Handling Units

General

Handling Unit is a collective name for all type of containers in which parts can be packed independently of being used in inventory, purchasing, shop order or in shipment. The purpose of a handling unit structure is to describe the packing as done in one or several levels for pallets, boxes and parts. A handling unit can be solitaire or a part of a multi-level structure where handling units are stored in each other, alternatively be put on top of each other. In its original form when no goods have been put into a handling unit, the handling unit is not connected to any company or site. When parts are packed into a handling unit, the handling unit obtain the site of the location where they are being stored in inventory. When connected to a shipment the handling unit will be attached to the sender site of the orders that builds up the shipment. 

The packing process can be performed either manually or automatically. When parts are packed manually its allowed to mix different parts, lot batched, serials etc. within the same handling unit if needed. Handling unit structures are created by manually adding handling units and accessories that represents the packing requirements. Manual packing can also be performed by using a predefined packing instruction that creates an empty handling unit structure to which parts or shipment lines later can be attached. Handling unit structures can be modified and moved between handling unit structures within the same location or shipments connected to the same receiver.

Automatic packing can be performed by either packing parts into their lowest level handling unit or apply a packing instruction to already existing handling units, starting from the handling unit level stored in inventory or connected to a shipment line. It is also possible to pack according to a predefined packing instruction, building up the entire handling unit structure bottom and up, including handling unit accessories according to the definition of the packing instruction.

The handling unit is identified internally via a unique handling unit ID. Alternative identification of a handling unit can be achieved via SSCC (serial shipping container code) that can be created for all levels of an existing handling unit structure. Another option is to create an alternative handling unit label if desired. Note that you should not use the handling unit functionality if you are not labelling the handling unit with any a unique identifier i.e. handle it as a unique entity throughout all processes. You should not use handling units to represent packages of a certain pack size where all these packages might have the same GTIN-number. To represent this the Input UoM functionality should be used instead. If you use handling units for this purpose you might run into challenges when it comes to performance. Note that in general huge handling unit structures comes with a cost when it comes to performance.

The information from the handling unit structure, including, weight, and volume, is included in, relevant reports and DESADV messages.

Basic Data

The basic data required for handling units are:

Handling Unit Types:

Different handling unit types that can be used when packing parts or shipment lines. Handling unit types can be grouped in to different categories.  Weight, volume and dimensions of handling unit type can be specified per handling unit type. By specifying additive volume for a handling unit type, it determines that the volume of the handling unit is dynamic and defined by the content attached to this handling unit. A typical example of such a handling unit type is a pallet. Handling unit types not having additive volume would typically be a box which has a fixed volume, regardless of content.

Handling Unit Accessories:

The accessories needed when packing parts. This could typically be pallet collars or a lid for a pallet or some insulation material for a box. For each handling unit accessory, it is possible to define weight and volume that will be included as part of the handling unit structure. A handling unit accessory can be set as having additive volume, meaning that the volume of the accessory will be added to the total volume of the handling unit. It will also mean that the volume for the handling unit is fixed to that total volume. A typical example of this would be having a pallet and then adding one or several collars to that pallet as accessories (additive volume set). The total volume for that handling unit including accessories and any parts attached, will then be the pallet volume plus the accessory volume, as it can be seen as a fixed box. If the accessory does not have additive volume, it will not be included in the volume calculations for the handling unit. A typical example of the latter would be an insulation material used as an accessory. Using our example, the volume of the parts or any child handling units would be added to the total volume of the pallet (that have additive volume). Handling unit accessories can be added to a handling unit manually or as part of the packing instruction.

Handling Unit Capacity:

When performing automatic packing, it is vital to know how many parts that can go into a certain handling unit type. This can be defined in the part catalog - per part, or per storage requirement group for capacity. Note that the handling unit capacity is defined per UoM, meaning that depending on which UoM that is used for the part, there can be different quantities packed into the same handling unit. For example, the handling unit capacity for a part could be 100 pcs on a pallet, but using the same part and 10PK as UoM on another site, it could then have a handling unit capacity of 10 "10PK" for the same pallet. This definition is later used when performing the automatic packing into handling units or as a first step when packing according to a pack instruction. It is possible to define several different handling unit types for one part and UoM combination.

