Order Release Method
Freedom Series/ec21 supports three major methods for the release of sales orders to the warehouse. Each is designed to give you control of the activity in your warehouse. The choice of release method is made at the location level; therefore locations within your company can be operated differently. Factors established at the Customer level, such as ship-via and priority code also impact the shipment of goods.
Immediate
Freedom Series/ec21 supports the immediate release of a sales order to the warehouse. Regardless of how the sales order is entered in Freedom Series/ec21, as soon as it passes all Freedom Series/ec21 checks (credit, margin, credit card, license, etc.) it is immediately released to the warehouse for action.
Wave
The Wave or Truck Route method of order release is designed to allow you control when orders are released to the warehouse. Orders are placed into an order pool until time of release. For example, if you use your own trucks, the wave or truck route method can be used to release orders for today's delivery in the order in which you need to load the trucks. Other criteria available include releasing by Priority Code, Pick Type, Customer Number and Order Number.
Bulk Picking
The Bulk Picking method of order release is designed to help you maximize the productivity of your warehouse operation. Though most often used with orders that have been released from order pools, Bulk Picking can apply in either immediate or wave picking. When orders are released, Freedom Series/ec21 produces Bulk Pull Sheets by warehouse section listing all items across all orders in bin location order. Your picker only makes one trip to a section to pick all the items needed for this group of orders.
Bulk Pull Controls
If you choose the Bulk Pull method, you can limit the size of any one Bulk Pull by parameters you set by location or at the company level. This Freedom Series/ec21 control lets you optimize the Bulk Pull in terms of work load and insures a steady flow of orders through the picking, checking, and shipping functions. These parameters are maximum dollar value, maximum number of orders, maximum number of lines, maximum cube, and maximum weight.
Productivity Reporting
Picker productivity can be tracked as employees check-out and check-in picking documents. On-line screens provide immediate order status information as well as total and average pick times.
Picking Bin Assignment
What ever method(s) you use to move orders to a picking status, Freedom Series/ec21 calculates what bin(s) an item is to be picked from. Does the item require repacking? What unit(s) should I pick in? Do I need to let down stock? Some items may require a let down to take place in order for a pick to be successful. In this case an Emergency Bulk to Bin label (EBB) is printed as a part of the picking documents. This directs the warehouse what inventory movements need to take place prior to picking.
Freight Method
Freedom Series/ec21 supports both basic methods for handling freight: the use of outside carriers and/or a self operated truck fleet. The freight method is designated for each sales order. You may set a default freight method to use company wide or for a particular branch. You may also set a default freight method for each customer. The result of setting these defaults is that the person entering a sales order only changes the freight method designation on the sales order on an exception basis.
UPS or Other Package/Common Carrier
The UPS method of freight handling is a full manifesting system that handles many UPS services including C.O.D's, A.O.D.'s, Call Tags, Hundred Weight, Ground Saver, Hazardous Material Charges and Insurance. This method allows you to build the necessary rating tables for each carrier and service.
The UPS system allows you to record the contents of each package and to record tracking numbers for premium services. The specific knowledge of the contents of each package in a multi-package shipment to a customer has provided our users with a powerful customer service advantage in responding to customer inquiries.
While not part of the standard Freedom Series/ec21 offering, we also have worked with customers to create an interface from Freedom Series/ec21 to both UPS's and DHL's proprietary shipping systems.
Using Your Own Truck Fleet
This method of freight handling allows you to assign customers to one or more truck routes and release orders for shipment based on your truck routes. You also have the ability to display, on-line, the status of each order that has been released so that you can anticipate when a truck can be loaded. You can print, on demand, a work copy of the delivery tickets to use for truck loading check off. The delivery tickets list all piece types and the quantity of each for each order along with the total weight and weight of each DOT hazardous material included in the order. You can also track returnable containers that are being delivered to and that should be picked up from each customer on the delivery ticket.
Serial Number Tracking
Freedom Series/ec21 provides you with the features and functions you need to track the movement of serial numbered items. You receive items by serial number, maintain precise serialized inventory records, and pick items based on pre-assigned serial numbers. Or optionally, you may only record and track serial numbered items as they are shipped. Serial numbers can also be tracked for non-stock items, customer returns, and returns to the vendor. Special on-line displays and reports are available to keep you informed of the activity of all serial numbered items.
