large carton would be selected only for orders that contained the
bat.
Consolidate This field establishes a threshold that determines whether the parceling program
Percentage attempts to consolidate the parcel with parcels from another pick zone. This field
requires an entry of 0 or greater. This field has no impact in warehouses that do
not use parcel consolidation option 2, or in pick zones that are not associated with
a consolidation area.
Maximum Fill Pct For packing method 2 (total packed volume) only, this field establishes a “fudge
factor” to account for unusable space in the carton. An item is not included in the
carton if the item would cause the total volume of the items in the carton to
exceed this percentage of the carton’s total available volume.
There is one exception to this rule. If the optimize option is selected, and all
items in the carton are known to be the same size, the exact capacity of the carton
can be determined. Note that a value greater than zero and less than or equal to
one-hundred is required in this field. Also, for packing method 1, the percentage
is set to zero and protected from operator entry.

Packing Logic Overview

This outline is not intended to represent finished program logic; it conveys only
the basic steps involved in packing an order.
All picks (shipment assignment records) for piece quantities are read sorted by:
■ Packing category
■ Picking warehouse
■ Carrier
■ Order ID (order type, order number, shipping warehouse)
■ Consolidation area
■ Pick zone
The sort sequence of picks within this grouping depends on the packing
sequence option selected when the picking warehouse was defined. Alternatives
for the low order portion of the sort key are:
■ Option 1: Picking location address (aisle, bay, level)
■ Option 2: Packing dimensions (length, width, height)
Picking location address (aisle, bay, level)
■ Option 3: Item volume (length times width time height)
Picking location address (aisle, bay, level)
Each time the picking warehouse changes, the warehouse level packing options
(ship label lines, label lines exceeded flag, packing sequence, etc.) are retrieved
from the associated warehouse record.
For each packing category, the packing category record is read and a valid carton
list is built from the records entered with the Packing Cartons Definition
function.
The carrier record is read each time the carrier changes to retrieve any weight or
size limitations that can apply to the carrier.

A To Be Packed list is created for each set of picks that can be packed together
into a single parcel. Picks that can be packed together fall into two categories,
depending on which parcel consolidation option was specified for the picking
warehouse.
■ If parcel consolidation option 1 was selected, or if option 2 or 4 was selected
and the pick zone is not associated with a consolidation area, all sort fields
from the picking warehouse through area must have the same values.
■ If consolidation option 2 or 4 was selected and the pick zones are associated
with a consolidation area, the picks (ship assignments) must have the same
values in the sort fields listed above, from picking warehouse through
consolidation area.
■ For consolidation option 3, the picks (ship assignments) must have the same
values in the sort fields from picking warehouse through order ID.
For each To Be Packed list, the packing algorithm identified by the packing
category record is executed. The basic logic flow within each packing algorithm
is the same. This flow is summarized below.
■ A starting carton (working parcel) is selected for the first item on the To Be
Packed list. The starting carton is the first carton in the valid cartons list that
is large enough (both volume and maximum weight capacity) to contain the
entire pick. Exceptions:
– If there is no carton large enough to contain the entire pick, the program
selects the first carton in the valid cartons list having sufficient capacity
to hold at least one piece of the item.
– If there is no carton large enough to contain a single piece of the item,
the entire pick is packaged in a separate parcel with the Error carton
type (blank).
■ The program attempts to add each subsequent pick on the To Be Packed list
into the working parcel. If only part of a pick fits in the carton, and if the
pick can be split, the program packs as much as possible into the carton.
Any pick or part of a pick that does not fit in the carton remains on the To Be
Packed list, and the packed items are moved to a Packed Items list.
Exceptions:
– If the picking warehouse uses parcel consolidation option 1 or 2, items
from different pick zones are not packed in the same working parcels.
■ This process repeats, starting at the top of the To Be Packed list, until the To
Be Packed list is empty.