Packing Instruction:

The packing instruction describes a default way of packing different handling units in a structure. Automatic packing using packing instruction can be applied both on parts and handling units. The later means that additional handling unit structure will be added to the selected handling units. Note that the reference to part when performing pack according to pack instruction for parts is achieved via the handling unit capacity for the lowest level handling units in the packing instruction. So for the packing instruction, there is no direct reference to how large a quantity of a part can be packed. A typical packing instruction could be one pallet at the top on which four big boxes can be stored and then in each big box, two small boxes can be stored - that would be the packing instruction as described in the structure above. In the packing instruction, it is also possible to define whether there should be handling unit accessories added as a part of packing. This is defined per level in the packing instruction. Per level of the packing instruction, it also possible to define rules regarding a mix of parts, lot batches or condition codes. These rules will then be validated when performing manual packing. For automatic packing that uses a packing instruction, these rules will be considered, but note that in the lowest level handling units, there will always be only one part number or condition code, regardless of the setting of the mix blocked options. So for automatic packing, it will only be the Mix of Lot Batch Numbers Blocked option that would have an effect when enabled on the lowest level. The packing instruction can also be applied in order to create an empty handling unit structure that can work as a base for manual packing of parts or shipment lines.

The packing instruction can also be applied to fill the handling unit structure with empty handling units. Consider the packing instruction again as described in the above paragraph.

No of Units No of Incremental Units Fill Empty Parents with Handling Units
Pallet 1    
Big Box 4 2 No
Small Box 2 2 Yes

Assume that we can pack 5 quantities into a small box and need to pack 25 quantities using the above packing instruction.

Accordingly, the final handling units structure will look like this:

Pallet      
  Big Box    
    Small Box 5 Qty
    Small Box 5 Qty
  Big Box    
    Small Box 5 Qty
    Small Box 5 Qty
  Big Box    
    Small Box 5 Qty
    Small Box Empty
  Big Box    
    Small Box Empty
    Small Box Empty

 

 

Default Packing Instruction:

Shipment:

The packing instruction can be setup to be default per customer order/shipment line in a specific page, Default Packing Instruction. The pack according to packing instruction can then be triggered as an optional event as a part of the shipment type or manually. The default packing instruction on customer order line is passed to the shipment line and can then be applied when triggering the pack according to pack instruction on the shipment or shipment lines. The default packing instruction can be set for a capacity requirement group, for a global part number, a part number/site, a part number/site/customer or for a part number/site/customer/address combination. On the customer order line, the default packing instruction with the most specific definition is used. Note that it is possible to change the default packing instruction if required, on the customer order or shipment line.

Purchase Order:

The packing instruction can be setup to be default per supplier for purchase part. This packing instruction is then passed to created purchase order lines and further to the purchase order receipts where it can be used to pack according to packing instruction.

Shop Order:

The packing instruction can be set to be default per product structure alternate and is passed to created shop order and production schedule. A shop order created directly from a customer order line will in first hand inherited the packing instruction from this customer order line.

- The packing instructions and default values for packing instructions are a part of the basic data for handling units in inventory.

Handling Unit Structure

Manual Packing:

Manual packing of handling units can be done throughout the supply chain - from receipt, in inventory and as a part of shipment. When packing is done of parts stored on an inventory location the inventory part in stock record will give information regarding the actual handling unit in which the part and quantity is packed. Then the rest of a handling unit structure information is given on the handling unit record via parent child relationship. Parts not packed in handling unit can be identified as having handling unit = 0 when looking at the inventory part in stock record.

Inventory:

In inventory the manual packing of handling units can be done either from a part perspective or a handling unit perspective.

From Inventory Part in Stock it is possible to select one or several records with handling unit = 0 (not packed) and then either attach them into a certain handling unit type (creating new handling unit id) or to an existing handling unit id.

In the handling unit page you can add new handling units, build a handling unit structure manually, or apply an empty packing instruction to get a predefined structure. Optionally, you can also connect accessories to the handling units in the structure.