If Radio Frequency (RF) is used, the user will have the opportunity to scan a bar coded serial number instead of keying it.
Lot Controlled Items
Lot controlled items are easily handled with Freedom Series/ec21. These items are received by lot and may include an expiration date. They may be stored in a single bin or across multiple bins. When performing inventory transactions for these items, Freedom Series/ec21 always prompts for the lot or lots affected.
MSDS Support
If you carry merchandise that requires you to provide MSDS sheets to your customers, Freedom Series/ec21 has the facilities that you need to insure your compliance with MSDS requirements. Freedom Series/ec21 tracks which items require MSDS sheets, notifies the picker when one needs to be sent to the customer, and even handles sending a new MSDS sheet to customers who already have one when the content of the MSDS sheet changes.
Backorder Pre-release During Receiving
Freedom Series/ec21 gives you the ability to pre-release backorders during receiving. If you choose this option, the receiver is notified by Freedom Series/ec21 that backorders exist for an item being received. The receiver is given the ability to pre-release these backorders so that the inventory is allocated to the backorders immediately, before new orders can be allocated. The actual release of the backorders for picking can be done during your normal picking cycle.
The Inventory Locator System
The heart of managing inventory in a warehouse is the inventory locator system. The days when you could rely on long term, knowledgeable employees to know where merchandise is located and to utilize space well is gone for most distributors. Freedom Series/ec21 provides the tools you need to maintain inventory locations accurately, optimize space utilization, improve productivity and reduce shrinkage.
Warehouse
Locating inventory in Freedom Series/ec21 starts with the warehouse. Warehouses in Freedom Series/ec21 include physical locations and logical ones. Physical locations can be a single large facility or could be multiple buildings and outside yards. A logical warehouse within a physical facility can be used for merchandise not for sale; merchandise awaiting quality inspection, returned goods, sales samples, etc.
Section
Freedom Series/ec21 also lets you designate Sections (zones or areas) within a warehouse. Sections can be used for different types of storage (bulk vs. flow rack vs. pallet racks), for different areas (different buildings, different floors, outside yards, cold storage, etc.) or for different types of merchandise. The section designation in Freedom Series/ec21 can also be an element in sales order release and bulk pick ticket generation.
Bin
Bin location in Freedom Series/ec21 is a 10-position, alphanumeric field that should easily accommodate your warehouse section layout Freedom Series/ec21 supports multiple bin locations per item. You may designate the primary pick location for the item and set the system to recommend the let down of merchandise from back-up locations to the primary
Bin Type
You may map your warehouse by defining Bin Types. Height, depth and width of the bin can be established as can the maximum weight allowed. Bin Locations can then be categorized by Bin Type. This information, combined with similar information stored at the item level, allows Freedom Series/ec21, to optimize the use of your warehouse space.
Min/Max
A min/max may be specified on item/bin records to facilitate the letdown of stock from over flow locations to your picking location(s).
Receiving
One of the core functions of any warehouse operation, receiving is given excellent support by Freedom Series/ec21. Designed to insure the accurate and fast check-in of merchandise, the Freedom Series/ec21 receiving function will allow you to clear your dock quickly.
Receiving from your Suppliers
Most of the activity on the receiving dock involves the check-in of merchandise purchased from your suppliers. Freedom Series/ec21 has the features you need to quickly identify the purchase order(s) involved, receive the merchandise accurately, handle exception conditions, and put away the items.
On-line Display of Open Purchase Orders
If your purchase order is not identified by your supplier, you can find an open purchase order in Freedom Series/ec21 by vendor or by one of the items on the purchase order. Both methods include search capabilities and present both the original order quantity and the quantity previously received, if any, for each item on the P.O.
Advance Shipping Notice (ASN)
As the trend accelerates towards just in time movement of goods, many of our users are receiving Advance Shipping Notices (ASN's) prior to actual receipt. ASN's are particularly useful when multiple shipments are anticipated and Radio Frequency (RF) technology is employed in receiving. Based on the ASN, the exact quantity and type of bar code labels can be printed to facilitate RF receiving. In addition to employing RF, many of our customers are receiving ASN's using the latest EDI techniques.
