Pick & Pack Operations

Efficient pick and pack operations are crucial for timely order fulfillment and customer satisfaction. This guide covers comprehensive picking and packing workflows in Angage ERP.

Understanding Pick & Pack

Process Flow

graph LR
    A[Order Release] --> B[Pick List Generation]
    B --> C[Picking]
    C --> D[Packing]
    D --> E[Shipping]

Picking Strategies

Discrete Picking

• One order, one picker
• Complete order integrity
• Simple process
• Lower efficiency

Batch Picking

• Multiple orders simultaneously
• Sort during or after pick
• Higher efficiency
• Requires organization

Zone Picking

• Pickers assigned to zones
• Orders travel between zones
• Specialized knowledge
• Reduced travel

Wave Picking

• Orders grouped by criteria
• Coordinated release
• Balanced workload
• Optimized shipping

Pick List Management

Generating Pick Lists

Automatic Generation

1. Orders reach "Ready" status
2. System groups by rules:
   • Shipping method
   • Delivery date
   • Customer priority
   • Warehouse zone
3. Optimizes pick sequence
4. Assigns to pickers

Manual Generation

1. Navigate to Warehouse → Pick Lists
2. Click New Pick List
3. Select orders to include
4. Choose picking strategy
5. Assign resources
6. Release for picking

Pick List Components

Header Information

• Pick list number
• Generation time
• Priority level
• Due time
• Assigned picker

Pick Details

• Optimized sequence
• Location → Item → Quantity
• Customer/Order reference
• Special instructions
• Alternates allowed

How-To Guides

How to Configure Picking Rules

Pick Priority Rules

1. Go to Settings → Warehouse → Picking
2. Set priority factors:
   • Customer tier (40%)
   • Shipping method (30%)
   • Order value (20%)
   • Due date (10%)
3. Configure cut-off times
4. Enable auto-release

Pick Path Optimization

1. Define warehouse zones
2. Set pick sequence:

   SHIP → A-Zone → B-Zone → C-Zone → PACK

3. Configure within zones:
   • Serpentine path
   • Optimal routing
   • Heavy items first
4. Test and refine

How to Execute Picking

Paper-Based Picking

1. Print pick list
2. Get picking cart/tote
3. Follow sequence:
   • Go to location
   • Verify item
   • Pick quantity
   • Mark complete
   • Move to next
4. Deliver to packing

Mobile Picking

1. Login to mobile device
2. Get assigned picks
3. For each pick:
   • Scanner guides to location
   • Scan location barcode
   • Scan item barcode
   • Confirm quantity
   • System updates
4. Complete notification

Voice-Directed Picking

1. Put on headset
2. Login with voice
3. System speaks:
   • "Go to A-01-B-3"
   • "Pick item 12345"
   • "Quantity 5"
4. Confirm verbally
5. Next pick announced

How to Handle Pick Exceptions

Insufficient Stock

Options when short:

1. Partial Pick
   • Pick available
   • Flag shortage
   • Backorder rest
2. Substitute
   • System suggests
   • Picker confirms
   • Note change
3. Skip
   • Move to next
   • Escalate issue
   • Supervisor handles

Wrong Item in Location

1. Do not pick wrong item
2. Flag in system
3. Photo evidence
4. Try alternate location
5. Trigger cycle count

How to Optimize Batch Picking

Setup

1. Enable batch picking
2. Set batch size (e.g., 10 orders)
3. Configure sort method:
   • Sort while pick
   • Sort after pick
   • Automated sorter

Execution

1. Get batch pick list
2. Use multi-compartment cart
3. Pick all items for batch
4. Sort into orders:
   • By order number
   • Color-coded totes
   • Numbered slots
5. Verify completion

How to Manage Wave Picking

Wave Planning

1. Go to Wave Management
2. Create wave rules:
   • Carrier cut-offs
   • Shipping zones
   • Order types
   • Volume limits
3. Schedule releases:
   • Morning wave: 8 AM
   • Afternoon wave: 1 PM
   • Express wave: 4 PM