■ Next, the program attempts to combine working parcels. Depending on the

sequence of carton types in the valid cartons list, it is possible to select a
larger starting carton on the second (or subsequent) pass through the To Be
Packed list than on the first pass. In this case, the parcel created on the first
pass can be small enough to combine into the larger carton selected on the
later pass. Exceptions:
– If parcel consolidation option 1 or 2 is used, only working parcels picked
from the same pick zone are combined. If consolidation option 3 is used,
the program attempts to combine working parcels without regard to
pick zone. If option 4 is selected, working parcels are combined within
the same consolidation area.
■ If the picking warehouse uses parcel consolidation option 2, the program
attempts to consolidate parcels from different pick zones.
■ Lastly, the downsizing routines are executed if downsizing has been selected
for the picking warehouse. For each working parcel, the program identifies
the smallest (by volume) carton in the valid cartons list capable (both volume
and physical dimensions) for holding all of the items packed in the working
parcel. The method of determining whether the items fit in the smaller
carton depends on the packing algorithm selected for the packing category.
The packing module returns a Packed Parcels list. The primary packing
program uses this list to assign parcel numbers and update the appropriate files.

Packing Algorithm 1 – Virtual Dimensions
Packing algorithm 1, the Virtual Dimensions method, attempts to pack items in

the container as efficiently as possible and, at the same time, guarantee that all
items physically fit in the carton. To accomplish this, the program treats
multiple items of different sizes as if they all have the same length, width, and
height dimensions.
This section describes the program logic behind this packing method. As with
the packing logic overview, be aware that this description does not represent
finished program logic. A number of exception conditions that are handled by
the program are not mentioned here, and the program does not necessarily
perform its decision and calculations in the same order as they are described
here.
As each item is added to the parcel, the program determines whether the item’s
length is larger than the length of any item already packed in the container. If
so, the new item’s length becomes the new virtual length of all items in the
parcel that is, everything already in the container logically grows to match the
length of the new item. At the same time, the virtual width becomes the width of
the widest item in the container, and the virtual height is the height of the tallest
item packed in the carton.
Note: The dimensions used in this description are packing dimensions, which
are not necessarily the same as the dimensions defined in the item master record.
If the item’s packing category allows the item to be rotated, the packing length is
the largest of the item’s length, width and height dimensions, packing width is
the second largest, and packing height is the smallest of the three. If the packing
category does not allow rotation, the packing height is the item height, packing
length is the larger of the item length and width, and packing width is the
smaller of length and width.
The program determines how many items with the new virtual dimensions can
be fit in the best basic cube in the container. The basic cube is the space
consumed when the items are all packed with the same orientation, that is, all
length, width, and height dimensions are the same direction. The program
calculates the capacity of the basic cube with the virtual items in all possible
orientations (length and width are interchanged, length and height are
interchanged, etc.). The best basic cube uses the orientation that provides the
largest capacity. A basic cube of 12 virtual items is illustrated in Exhibit C1, and
is shown inside the container in Exhibit C2.
Note: The height dimension is not interchanged with length and width unless
the item’s packing category allows the item to be rotated.

Exhibit C1: Basic Cube of 12 Virtual Items
Exhibit C2: Basic Cube of 12 Virtual Items in Container
Items are added to the parcel until the capacity of the basic cube is reached. At
that time, the program begins attempting to pack items in real space—the extra
space surrounding the basic cube in the carton. Real space can be logically
divided into three segments (A, B, and C) as illustrated in Exhibits C3, C4, and
C5.
Exhibit C3: Dividing Real Space

The program keeps a separate set of virtual dimensions for the items packed in
real space, that is, the previous largest dimensions are reset to zero when the
program begins using real space. As each item is added to the container, these
dimensions are adjusted, the capacity of each real space segment is calculated,
and a total real space capacity is accumulated.
Notice in Exhibit C3 that real space segment A overlaps both segments B and C,
segment B overlaps segment C but not A, and segment C does not overlap either
A or B. Including the layout in Exhibit C3, there are six possible combinations
for arranging the segment overlaps. Exhibit C5 illustrates an arrangement that
allows both segments B and C to grow taller than in Exhibit C3, while segment A
shrinks inward at the sides. When real space capacity is calculated, all six
combinations are tested. The one that offers the largest total capacity with the
current virtual item dimensions is chosen.