On Demand Printing of Receiving Document
Freedom Series/ec21 gives you the ability to print a receiving document on demand. This document lists all open items on a purchase order with their balance due, net of any quantity from a prior receipt, and the item's put-away location. The report also includes the vendor's number for the item for fast identification.
Serial Numbered Items
If you handle serial numbered items that you need to track starting with receipt, Freedom Series/ec21 prompts you to record the serial numbers during the receipt entry. You also have the option to record the serial numbers later.
Lot Controlled Items
When lot controlled items are received in Freedom Series/ec21, you are prompted to enter the lot number and other information about the lot including the expiration date if any. You can also indicate that more than one lot is being received and the quantity for each lot.
Items Canceled by the Vendor
If the supplier ships none or only a partial amount of the order quantity for an item, it is easy to indicate to the system that the balance is to remain on order or be canceled.
Backorder Pre-Release
If you choose, the receiving system will notify the receiver that backorders are pending for an item that is received. The receiver is given the ability to pre-release or allocate all or some of the just received quantity to pending backorders. This procedure insures that no new orders are allocated merchandise before any pending backorders.
Special Order Conditions
If the item received is a Special Order Item, Non-Stock Item, or a Warranty Return that has been repaired, Freedom Series/ec21 informs the receiver of the pending Sales Order that needs to be released. Special order conditions like these are associated with specific sales orders for specific customers. Freedom Series/ec21 ensures that the merchandise is handled correctly from the moment it hits the dock until it is delivered to the correct customer.
Receiving from your Customers
For many distributors, handling returns from customers, whether expected or not, is one of the most poorly handled functions in the warehouse. Freedom Series/ec21 is designed to allow you to bring discipline to this area or maintain the disciplines you now have in place.
Return Authorizations
In Freedom Series/ec21, the returns process normally starts with a Return Authorization. A Return Authorization lists the items that have been authorized for return, along with a disposition code for each item. A disposition code indicates to your people and to Freedom Series/ec21 how the merchandise is to be handled when received and how to account for the sales and cost dollars.
Freedom Series/ec21 has a special customer returns receiving function that allows you to check-in the merchandise received and informs you of the disposition of each item. The receiver, if it is your policy, can release the Return Authorization to the Freedom Series/ec21 Billing System for the issue of a credit to the customer.
Warranty Returns
Items returned to you for warranty repair can be temporarily located and then shipped to the vendor using the Vendors Return Function. There is a separate function in Freedom Series/ec21 for the receipt of these items back from the vendor when they are repaired and a special function for the reshipment of the warranty item back to your customer. It is important to note that Freedom Series/ec21 tracks serial numbered merchandise throughout this process.
Damage Goods Handling
Many distributors request that damaged merchandise be returned to them by their customers. This may be practiced because the merchandise can be returned to the vendor, to insure proper destruction, or just as a double check on the damage claim. Freedom Series/ec21 disposition codes will instruct your receiver on the proper action concerning damage returns, insuring that this merchandise is accounted for properly and does not end up back in your inventory.
Picking/Packing/Checking
The warehouse actions, supported by Freedom Series/ec21, associated with filling sales orders are discussed below. Freedom Series/ec21 is designed to give you the tools to control the release of sales orders to your pickers, to improve accuracy, and to increase productivity.
Immediate
Orders can be released immediately in Freedom Series/ec21. Most distributors who choose this option actually print the picking documents periodically, two or three times a day. Some distributors, however, have a printer set aside for picking documents and Freedom Series/ec21 prints the picking document as soon as an order is entered in the system.
After picking the order, the Shipment Confirmation function discussed below can optionally be used along with its Manifesting capabilities. You may, however, simply return the document to those charged with billing and immediately bill the order.
Bulk Pull
The Freedom Series/ec21 Bulk Pull feature gives you control of a high order volume operation and increases the productivity of your warehouse operation.
Order Selection
To begin the Bulk Pull, Freedom Series/ec21 lets you select the orders to be picked. All orders in the pool are eligible to become part of the Bulk Pull. You may select orders based on warehouse section, division and order priority. The result of the Bulk Pull release is the creation of Bulk Pull Sheets which are produced by warehouse section. Each sheet lists all the items to be picked, across the selected orders, in bin location order. Freedom Series/ec21 also creates an internal table that mirrors the Bulk Pull Sheets.