Then unattached inventory parts in stock record lines can be attached to a handling unit of choice.

Note that several inventory part in stock records can be attached to one handling unit at the same time. For each part record being attached it is possible to adjust the quantity to be attached.

It is also possible to unattach quantity for handling units manually. You can also completely detach attached inventory part in stock records from the handling unit without removing the handling unit itself - thus keeping additional ID information like SSCC etc for the handling unit.

Changes to the handling unit structure can be done for one handling unit at a time in the graphical navigator, or by a more general change of parent handling unit ID performed for one or several handling unit lines in one go, if required.

You can also manually update the gross weight, volume and dimensions for handling units. These changes (weight and volume) might be reflected upwards in the handling unit structure, depending on whether or not manual values are entered for parent handling units, or if additive volume is used.

Shipment:

On the shipment, any shipment lines that are not packed yet, are displayed as unattached shipment lines on the shipment. Packing of handling units on shipment must be done from the shipment page even though it is possible to view these handling units in the handling unit page.

On the shipment you can add handling units and build a handling unit structure manually, or apply an empty packing instruction to get a predefined structure. Optionally, you can also connect accessories to the handling units in the structure.

The unattached shipment lines can then be attached to a handling unit of choice on the shipment. Note that several shipment lines can be attached to one handling unit at the same time. The information attached from the shipment line can be just the quantity from a shipment line attached to a handling unit or be more specific about tracking information, like lot batch numbers and serials etc. The tracking information can either be specified directly when attaching shipment lines or updated later on for shipment lines only attached with a quantity.

It is also possible to update the quantity attached for handling units manually, after an initial attachment has been done, both for shipment and shipment reservation lines. You can also completely detach shipment lines or tracking/reservation information from the handling unit without removing the handling unit itself - thus keeping additional ID information like SSCC etc for the handling unit.

Changes to the handling unit structure can be done for one handling unit at a time in the graphical navigator, or by a more general change of parent handling unit ID performed for one or several handling unit lines in one go, if required.

You can also manually update the gross weight, volume and dimensions for handling units on the shipment. These changes (weight and volume) might be reflected upwards in the structure and ultimately for the whole shipment, depending on whether or not manual values are entered for parent handling units, or if additive volume is used.

Shop Order:

Using the shop order handling unit functionality allows you to receive the completed parts of the shop order to stock in the handling units prepared for the shop order.

Prepare the packing of the shop order by connecting either existing handling units, manually create new handling units, or automatically create the handling units needed for the shop order by using a packing instruction. If the lowest level handling unit type has a max capacity defined for the manufactured part, this value will be suggested as the Qty to Attach but can be manually changed. Optionally you can also connect accessories to the handling units, generate SSCC and print handling unit labels.

When receiving the shop order, enable the Pack option to attach the received parts to the handling units connected to the shop order. If no handling units has been connected to the shop order prior to the receipt, but a packing instruction is connected to the shop order, handling units will be generated automatically. You can also receive a completed handling unit from the handling unit structure tree view on the shop order.

The received parts will be automatically distributed among the handling units according to the Qty to Attach defined. However, you can manually move parts between the handlings units to make sure it reflects how the finished goods have been physically packed. If required, the handling unit content label can be printed showing the contents of each handling unit.

Production Schedules:

Using the production schedule handling unit functionality allows you to receive the completed parts in handling units automatically generated from a packing instruction entered in the Production Receipt dialog.

Handling units will be generated according to max capacity defined for the lowest level handling unit type of the selected packing instruction and the number of parts received. The received parts will be automatically attached to the handling units, however, you can manually move parts between the handlings units to make sure it reflects how the finished goods have been physically packed. If required, the SSCC can be generated, and labels printed for the created handling units.

General rules for manual packing:

The options Mix of Part Numbers Blocked, Mix of Lot Batch Numbers Blocked, Mix of Condition Codes Blocked and if SSCC should be generated and handling unit labels should be printed, is also possible to update per handling unit ID.