Wave Execution

1. System releases wave
2. Pick lists distributed
3. Coordinate zones
4. Monitor progress
5. Adjust resources

Packing Operations

Packing Stations

Station Setup

Essential components:

• Packing table
• Computer/tablet
• Scale
• Label printer
• Packing materials
• Barcode scanner

Station Configuration

1. Assign station ID
2. Link peripherals
3. Set default settings:
   • Carrier preference
   • Box sizes available
   • Packing rules
4. Enable features

Packing Process

1. Order Receipt

1. Receive picked items
2. Scan order barcode
3. System displays:
   • Items expected
   • Shipping method
   • Special instructions

2. Verification

1. Scan each item
2. System validates:
   • Correct item
   • Right quantity
   • Order complete
3. Flag discrepancies

3. Package Selection

System suggests box based on:

• Item dimensions
• Total volume
• Weight limits
• Shipping method
• Cost optimization

4. Packing Execution

1. Place items in box
2. Add protection:
   • Bubble wrap
   • Air pillows
   • Foam inserts
3. Include documents:
   • Packing slip
   • Invoice
   • Marketing materials
4. Seal package

5. Shipping Label

1. Weigh package
2. System calculates shipping
3. Print carrier label
4. Apply to package
5. Update tracking

How to Configure Packing Rules

Box Optimization

1. Define available boxes:
   • Dimensions
   • Weight limits
   • Cost
   • Carrier restrictions
2. Set packing algorithm:
   • Best fit
   • Lowest cost
   • Fastest method

Item Rules

Configure special handling:

• Fragile items
• Orientation requirements
• Incompatible items
• Temperature control
• Hazmat compliance

How to Handle Multi-Package Orders

Split Package Logic

When order requires multiple packages:

1. System identifies need
2. Suggests split:
   • By size/weight
   • By ship-from location
   • By item compatibility
3. Pack separately
4. Link packages
5. Single tracking provided

Package Consolidation

For efficiency:

1. Identify same destination
2. Combine if possible
3. Update documentation
4. Single shipment
5. Cost savings

Advanced Features

Automated Packing

Pack Verification

• Weight verification
• Dimension scanning
• Photo documentation
• AI quality check

Robotic Integration

• Automated box selection
• Robotic packing
• Conveyor systems
• Sortation equipment

Performance Analytics

Picking Metrics

• Picks per hour
• Error rate
• Travel distance
• Order cycle time

Packing Metrics

• Packages per hour
• Material usage
• Shipping accuracy
• Damage rates

Quality Control

Pick Accuracy

• Random audits
• Weight checks
• Scan verification
• Customer feedback

Pack Quality

• Seal inspection
• Label accuracy
• Document verification
• Damage prevention

Best Practices

Picking Efficiency

• Maintain clean locations
• Update inventory real-time
• Use appropriate strategy
• Regular slotting review
• Continuous training

Packing Excellence

• Right-size packages
• Minimize materials
• Protect products
• Accurate documentation
• Professional presentation

Error Prevention

• Scan verification
• Weight checking
• Double confirmation
• Clear procedures
• Regular audits

Configuration

Pick & Pack Settings

Navigate to Settings → Warehouse → Fulfillment:

• Pick Strategies: Enable/configure
• Batch Limits: Maximum size
• Wave Schedule: Timing rules
• Pack Station: Requirements
• Quality Checks: Mandatory steps

Integration Options

• WMS integration
• Shipping software
• Robotics interface
• Conveyor controls
• Voice systems

Troubleshooting

Common Issues

Pick list not generating

• Check order status
• Verify inventory
• Review rules
• Check schedule

Cannot complete pick

• Verify all items picked
• Check exceptions
• Review quantities
• Clear shortages

Packing errors

• Validate items
• Check scale
• Verify printer
• Review settings

Next Steps

Learn about Inventory Control for cycle counting and reconciliation.