GELIDA WAREHOUSE

PROCESS DOCUMENT

Arjowiggins - Wipro

Sensitivity: Internal & Restricted

Contents
Introduction: 1

Order process Flow Summary: 1

Vehicle Plan Creation: 3

Load Creation: 4

Shipment selection: 5

Vehicle plan approval. 6

Pick requests generation 6

Process Pick Requests 7

Pallet Planning Generation 7

Pallet Planning for Normal stock lines. 9

Pallet planning for Hot Pick lines 10
Pick Confirmation 11

Pack Confirmation 12

Vehicle plan confirmation: 14

Knowledge Base of Common issues: 15

Introduction:
The Process document is to understand the step by step process of order progression
on Gelida warehousing. The warehousing process involves advanced warehousing
concepts.

Order process Flow Summary:

The Order progression with status and the process name is summarized below:

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Process Status Application Menu/ Scheduler
Order creation Order Status P4210
500 - 515
Order acknowledgement Order status R5542565 Scheduled batch
515 - 527
Creation of Vehicle Plan VP status 20 P55T0010 G55HGWDCL
 Creation of Load. Load status 20 Add button
 Select Shipments Shipment Status 10

Vehicle plan Approval VP status 30 P55T0010 G55HGWDCL

Load status 30 Row exit
Shipment status 25
Order status
527 - 535
Pick requests Generation PR status 200 --Automatic---
Process Pick requests PR status 220 P55T0010 G55HGWDCL
VP status 35 Row exit
Suggestion status 340
Pallet planning Generation and P55T0060 G55HGWDCL
processing From Load revisions
 Stock lines
 Hot Pick lines

Pick Confirmation Suggestion status 399 P4617 | H55WE241 G55HGWDCL

PR status 299
Sales order status
535 - 540
Pack Confirmation Sales order status P55T0060 G55HGWDCL
Pallet height update and Label 540 – 560 Row exit – Load
generation

Vehicle plan confirmation VP status 50 P55T0010 G55HGWDCL

Shipment status 30 Row exit
Load status 50
Sales order status
560 - 575
Ship Confirmation Sales order status R42500 Scheduled batch
575 - 579
Whole order check Sales order status R55F0260 Scheduled batch
579 – 580
Invoicing Sales order status R5542565 Scheduled batch

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Process Status Application Menu/ Scheduler
580 - 620
Sales update Sales order status R42800 Scheduled batch
620 - 999

Vehicle Plan Creation:

The key elements for a vehicle plan creation are below:

 Vehicle type
 Plan description
 Loading location and
 Carrier number.

Loading Location:
For Gelida warehouse, the loading location defined is ‘EX-99-’

Carrier Number:
The Carrier number is also a common one – ‘2636109’

Once VP creation is completed the next step is to create the Load number for the VP.
*Container number and seal ref*

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Load Creation:
The key thing we need to be aware of before creating a load is if the order which we are
going to load comes under Overseas or European.
If the Load is for an overseas order ‘FO’ type. The Zone number needs to be specified as
‘FXX’

Apart from Overseas other orders can have a blank Zone number.

There is no other key field to be added during load creation as all the information’s are
captured from the VP.

Once the load is created the next process is to add the sales order shipments to the Load.

After the shipments are selected for a load, Load sequence needs to be defined
mandatorily on the below screen.

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Shipment selection:
Shipments can be selected on any basis, such as
origin, destination / dates / etc.

Shipments can only be selected to a load if the

shipment status is ‘10’ incase if the shipment is not
selectable, this infers the shipment has already been
in another load.

 Form -> Select Shipment.

After identifying the shipments through the

selection criteria,

 Check the shipments which needs to be loaded

 Row -> Select shipment.

*Addon shipment 2nd time *

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Once the shipment is selected, we will see a Green tick near the selected
shipments.

Vehicle plan approval.

After the Loading process is complete, the next step is to approve the Vehicle.

Vehicle approval is a key step on the warehousing process, below are the main validations
which needs to be done before a vehicle should be approved.

 Item availability needs to be validated before the VP

approval process.

 A valid carrier needs to be on the VP.

This means, the Carrier / Zone / Country combination
should be setup.

Pick requests generation

After the approval of Vehicle Plan, the VP status moves to 30, the load status moves to 30
and the sales orders associated to the VP will be progressed to 535/527 status.

During this process a Pick request will also be generated automatically. This can be
validated on the table F4600. Pick requests generated will be at the status 200.

Process Pick Requests

After the Pick requests & pallet planning are

generated, they need to be processed.

This pick request process validates the order

commitments and checks whether the committed
location is a fixed pick location.

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Incase not a fixed pick replenishment will be generated, and the stock will be moved to the
Fixed pick location of the item.

After the Pick suggestion is create the status of the pick requests will be moved to 220.

The VP status will be progressed to 35.