Handling unit composition will be defined for each handling unit based on the content of the handling unit and its sub-structure:

Mixed - represents a handling unit which contains at least two different part in itself or its underlying structure.
Homogenous - represents a handling unit that have an underlying structure of other handling units but only contains one part number throughout the handling unit structure.
Simplified - represent a handling unit on the lowest level, no sub-structure, that only contains one part number.

Note that the handling unit composition could be changed when content is changed or a handling unit is moved within the handling unit structure.

Automatic Packing:

In addition to the manual packing of parts and handling units, it is also possible use a more automatic approach for packing - meaning that the system will pack parts or handling units and also create handling unit structures automatically based on the basic data setup and the parts and quantities. There are two different ways to perform an automatic packing:

Pack according to handling unit capacity:

The automatic packing using pack according to handling unit capacity can be applied for inventory part in stock records with handling unit = 0, meaning unattached inventory parts, when packing in inventory.

For shipment, pack according to handling unit capacity can be applied for unattached shipment lines. Pack according to handling unit capacity can also be defined as an optional event for shipment types.

This means that the parts and quantities are packed into their lowest level handling unit types according to the handling unit capacity for that handling unit type. Also note that when parts are automatically packed into handling units, there will only be one part in each handling unit on the lowest level - that includes configurations and condition codes.

Using the pack according to handling unit capacity functionality could be a way to reflect the actual packaging used when storing parts in inventory (if not using handling units in inventory), or could represent a shipment-specific way of packing parts.

Pack according to packing instruction:

This automatic packing can be applied for inventory part in stock records with handling unit = 0.

For shipment pack according to packing instruction can be applied for the whole shipment or specifically for unattached shipment lines. Pack according to packing instruction can also be defined as an optional event for shipment types.

Pack according to handling unit capacity can also be applied on handling units that don't have parents. Pack according to handling unit capacity for handling units can be applied in Handling Units in Stock. For shipment it can be applied for handling units in the handling unit structure.

When applying pack according to packing instruction on part level it means that parts and quantities not previously packed first will be packed into the lowest suitable handling unit as defined in the packing instruction. Then the additional handling unit levels in the packing instruction will be created from bottom up, including the accessories specified as being a part of the packing instruction. So the end-result will be a complete handling unit structure based on the packing instruction definition.

Applying pack according to packing instruction on existing handling units means that additional parent handling units and handling unit structure is applied on the top of the selected handling units.

Note that the automatic packing according to packing instruction will use the base method for pack into handling units but can also consider the value on the Mix of Lot Batch Numbers Blocked option defined in the packing instruction. The packing instruction can also be used to decide for which handling units you should generate and for which you should print different handling unit labels.

Weight and Volume

Weight:

The weight and volume of parts, handling unit types and accessories are all considered when it comes to the weight and volume calculation for the handling unit structure and also for the total weight on a shipment. For each handling unit, there is a calculation of the net and tare weight based on the values given in the basic data for parts, handling unit types and accessories. On shipment there is also an adjusted net weight calculated that considers the freight factor given per part. The gross weight and adjusted gross weight are then initially calculated using the net, adjusted net and tare weights to indicate a gross and adjusted gross weight per handling unit ID.

Note that the adjusted gross weight is used for the freight charge calculations on shipment. On all shipment reports and DESADV messages, it is the gross weight excluding freight factor that is used.

In addition to the calculated values for weight, it is also possible to enter a gross weight manually per handling unit ID. A manually entered gross weight will also affect the adjusted gross weight calculation - the difference between net weight and adjusted net weight will be considered to calculate a new adjusted gross weight based on the manually entered value for gross weight. So if a manual gross weight is entered, the new adjusted gross weight is calculated as:

New Adjusted Gross Weight = Manual Gross Weight + (Adjusted Weight - Net Weight). This is done so that the new adjusted gross weight still considers the freight factor applied on net weight for weights on shipment.

A manually entered value for gross weight on a lower level of a handling unit structure will be used for total gross weight calculations on the parent levels. For shipment a manually entered weight on a handling unit will also affect the total weight on the shipment. Note that when the content of a handling unit is changed, any manually entered value will be removed and the gross weight calculation (operative value) will revert to a calculated value.