Bulk Sheet Sign On
When a picker is assigned a Bulk Pull Sheet to work, he checks out the sheet in Freedom Series/ec21 indicating the Bulk Pull Sheet number and warehouse section he is working. Your managers can view a display, whenever they choose, that lists all Bulk Pulls by warehouse section, the number of lines to be picked, the assigned picker and the current status of the sheet.
Bulk Sheet Sign Off
When the picker completes a Bulk Pull Sheet, he places the merchandise in a staging area. Then the picker indicates to Freedom Series/ec21 that he has completed the Bulk Pull Sheet and records the staging area information. Freedom Series/ec21 can display to your managers that the sheet has been completed along with the start and finish times, the elapsed time to complete the sheet, and the average lines per hour picked.
Since Bulk Pulls are divided by warehouse section, different pickers are normally working a Bulk Pull. When the last picker working a Bulk Pull 'Signs Off', Freedom Series/ec21 automatically produces the individual orders involved in the Bulk Pull to be used in Checking and Shipping.
Checking Orders
The checking process involves retrieving the merchandise from the staging area, separating it by sales order and checking the pick quantities. This can be done using the sales orders printed at the end of the picking step, by using an optional Freedom Series/ec21 On-line Checking function, or some combination of both.
The Freedom Series/ec21 On-line Checking function is designed as a bar code scanning process. When the checker indicates the Bulk Pull to be checked, Freedom Series/ec21 responds by displaying all the staging areas for the Bulk Pull. The checker can then start scanning, with a device attached to a terminal, either a UPC bar code on the item or a bar code that represents your item number. As each item is scanned, Freedom Series/ec21 displays a tote number in which the checker should place the item, one tote per order. Freedom Series/ec21 can catch over picks or wrong items picked using this method. Freedom Series/ec21 also informs the checker of items not picked that were allocated.
Wave or Route Pull
This method of sales order release is based on a wave/route assignment for each customer. A customer is assigned to one or more waves/routes. These assignments are normally made based on either your truck schedule or on the schedule of an outside delivery service.
Selecting Orders from the Pool
If you choose to use this method, early each warehouse shift you will indicate to Freedom Series/ec21 the wave you wish to release for picking. This wave can include one or more truck routes. In response, Freedom Series/ec21 selects the sales orders matching your request and prints them in warehouse section order. Within section, the orders are printed in truck route and stop order, if you are using your own trucks.
Released Order Status
When a wave is released for picking, Freedom Series/ec21 makes an entry in an internal table for each sales order/warehouse section combination. This table is updated when the picker completes working the order/section and when shipment confirmation for the order/section is completed. Your manager or loading supervisor can view this table to monitor the progress of the picking process.
Piece Types & Returnable Containers
If you use your own truck fleet, Freedom Series/ec21 has two other features that can increase your productivity and accuracy. The first is Piece Types, which refers to the standard terms you use to describe the boxes, cartons, bundles, etc. on your bill of ladings. These Piece Types are entered by the picker after picking an order and indicate how the order was packed. This information can then be used in loading the truck and by your driver to insure that the order is fully loaded and delivered.
The second feature is an extension of Piece Type. You can indicate to Freedom Series/ec21 that a particular Piece Type is a returnable container. Freedom Series/ec21 will then track when and to which customers returnable containers are shipped and when they are returned. This enables Freedom Series/ec21 to keep a running balance of returnable containers in the possession of a customer. Additionally, Freedom Series/ec21 can print on the delivery ticket/bill of lading the number of returnable containers your driver should or can pick up.
Picker Actions
Orders may be picked individually, broken by warehouse section or grouped through the Freedom Series/ec21 Bulk Pull routine. After the order is picked, checked and packed, the packer indicates to Freedom Series/ec21 how the order was packed by Piece Type and can request the number of shipping labels needed for the order. These shipping labels are printed immediately on a printer at the packing station, and normally display the wave/truck route information very prominently. The merchandise is then moved to the loading dock. The paper work goes to shipment confirmation and Freedom Series/ec21 updates the internal table indicating that picking has been completed for an order, section or bulk sheet.