During this process the below batches will be triggered.

Process Pick Request Guarro Fines R46171_H55WA242

Task and Trip Creation R46471_H55WA201
Move Slips R46472_H55WA200
Move Tags (Automatic replenishment) R46473_H55WA300

This process creates the pick suggestion on the table F4611. Pick suggestion status will be
340.

After the Process pick requests is completed the next step on the process is ‘Pick
confirmation’.

Pallet Planning Generation

Once the VP & Pick requests are created pallet planning needs to be generated.
This can be done from the same VP application. Browse to load screen.

Row exit -> Pallet planning.

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This will move to the pallet planning screen with VP and load details. To generate the
pallet planning, Select Form Exit -> Generate pallet planning.

Once the pallet planning is generated the table F55T0060 will be populated.

Pallet planning for Stock order lines and Hot pick lines have 2 different processes.

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 Pallet Planning for Normal stock lines.

The Generated pallet planning needs to be processed now; this can be processed based on
the need.

The lines on the pallet summary can be planned to a single pallet or multiple pallets based
on the need.

Browse to Pallet planning details screen from VP application.

To Split the pallet quantities

Row exit -> Split pallet

This will take us to the planning details screen where we can provide the number of pallets
through which we split the order. In below example the whole order quantity 12000 SH is
split across 2 pallets as P1 6000 and P1 6000.

After the split pallet is completed the table F55T0061 will be recorded with the details.

The Split pallet screen looks as below:

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Once the split pallet details are entered and OK is pressed.

This will bring us to the previous screen where the planning details will now be refreshed
with 2 lines.

This process would generate 2 Unique pallets to hold the stock. Such as

Pallet planning for Hot Pick lines

This is the only process where the stock and the hot pick line processing differs.
The difference is only the lines which needs to have same Pallet needs to be consolidated
and planned.

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Consolidate pallet screen.

Pick Confirmation

Before we start the pick confirmation process, there needs to be a validation done on Pick
suggestion and sales order lines.

All the sales order lines which needs to go through this VP needs to be at 535 status.

This process is triggered from the menu – G55HGWDCL.

The Pick suggestion entry on the table F4611 has the details of location and lot details
from where the item will be transferred to the loading location. This is pick needs to be
now confirmed from the application.

Select the Pick from the order. Row exit -> Confirm.

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Once the Pick is confirmed we will see a Green tick near the Pick task number as
below.
Once the confirmation is done.
Select Process button from Exit bar to complete the process. This will progress the sales
order to the status 540/535.
In addition, the loading location and lot will be updated to the sales order line.

Pack Confirmation

Pallet height update and Label generation

Once the pick is confirmed we need to next update the pallet height of the generated
pallets.

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Browse to pallet planning details screen and select Row exit -> update pallet height.

Once the pallet height is updated and ok button is pressed.

We can generate labels for pallets by selecting Row exit -> Labels. This is generated
through the batch mentioned below:

Execute Export Packing Func R55T0062_AW55FF001

This process will also update the related sales order.

The sales order status will be moved to 560/540. Pallet details will be updated on the sales
order detail line as below:

This will also update the pallet planning detail table F55T0061 with packed quantity.

Once this is completed before next step of VP confirmation few validations need to be
done.

 Validate load charges

 Validate sales order lines

Load charges should be validated on the below screen. Row exit from VP application.

Order lines should be validated if they all are at status 560 before the VP confirmation.
Incase if any order lines are not at status 560 we need to process them if not, VP
confirmation will be failed, and VP status will be stuck at status 47.

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Vehicle plan confirmation:

This will be final step of the warehousing process. Once all the other processes are
completed the VP needs to be confirmed.

This can be done from the VP application Row exit -> Confirm Vehicle.

This will move the VP to the status 50 and sales order line status to 575/560.

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Knowledge Base of Common issues:
1. Item availability error in VP process:

Process - After an order is added to a VP and approved if a change is made to the order
or if it is cancelled.

The related shipment will be removed from the VP. But the Pick requests need to be
cancelled manually.

This Pick requests being open has commitments to the stock hence shows item
availability errors.

Point to be noted – When item availability errors occur, for a VP, and if the order in
VP are amended, the related Pick requests need to be validated and cancelled.

2. Pallet planning doesn’t process all lines of a sales order

Process – After VP creation process is completed, when order hot pick location is
committed, there is a chance of split line creation.

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 Assuming Line 1.000 of an order has quantity 1000 SH, when Hot pick location is
committed to order, this might split the order to 2 lines 1.000 – 500 SH and 1.001 –
500 SH.

In this case the split line 1.001 will have a different shipment number from parent line
1.000.

During pallet planning, not all order lines are at status 535, it is observed by users the
split line is missing from the planning process.

Point to be noted – It is to be validated after hot pick location commitment, all split
lines with different shipment numbers are allocated to the pallet planning.

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