Shipment specific weight calculations:

The total gross weight for a whole shipment or consolidated shipment can also be manually updated to better reflect the actual weight for the whole shipment.

Depending on the setting for Unattached Shipment Lines Allowed the total weight calculation will be different:

This behavior is needed in order to support a scenario where the customer isn't attaching shipment lines to handling units in the application but parts are actually stored in handling units and manually entered gross weight for handling units will then include the weight of parts.

Volume:

For volume per handling unit, there is a total volume calculated per handling unit ID. If the handling unit type is additive and there are no additive accessories added to that handling unit ID, the volume will be the sum of the handling unit type from basic data + the volume of the parts or handling units one level down (children) attached to that handling unit. If the handling unit type is not additive, the volume of the handling unit ID is the volume of the handling unit type as given in the basic data. If a handling unit accessory with additive volume is connected to the handling unit, the volume of that accessory is added to the volume of the handling unit type to give the total volume of the handling unit type ID.

As described above, the volume of a handling unit might also affect the volume of the parent handling unit ID.

Then it is also possible to manually enter a total volume for a handling unit ID. This might then affect the volume calculations on the parent levels all the through the handling unit structure. For shipment it will also affect the total volume of the shipment. Note that when the content of a handling unit is changed, any manually entered value will be removed and the total volume calculation (operative value) will revert to a calculated value.

Shipment specific volume calculations:

The total volume of the shipment is the sum of the total volume for all the top nodes of the handling unit structure and can also be manually updated per shipment or per consolidated shipment.

Depending on the setting for Unattached Shipment Lines Allowed the total volume calculation will be different:

This behavior is needed in order to support a scenario where the customer isn't attaching shipment lines to handling units in the application but parts are actually stored in handling units and manually entered gross volume for handling units will then include the volume of parts. Note that the volume calculation for a handling unit also is dependent on the flag for Additive Volume.

Reserve Handling Unit

Reservations of required quantity can in addition to reserving part and quantity also be done per handling unit. As reservations are done for one demand line at a time it will only be handling units that are homogenous and contain the same part throughout the handling unit structure that is available for reservation.

Manual reservation:

Manual reservation of handling units is available as an option for customer order, shipment order, shipment and shop order. It is then possible to state that certain handling units is reserved for the demand - actual reservation is then made on stock records that make up the content for those handling units.

For other demand sources reservations needs to be made per inventory part in stock which means that one specifies part and quantity per reserved stock record. It is then possible to fully or partially reserv stock records that are attached to handling units. This option to make detailed reservation is also possible for customer order, shipment and shop order.

Automatic reservation:

If automatic reservations is set up to prioritize handling unit optimization it means that the automatic reservation will try to find and reserve as few whole handling units as possible. Or rather try to reserve as large handling units as possible given the demand quantity. Handling units reserved via automatic reservations will be homogenous - only containing the same part throughout the handling unit structure. In addition, if you use putaway zone ranking, you have the option to configure an alternative putaway zone ranking to be used at reservation of complete handling units. For instance, this implies that you can prioritize to reserve complete handling units in bulk zones prior to the picking zone.

In the scenario that the quantity to be reserved is less than any available handling unit in stock, the automatic reservation will first prefer to reserve any single parts (not in handling units). If no such quantity is available, the automatic reservation will then reserve a partial quantity of a handling unit. When breaking an existing handling unit the reservation logic will try to do as little harm as possible, trying to break as small handling units available with as high structure level as possible.

Pick Handling Unit

Pick of handling units is available as an option for customer order, shipment and shop order. On the pick lists for these demand sources it is possible to view an aggregated view of the pick list lines per handling unit or per location. An aggregated view means that the pick list will show the whole handling unit that could be picked on the pick list and having content that is entirely represented on the pick list. Picking could then be reported per handling unit rather than for each individual inventory part in stock record that is a part of the content of the handling unit.

Detailed pick list lines displayed as aggregated per location are those pick list lines that are not packed in handling units or pick list lines that should be picked out of an handling unit - meaning that there is partial picking of the handling unit, while still all of these lines are reserved on the same location. It is possible to report picking of these aggregated lines per location as well but this should rather be used as a follow-up reporting location by location after actually picking all the detailed pick lists lines for a location. 

