Zone Picking

Zone picking divides the warehouse into distinct picking zones and assigns specific employees to pick product from each zone.

  • Zones can be sequenced to create a logical flow through the warehouse and ensure product is stacked on the pallet in a stable and efficient manner.
  • When a picker completes picking their zone’s product onto a pallet, it is placed in a staging location and a hand-off pick is generated to direct the next zone’s picker to the correct product.
    • The hand-off can be configured to be performed at the start or end of the next zone’s picking.
    • It is possible to manually record a zone-pick hand-off on the record picks window in the Work Queue tab of the WMS pick dispatcher.
    • Full pallet picks are excluded from zone-pick logic and have no hand-offs.
    • See the Vocollect page for a sample hand-off exchange between a picker and Vocollect.
  • It is also possible to set multiple zones to the same sequence, pick from them at the same time, and an “assembling pick” will be generated to merge the product onto a single pallet after picking is complete.
    • There must be a zone sequenced after the zones picked at the same time for the assembling pick to be generated.

Feature Information

  • Functional Area: Operations
  • Roles Impacted: Warehouse Manager, Warehouse Staff
  • Platform: eoStar Backend, eoWarehouse, Vocollect
  • Plugins: WMS Plugin

Setup

Permissions

Access Records

This permission controls if a user can access records required to set up Zone Picking. For more information see: Access Records.

Records > Employees > Records > Access Records panel:

  • Warehouses
  • Warehouse Areas
  • Warehouse Zones
Plugins Panel

This permission controls if a user can access screens required to set up Zone Picking. For more information see: Plugins Panel.

Records > Employees > Records > Plugins Panel:

  • WMS -> Assign Products to Zones: May Access
  • WMS -> Employee Setup: May Access

Setup Options

There are two ways zone picking can be set up:

  1. With the WMS Ops Plugin.
  2. Without the WMS Ops Plugin.
WMS Ops Setup

Enable Zone Picking

Zone picking must be enabled at the warehouse level.

Records > Warehouses > Records > Pick Settings panel:

  • Enable zone picking for warehouse

WMS Zones

Picking zones must be created as WMS Zones, given a sequence number, and assigned to a Warehouse.

  • Zones must be flagged as Used for voice/electronic picking.
  • Zones will be picked in the order they are sequenced.

For instructions on creating WMS zones, please see the WMS Zone Records article.

Assign Pick Locations to Zones

Pick locations are assigned to a warehouse area, each warehouse area must be assigned to a zone.

  • Multiple warehouse areas can be assigned to the same zone.
  • The pick location determines which zone a pick is for: Pick Location > in a Warehouse Area > which is assigned a Zone.

Assign Pickers to Zones

Each picker must be designated to pick from a single zone, or all zones.

  • Pickers are restricted to only receive work for their assigned zone.

For instructions on assigning pickers to zones, please see the WMS Employee Setup article.

Non-WMS Ops Setup

Enable Zone Picking

Zone picking must be enabled at the warehouse level.

Records > Warehouses > Records > Pick Settings panel:

  • Enable zone picking for warehouse

WMS Zones

Picking zones must be created as WMS Zones, given a sequence number, and assigned to a Warehouse.

  • Zones must flagged as Used for voice/electronic picking.
  • Zones will be picked in the order they are sequenced.

For instructions on creating WMS zones, please see the WMS Zone Records article.

Assign Products to Zones

Products must be assigned to WMS zones.

  • Each product can only be assigned to one zone.

For instructions on assigning products to zones, please see the WMS Assign Products to Zones article.

Assign Pickers to Zones

Each picker must be designated to pick from a single zone, or all zones.

  • Pickers are restricted to only receive work for their assigned zone.

For instructions on assigning pickers to zones, please see the WMS Employee Setup article.


Carton Picking

Carton picking is not required for zone picking, but is an additional feature that can be utilized in a zone picking environment.

When multiple customers have units (usually bottles) on the same pallet, placing all the units together on the pallet can make it difficult and time-consuming for the delivery driver to identify the correct units for each customer. Carton picking will assign a carton ID to each customer’s units and print an ID label for each carton, alleviating this issue.

  • A customer may require multiple cartons for their units, but each one will have the same carton ID on its label.
    • When multiple cartons are required, eoStar will not split a product across multiple cartons.

Setup

Enable Carton Picking

Carton picking must be enabled at the warehouse level.

Records > Warehouses > Records > Pick Settings panel:

  • Enable carton picking in Vocollect
    • Currently, carton picking only works with Vocollect.
  • Pick carton items last (per assignment)
    • Enable this setting to ensure cartons are placed on the top of the pallet.
    • Does not work with the Pick sequence determined by palletization setting.

Vocollect Task

Carton picking also requires an additional Vocollect task. Please contact Rutherford Support to acquire the new task.

Set Up and Assign the Carton Label

Create a DX layout for the label using the “Pallet Information” source and the “PickAssignmentCartonNumber” field.

Assign the layout as the carton label at File > Database Administration > Configure > WMS Panel:

  • Carton Label

See the Vocollect page for a sample exchange between a picker and Vocollect to print a carton label.

Mark Products for Carton Picking

  • Create an alt-pack for units.
  • Mark the product’s package as “Bottle” in the Less than primary pack menu on the package’s settings panel.
  • Assign the Pick Carton to Use and Units per Carton for the package, also on the package’s settings panel.


Zone Picking Operations

Zone picking flows through the same processes as normal WMS picking.

WMS Ops Picking

Non-WMS Ops Picking


Webinar on Zone Picking – 10/19/2018

Updated on March 14, 2019

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