To summarize, the primary advantage of this algorithm is that it guarantees that

all items packed in a parcel can physically fit in the parcel. In addition, when all
items being packed have the same or nearly the same dimensions, this method
can make extremely efficient use of space in the carton. However, space
utilization becomes much less efficient when the product line contains items
with dissimilar dimensions.
Note: The impact of dissimilar dimensions on space utilization can be

minimized by selecting packing sequence option 2 or 3 when the picking
warehouse record is defined. This forces the large items to be packed first, and
allows the program to pack smaller items in real space around the large items.

Packing Algorithm 2 – Total Packed Volume
The Total Packed Volume packing method is intended for situations where the
difference in dimensions of the items packed prevents the virtual dimensions
algorithm from making efficient use of space in the cartons. Also, in an
environment where all items have exactly the same dimensions and the available
cartons have been chosen to match those dimensions, packing algorithm 2 can
produce the same results as algorithm 1 and use less of the CPU resource.
Note: To accomplish this, define the packing category to use packing method 2
without optimization. Then, define the packing cartons with maximum fill
percentage of 100.
In general, for each item to be packed, the program verifies that the physical
dimensions of the item (length, width, and height) are less than or equal to the
container’s dimensions – that is, the program makes sure that one piece of the
item can fit inside the container. If the item fits, it is added to the parcel. As
items are added to the parcel, the program keeps a running total of the physical
volume of the items in the parcel. Pieces are not added if the total volume would
exceed the maximum fill percentage entered on the Packing Cartons Definition
form.
This packing algorithm also offers an optimization option. When optimization is

selected, the program uses packing algorithm 1 as long as the items being packed
in the container have exactly the same dimensions. For example, without
optimization, a 10 by 10 by 10 container defined with a 50 percent maximum fill
percentage can hold only 4 pieces of a 5 by 5 by 5 item, although 8 pieces
physically fit in the container. In this case, an order for 5 pieces of the item
would be split into two containers or would be packed in a larger container.
Using the optimize option allows all 5 pieces to be packed in one parcel.
The disadvantage to this packing algorithm is its inability to guarantee that all
items assigned to a parcel can actually be packed in the parcel. Assume an order
is placed for one piece each of two items, where one item’s dimensions are 6 by 6
by 6, and the other’s are 5 by 5 by 5. Using the same 10 by 10 by 10 container
and 50 percent maximum fill percentage as in the above example, the program
assigns both items to the same container. However, it is physically impossible to
fit both items in the container. Separately, either item fits in the container (this
satisfies the first criterion), and together they consume only 34.1 percent of the
container’s total volume, substantially less than the 50 percent threshold.

Appendix
Pick Resource Detail Components

B
Pick Resource Detail Components .............................................................. B–1

Pallet Pick Type ........................................................................... B–1
Case Pick Type ........................................................................... B–2
Piece Pick Type ........................................................................... B–3
Other Labor Components ...................................................................... B–4
Labeling Batch Pallets ..................................................................... B–4
Replenishment Labor ...................................................................... B–4
Consolidation Labor....................................................................... B–5
Pick Resource Detail Components B–i

Appendix

B
Pallet Pick Type
To determine the time required to pick a pallet or batch pallet of product, MK

performs the following calculation for each pick assignment. The same
computation is used for picking a batch pallet.
Pallet Pick Time = (1/(Locs/Hour) + 1/(Picks/Hour) ) X # of Workers
The definitions for the terms in this equation are:
Term Definition
# of Workers Number of workers required for a pallet pick defined in the
Pick Zone Definition form.
Locs/Hour Locations per hour term. It is the rate for estimated travel
time between locations. The rate for the specific storage
type is typed on the Storage Type Handling Standards
form.
Picks/Hour Rate for estimated pick time at a given location. The rate
for specific storage type is typed on the Storage Type
Handling Standards form.
Pick Resource Detail Components 2–1

Case Pick Type
To determine the time required to pick cases of a product, AWM performs the
following calculation for each case pick sheet header.
Case Pick Time = ( (# of Locations X 1/(Locs/Hour)) + (# of Cases X 1/(Picks/Hour) )

X # of Workers
The definitions for the terms in the equation are:
Term Definition
# of Workers The number of workers required for a case pick defined in
the Pick Zone Definition form.
type is typed in the Storage Type Handling Standards
form.
Picks/Hour The rate for estimated case pick time at a given location.
The rate for specific storage type is typed on the Storage
Type Handling Standards form.