For other demand sources there is only the option to report picking on a detailed level, which means that one specifies part and quantity to be picked per reserved stock record. It is then possible to fully or partially pick stock records reserved in handling units as well as report picking stock records reserved for unpacked parts (handling unit=0). This option to make detailed picking is also possible for customer order, shipment and shop order.

Pack handing units from inventory on shipment

When picking handling units that are packed in inventory on a shipment they could be automatically added as being a part of the handling unit structure on the shipment. This will happen in the case that the content of the handling unit have not been pre-packed to other handling unit on the shipment. In such a case the pre-planned packing will be executed at the time of picking and in shipment inventory it will be the handling units planned from shipment that appear.

Counting

When performing counting on records attached to a handling unit Count Handling Units and Count per Count Report/Aggregated tabs can be used. Count per Count Report/Aggregated tab is used when a count report is created.

Handling Unit Reports

The information found for a handling unit structure is included on a number of printed reports:

Inventory reports:

Count Report: The user can print a aggregated or a detailed count report. The aggregated count report is used to count stock records aggregated per handling unit or per location.

Handling Unit Label: This label contains information about handling unit ID, SSCC and alternative handling unit label ID. Handling unit labels can be printed for a specific handling unit or an entire shipment/shop order. 

Handling Unit Content Label: This label contains information about the handling unit ID, SSCC, and alternative handling unit label ID as well as the content of the handling unit. Handling unit content labels can be printed for specific handling units in inventory or for an entire shop order.

Pick list report: The pick list can be printed either on a detailed or and aggregated level. The detailed level report lists all inventory part in stock records on the lowest level (down to serial number) but includes information about the path on how to find the specific stock record. This path starts with the location and then includes up to 3 levels of handling units. (all levels, if more than 3, are included in the XML information for the report). When printing the pick list report on an aggregated level it lists the top level that can be entirely picked when consider the content on the pick list. There is also a path describing the location and up till 3 levels of handling units if the handling to be picked is lower done in the handling unit structure.

Shipment reports:

Consignment Note: This report includes a list of the top node handling units on the shipment. The weight and volume of these handling units are listed.

Bill of Lading: This report includes a list of the top node handling units on the shipment and the weight of these handling units.

Delivery Note: This report lists a total net and gross weight as well as volume for the shipment, and that is based on the handling unit structure. If no handling unit structure is created, it will show the net weight values for the shipment lines connected to the shipment.

The DESADV message includes information regarding the handling unit structure and parts attached to that, down to a two-level structure. If the handling unit structure on the shipment has more than two levels, it is summarized into the second level of the DESADV information so that all shipment line specific information is included in the message. This also includes ITS message for DESADV.

Handling Unit Label: This label contains information about handling unit ID, SSCC and alternative handling unit label ID. Handling unit labels can be printed for a specific handling unit or an entire shipment/shop order.

Shipment Handling Unit Label: This report lists information about delivery note ID, handling unit ID, SSCC, and alternative transport label ID as well as weight and volume of the handling unit ID. Quantity of all parts attached to the handling unit and sub-structure as well as the number of child handling units is also listed. There could also be information about part numbers and some tracking information if it is unique for the handling unit.

Packing List: The packing list is a support when performing the shipment process, e.g. when reserving, picking, and packing, and can be included in the shipment when everything has been picked and packed. The packing list can be printed several times throughout the shipment process, each time displaying the current contents and status of the shipment.

Performance Note for clients with compiled view columns

In the clients listed below the concept of compiled view of certain columns have been applied. It means that for a handling unit those columns display for example one common value for all the content of a handling unit or if there is a mix of values it is displayed as NULL or ...

If the column is a quantity, the compiled view is a sum of the quantity for all the attached part lines in the underlying structure.

As the columns using the compiled view have a performance impact these columns have been hidden in these clients by default. Those of interest can easily be added to the view of the handling unit but will come at a performance cost. Adding all these columns to a client could give bad performance when viewing these pages so one should consider only adding those of most interest.

Pages that have columns hidden by default are: