This concept is particularly useful when there are locations/areas in the warehouse where it is more
efficient to operate on complete top level handling units instead of single reservations. This might be the case in
bulk zones or locations that are hard to reach. There are three different scenarios and the idea is that you would
like to pick those in different ways, either in one step or in two steps:
The reservation logic can be set up to prioritize reservations of full top level handling units as per below. Handling units that get completely reserved by one demand can be picked straight from their respective location to the destination e.g. shipment location. This can be achieved by running Create Consolidated Pick List, Create Consolidated Pick List for Customer Orders or Create Consolidated Pick List for Shipment. Select the option Only Handling Units to be Picked in One Step. This will filter out those handling units.
Two-step picking is a way of facilitating the picking of reservations that make out part of a handling unit or
when a handling unit is reserved by multiple demands. The picking is then devided into two steps. The first step is
to move all reservations in a certain part of the warehouse to a location were it is more efficient to pick, like a
staging area/temporary location or the actual picking location. This is done by running either of the batch
programs, Move Reservations with Transport Task / Move Customer Order Reservations with Transport Task / Move
Shipment Reservations with Transport Task. Here the user can define from which locations to move, criterias on
which reservations to move and what location to move to. To be able to run the picking process for a batch of
reservations, the selection criterias for reservations are the same as for Create Reservations / Create Customer
Order Reservations and Create Consolidated Pick List / Create Consolidated Pick List for Customer Orders / Create
Consolidated Pick List for Shipment.
The move is made by creating one or more Transport Tasks. The possibility to reserve from active transport tasks
makes it even more flexible. After executing the transport tasks you run the second step, Create Consolidated Pick
List / Create Consolidated Pick List for Customer Orders / Create Consolidated Pick List for Shipment, creating
pick lists for the reservations.
A common setup in a warehouse operation is to have a bulk zone and a picking area. In the bulk area you only
operate on top level handling units and in the picking area you pick parts of handling units. To achieve this in
the system you want to set up two storage zones, the bulk and the picking area. This is done in Storage Zone.
On the Site, Site - Inventory - Automatic Reservation, set Reservation Priority 1 = Highest Putaway Zone Ranking,
Priority 2 = Largest Quantity on Handling Unit and Priority 3 = Outermost Handling Unit. This will make sure that
the reservation will try to reserve as few handling units as possible and at the same time as full and close to the
top level as possible. To avoid locking up the inventory, also tick Reserve From Transport Task here.
Finally in Putaway Zone Basic Data you set the reservation ranking to prioritize full handling units in bulk and
less than a full handling unit in the picking area. In Ranking, set a lower number (higher ranking) for the picking
area and then vice versa in Handling Unit Reservation. This will make the bulk zone rank higher when looking for
full handling units and the picking zone rank higher for anything less than a handling unit.