Piece Pick Type
To determine the time required to complete a piece pick sheet (this time appears
on the bottom of the pick sheets) AWM performs the following computations for
each shipping carton (container) of each pick:
Site Cartoning Time + (# Workers X 1/(Locs/Hour) X # of Locs) + (# Workers X

1/(Picks/Hour) X # of Picks)
The definitions for the terms in the equation are:
Term Definition
Site Cartoning The fixed time associated with a piece parcel expressed in
Time parcels per hour. This can include carton erection, ship
label application, travel to the first pick location, and travel
from the last pick location. This information is typed on the
Site Definition form in the Piece Parcel/Hour field.
# of Workers The number of workers required for a piece pick defined in
the Pick Zone Definition Form.
type is typed in the Storage Type Handling Standards form.
Picks/Hour The rate for estimated case pick time at a given location.
The rate for specific storage type is typed on the Storage
Type Handling Standards form.

Other Labor Components
Labeling Batch Pallets
The time value for batch pallet labeling is allocated to the team assigned this
activity in the Assignment portion of the Pick Team Definition form. The
labeling labor is calculated as follows:
Total # of Cases X (1/Pallet Case Rate)
Term Definition
Total # of Cases The number of cases assigned on batch pallet picks.
Pallet Case Rate The rate for separating and labeling batch pallets
expressed in cases per hour. This value is typed on the
Handling Standards Definitions form for the handling
category associated with the product being picked.
Replenishment Labor
The picking activities of replenishment are computed as described above for

pallet, case, or each picking in the pick zone and storage type is allocated. This
picking labor is related to wave 000, which is the replenishment wave. The
putaway portion of the replenishment is allotted to the team assigned to the pick
zone where the product is put away. For example, a team assigned to picking in
a carton flow rack will show labor related to the required replenishment of the
racking in wave 000. This labor is computed as follows:
Quantity Replenished X (1/Replenishment Rate)
Term Definition
Quantity Replenished The quantity calculated for putaway on wave 0. The
quantity can be in pallets, cases, or eaches, if these are
possible replenishment increments.
Replenishment Rate The rate typed in the Replenishment/Hour field on the
Storage Type Handling Standard form for the storage
type being replenished.

Consolidation Labor
Consolidation labor is associated with the pick team assigned to a consolidation

area. The computation is as follows:
# of Totes X (1/Consolidation Rate)
Term Definition
# of Totes The number of totes assigned to the consolidation of picks
from the related pick zones.
Consolidation Rate The totes per hour as defined on the Consolidation Station
form.

AWM Rejected Order Messages
Appendix
C from Generate Outbound Advice
Overview .................................................................................... C–1
AWM Rejected Order Messages from Generate Outbound Advice C–i

AWM Rejected Order Messages
Appendix
C from Generate Outbound Advice
Overview
The following table contains AWM Generate Outbound Advice Rejected Order
Messages.
Code Message
14 Hard Allocation - Insufficient inventory
17 Order line item rejected - non-split order
18 Order line item rejected - non-split order line
19 Order rejected - cannot split order
22 Item canceled by operator during shipping activities
23 Item adjusted during shipping activities
24 Soft allocation - insufficient labor
25 Shipping - Order cancelled by operator
26 Directed RF, picked less, remaining quantity unavailable and rejected
27 Directed RF, pick confirm operator could not pick from location
28 Directed RF, operator could not pick from location, all items for header rejected
45 Invalid packing category
46 All items failed hard allocation for header
50 Must enter an order type
51 Must enter a production wave
999 Pick Plan was backed out
AWM Rejected Order Messages from Generate Outbound Advice C–1