Shipment Confirmation
The Shipment Confirmation step in Freedom Series/ec21 is optional. It is identical to the Billing function. All the features discussed below pertain to both Shipment Confirmation and Billing. Shipment Confirmation is used by those distributors who desire to bill and produce invoices in a batch manner but want inventory and shipment information updated when warehouse action on a sales order is completed or who wish to review each order, after shipment confirmation, before it is invoiced.
Although any sales order header or line item detail information can be updated during Shipment Confirmation, the primary purpose of Shipment Confirmation is to confirm the quantities of each item picked. This is accomplished by exception. Freedom Series/ec21 assumes the quantity shipped to be the quantity allocated and handles any backorders that need to be created. You just need to make changes for any exceptions.
Manifesting
If you are using an outside carrier or delivery service like UPS, it is during Shipment Confirmation that manifesting takes place. You can indicate to Freedom Series/ec21 the contents and weight of each carton. If the service being used for the order requires a tracking number, Freedom Series/ec21 prompts you to enter the tracking number. If the order is being shipped C.O.D., Freedom Series/ec21 produces the C.O.D Tags during this function. Based on the weights entered and the type of service, Freedom Series/ec21 calculates the cost of the delivery, C.O.D charges, A.O.D. charges, the cost of insurance, any discounts based on service (ground saver) and any surcharges for oversize items.
Bill of Landing/Delivery Tickets for your Trucks
Using Piece Type information entered by the packers and file information about DOT Hazardous Materials, Freedom Series/ec21 prepares a Bill of Lading or Delivery Ticket for each order being delivered. This document prints automatically when Shipment Confirmation or Billing for an order is completed. The document includes any returnable container information and piece, hazardous material and total weights. It is normally printed in two copies, one to leave and one to have the customer sign and return for your files. Work copies of the Delivery Tickets can be printed on demand in the warehouse, in truck and stop order, to use as a guide for truck loading. The loading supervisor can display on-line the picking status of each truck route and customer order within truck route to monitor the flow of goods to the loading dock.
Confirmation by Warehouse Section
Shipment Confirmation or Billing can be done by warehouse section. There is no need to bring the picking documents together in order to perform this task. Freedom Series/ec21 keeps track of each section as it is confirmed and closes out the process after the last section is confirmed.
Billing
Whether you use the optional Shipment Confirmation function or not, sales orders must be billed in Freedom Series/ec21 to update Accounts Receivable, General Ledger, Inventory, and produce an invoice. All the functions mentioned above in Shipment Confirmation can be accomplished during Billing. Whether you use both Shipment Confirmation and Billing, or just Billing alone, is your option in Freedom Series/ec21.
If RF packing or manifesting is used, you have the option of having Freedom Series/ec21 auto billing the order once the last package for the order is completed. Optionally the order can also be auto invoiced and the invoice printed for inclusion with the shipment.
Invoicing
Online Invoicing
If you choose on-line invoicing, Freedom Series/ec21 performs all the necessary updates and produces the invoice as soon as a sales order is billed. This method allows you to deliver the invoice with the shipment.
Batch Invoicing
If you choose batch invoicing, the Billing function places the sales order in a 'Billed' status. As often as you like, you can run the Batch Invoicing function. Batch Invoicing will produce invoices for all sales orders in a 'Billed' status. These can be sorted for easy handling by your mail room.
Warehouse Transfers
Warehouse transfers of merchandise in Freedom Series/ec21 are easy to accomplish while maintaining accurate inventory records. Freedom Series/ec21 includes special warehouse transfer entry, shipment confirmation, and receiving functions. Transfers can be entered for immediate action or can be flagged as pending. Pending transfers can be released when there are sufficient items for transfer between two warehouses to make the transfer economical.
Memo Inventory
One or more logical locations in Freedom Series/ec21 can be set as 'Memo' inventory locations. Transfers to and from a 'Memo' inventory location update a special perpetual inventory record for the 'Memo' inventory location. These transfer transactions can be associated with a salesman, vendor, or customer. This feature is most often used to track sample merchandise. You will always know, down to the individual, who has merchandise that you still own.