Index
A E
AWM rejected order messages from generate Error labels, 4-30

outbound advice, C-1
F
B
Features
Benefits of AWM, 2-3 ABC analysis, 3-3
Advanced pick and putaway rules, 3-2
Alternative locations, 3-11
Associate carrier to dock floor/area, 3-18
C Block items and lots, 3-7
Carrier guidelines, 3-15
Carrier manifest, 5-25 Carton definitions, 3-3
Carton packing list, 3-15
Chapter descriptions, 1-2 Carton selection, 3-15
Cycle counting, 8-26 Change carrier, 3-17
Change order, 3-17
Control over and under receipts, 3-9
Cross docking, 3-9
D Cycle counting, 3-7
Directed fadio frequency, 3-4
Display unconfirmed picks, 3-17
Deleting an AWM pick plan, 5-18 Dynamic parceling, 3-15
Directed RF EDI support, 3-18
Dock floor spot confirmation, 8-37 Emergency picks, 3-18
General forms, 8-6 Fixed locations, 3-16
Maintaining assignments, 7-9 Flexible picking rules, 3-14
Pick confirmation, 8-33 Group orders for picking, 3-12
Printing shipping labels, 8-41 Inventory adjustments, 3-6
Putaway confirmation, 8-18 Item characteristics, 3-2
Receipt confirm, 8-14 Key features, 2-2
Vs non-directed RF, 8-2 Labor reporting, 3-3
Labor standards, 3-3
Dock floor confirmation, 5-27 Locating logic, 3-10
Directed RF, 8-37 Location capacity, 3-10
Non-directed RF, 8-35 Location control of shipping dock/area, 3-18
Location fill, 3-16
Index–1
Lot history query and reporting, 3-7 Inbound data
Lot query and maintenance, 3-6 Displaying, 4-14
Material disposition and locating, 3-8 Maintaining, 4-11
Optional confirmation, 3-11 printing, 4-16
Packing requirements, 3-15
Independent replenishments, 5-33, 5-35, 5-36
Paper confirmation, 3-10
Paperless picking, 3-14 Inventory location load, RF, 8-39, 8-40
Pick by travel zone, 3-13
Pick confirmation, 3-13
Pick planning optimizer, 3-12
Pre-receiving documents, 3-9
L
Product kitting, 3-5
Query inventory and locations, 3-6 Locating rule sets, 4-20
Query outstanding radio frequency tasks, 3-7 Displaying, 4-23
Radio frequency definitions, 3-4 Problem checklist, 4-25
Radio frequency putaway, 3-11
Radio frequency receiving, 3-9 Locating Rule Sets
Radio frequency task management, 3-4 In receipt processing, 4-23
Receipt status inquiry, 3-8
Lot control, 6-1
Replenish based on demand, 3-16
Blocking lots, 6-6
Replenishment calculations, 3-16
Converting items, 6-12
Replenishment optimizer, 3-16
Maintaining lots, 6-2
Resource allocation reports, 3-12
Releasing lots, 6-10
Reverse stop sequence for routes, 3-18
Serial number tracking, 3-5 Lot information
Shipment confirmation, 3-18 Displaying of, 6-12
Shipping documentation, 3-17
Split picks by zone, 3-13
Storage locations, 3-2
M
Track bulk vs pick stock, 3-16
Transaction log, 3-6
Unexpected receipt capability, 3-8 Material requisition stock transfer, 7-5, 7-14, 7-15
User-defined fields, 3-9
Warehouse zoning, 3-2
Wave pick management, 3-12
N
G Non-directed RF
Cycle counting, 8-26
Dock floor spot confirmation, 8-35
Generate outbound advice AWM rejected order Inventory location load, 8-39, 8-40
messages, C-1 Putaway confirmation, 8-17
Generating inbound advice, 4-6 Receipt confirm for non-directed putaway, 8-12
Generating outbound advice, 5-3
O
I
Outbound advice
Generation of, 5-3
Inbound advice Simulation of, 5-12
Generation of, 4-6
Outbound data
Index–2 MK Advanced Warehouse Management, Volume 2, User Guide

Deleting, 5-14 Simulating outbound advice, 5-12
Displaying, 5-14
Stock information
Maintaining, 5-13
Displaying of, 7-16
Printing, 5-15
Printing of, 7-23
Releasing, 5-13
Stock to stock transfers, 7-3
Stock transactions, 7-2
P
Packing algorithms, A-1 U

Parcels
Displaying/Maintaining, 5-29 Unconfirmed parcels, 7-18
Unconfirmed, 7-18
Unconfirmed picks, 7-14, 7-15, 7-16
Pick confirmation
Directed RF, 8-30 Unconfirmed putaway, 7-19
Non-directed RF, 8-30 User authorizations for stock transactions, 7-7
Paper -driven, 5-19
Pick planning, 5-3
Pick resource detail components, B-1
V
Pick rule set problem checklist, 5-22
Variable pallets, 4-35
Putaway confirmation
Directed RF, 8-18
Non-directed RF, 8-17
Paper-driven, 4-32
Putaway control sheets, 4-31
Putaway labels, 4-27
RF queue management, 7-11
Setting up MANMAN/X Advanced Warehouse

Management, 3-19
Item setup procedures, 3-19
Receiving setup procedures, 3-21
Warehouse setup procedures, 3-19
Setting up MK Advanced Warehouse Management
Shipping setup procedures, 3-21
Shipment confirmation, 5-31
Shipping, 5-24
Index–3

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MK

Advanced Warehouse Management Volume 2

Chapter 1: Welcome to MK Advanced Warehouse

Chapter 2: About AWM

Chapter 3: Getting Started

Chapter 4: Inbound Processing

Chapter 6: Lot Control

Chapter 7: Warehouse Administration

iv MK Advanced Warehouse Management, Volume 2, User Guide

Appendix B: Pick Resource Detail Components

Appendix C: AWM Rejected Order Messages from Generate

For a general description of the MK business management system, refer to MK

Welcome to MK Advanced Warehouse Management 1–1

Chapter 2, About AWM, describes Advanced Warehouse Management functions

Chapter 4, Inbound Processing, explains how to maintain receipts, generate and

Chapter 5, Outbound Processing, describes how to perform pick planning

Chapter 7, Warehouse Administration, explains how to perform most

Chapter 8, RF Processing, explains how to perform directed and non-directed RF

Appendix A, Packing Algorithms, describes the significant configuration functions

Appendix B, Pick Resource Detail Components, describes the various pick

Appendix C, AWM Rejected Order Messages from Generate Outbound Advice,

1–2 MK Advanced Warehouse Management, Volume 2, User Guide

For a description of the contents of each guide, refer to Getting Started.

Welcome to MK Advanced Warehouse Management 1–3

What You Need To Know

1–4 MK Advanced Warehouse Management, Volume 2, User Guide

Using MK to Manage Your Warehouse Needs ................................................... 2–1

About AWM 2–i

Using MK to Manage Your Warehouse Needs

AWM automates seven major operations:

About AWM 2–1

2–2 MK Advanced Warehouse Management, Volume 2, User Guide

Additional functional enhancements include cross-docking, the ability to direct

The key benefits of using MK AWM are as follows:

About AWM 2–3

Introduction .................................................................................. 3–1

Getting Started 3–i

AWM offers complete flexibility, which allows customers to tailor MK to meet

AWM supports multiple levels of warehousing, including multiple zones within

The new Advanced Warehouse Management module contains several additional

Getting Started 3–1

Advanced Pick and Putaway Rules

Warehouse zone definitions, used for picking, putaway, and allocation

In addition, dimension and weight determine maximum capacity. Location

Locating, picking, replenishment, handling, and packing categories have been

3–2 MK Advanced Warehouse Management, Volume 2, User Guide

In outbound processing, resource requirement reports can be generated during

Items are assigned an ABC movement class. System parameters specify

Getting Started 3–3

Directed Radio Frequency (RF)

Radio frequency terminal and bar coding equipment directs warehouse

Radio Frequency Definitions

Radio Frequency Task Management

Each RF task to be performed is placed in a queue. Tasks are displayed in

3–4 MK Advanced Warehouse Management, Volume 2, User Guide

Product kitting is supported in two ways. The first is termed “issue

Serial Number Tracking

Getting Started 3–5

Query Inventory and Locations

Inventory and locations can be queried in a variety of ways. Several different

Lot Query and Maintenance

3–6 MK Advanced Warehouse Management, Volume 2, User Guide

Lot History Query and Reporting