Logical to Physical Location Transfers
When entering a transfer, Freedom Series/ec21 allows you to specify the transfer as a complete transaction. In other words, Freedom Series/ec21 immediately updates the inventory records for both the shipping and receiving warehouses, and it does not expect shipping and receiving transactions to be entered. This feature is most often used to move merchandise from a logical warehouse where merchandise was held for quality inspection, for example, to the physical location that normally stocks the item.
Combined PO Transfers
Freedom Series/ec21 allows the buyer to combine the needs of several warehouses on one Purchase Order. The Freedom Series/ec21 database version of the P.O. includes the quantity being purchased for each warehouse to support the total on the P.O. When the item is received at the primary warehouse, Freedom Series/ec21 automatically sets up transfer pending records for each warehouse that was included on the P.O.
Physical Inventory
The Freedom Series/ec21 Physical Inventory System supports both full, wall-to-wall counts and product category counts. Freedom Series/ec21 prepares count sheets at your request. These count sheets can include the current on hand in the system if you desire. When Freedom Series/ec21 produces the count sheets, it also creates a mirror image of the count sheet in the Physical Inventory database. This mirror image is used to enter the counts. The entry of the physical counts is by exception, you only need to enter those counts that vary from the count displayed.
After the counts or inventory adjustments are recorded you can run reports or recount sheets to review those items where discrepancies were found.
The Paperless Warehouse
Freedom Series/ec21 allows you to perform warehouse functions electronically, eliminating paperwork, increasing accuracy and reducing operating costs..
The Freedom Series/ec21 Electronic Warehouse module includes many areas of the warehouse operation: Receiving, Picking, Package Assignment, Shipment Verification, Manifesting, Bin to Bin Transfers Item maintenance and Billing. You may elect to implement individual components allowing you to phase in changes to your operating procedures.
Item Scanning
For ease of use in throughout the RF panels entering items by scanning of UPC, item number and item aliases is supported. Freedom Series/ec21 supports multiple UPC per item unit of measure.
Receiving
Receipts can easily be scanned as they arrive at your dock, expediting visibility and availability of inventory. If your vendors are not bar-coding your product you can produce bar codes in advance using information provided on an Advanced Shipment Notice or produce them at the time of receipt. Print routines are also available for printing bar-coded bin labels.
Order Processing
Freedom Series/ec21 gives you the great flexibility in utilizing RF in processing your sales orders in the warehouse. You may find that some operations in your warehouse are more easily accomplished using 'traditional' methods while other tasks will benefit greatly from the addition of RF capabilities. Many of the options listed below can be done with or with out RF. Steps can be skipped or combined depending on your warehouse operating model. The users performing each of these steps will also be recorded for creating productivity reports.
Picking
Freedom Series/ec21 gives you the option to pick using RF. Items, quantities (along with serial numbers, if required) and locations are validated to give your picking the highest level of accuracy. If you are picking into shipping containers or cartons, that information may be scanned also.
Bulk items that do not require repackaging can be handled through the use of bulk pick labels that direct the picking of the item and act as the shipping label too.
Orders may be broken up, to allow multiple pickers to work on an order simultaneously.
Some variation of the Freedom Series/ec21 picking process allow the picker to pick multiple order simultaneously
Packing
Freedom Series/ec21 gives you the option to pack using RF. Items and quantities are validated as the packer indicates the packages that the items are packed to.
Manifesting
RF manifesting is done through scanning of the package ID. Freight charges, weight and tracking information are assigned.
Shipment Confirmation and Billing
Shipment Confirmation can also be expedited through the use of bar-coding. Users attach a package ID to a box, scan the ID and then begin scanning the picked items and placing them into the box. Upon completion of the shipment the system can automatically produce packing slips and shipping manifests. At your discretion the shipment confirmation can automatically release the order to Billing, providing you with an immediate print of the invoice.
Inventory Management
Many activities within the warehouse can be executed with the aid of RF, including:
- Inventory may be transferred within the warehouse
- Item units, UPC and dimensions can be maintained and updated
- Item and Bin labels can be printed
- Item Bin and Cycle Counts
- Item/Bin Inquiry
- Item Notes
- Picking
- Packing
- Manifesting
- Shipping Labels
- Receiving
- Put Away
- Let Downs
Back to Warehouse Management
