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1. Operations Training
SBISA, LLC
Grand Rapids, Michigan

2. WCS Training Syllabus
 Introduction Training
 Date/Time: Monday, November 28th
 Shift 2: 12:00PM –2:00PM
 Shift 1: 2:30PM - 4:30PM
 Attendees: Managers, Supervisors
 Training Location
 Start in training room
 Move to Pick Module for tour
Monday 11/20/2004 2

3. Who’s Who
 Who are the players and what do they do?
 SBISA, LLC
 Conveyor and Controls
 Grand Rapids, Michigan
 PCC
 Lightning Pick PTL
 Germantown, Wisconsin (Milwaukee Area)
 QC Software
 Warehouse Control System (WCS)
 Cincinnati, Ohio
Monday 11/20/2004 3

4. Agenda
 Terms
 Conveyor Control Overview
 Warehouse Control System Overview
 WCS Order Processing
 Carton Induction
 Zone Routing
 P3 PTL Picking
 Jackpot Area
 Batch Order Picking
 Batch Pick/Sort
 Pack Induction
 QC Operations
 Fill & Seal
 UPS Station and Shipping
 Questions
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5. Terms
 Lots of new Terms
 Ask Questions about any term not
understood?
 Glossary of Terms in handout
Monday 11/20/2004 5

6. Conveyor Controls Overview
 Control Panel
 Big grey box under platform
 System Start
 System Stop
 Reset
 Emergency Stop
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7. Warehouse Control System
 Warehouse Control System (WCS)
 PC Server in Computer Room
 Runs background programs
 Hosts WCS Database
 WCS screens accessible from selected PCs
 WCS Security
 Requires Username and Password
 Must be setup by administrator on WCS
 Access granted to user by menu, screen and/or
function
 Templates available
 (Supervisor, Carton Inductor, etc.)
Monday 11/20/2004 7

8. WCS Order Processing
 Orders Allocated to Pick Lines on Epicor
 P1/P2 Orders pulled into PTL (P1/P2 PTL Server)
 P3 Orders pulled into WCS
 Single line orders
 Batched together by SKU
 Cartonized to one or more totes (Large and Small)
 Carton Labels generated for each tote
 Multi-line Orders
 Cartonized by order into one or more cartons based on
defined SKU dimensions and defined box dimensions.
 Carton labels generated for each carton
Monday 11/20/2004 8

9. Carton Induction
 Cartons Erected and bottoms taped
 Bubble wrap added to bottom of carton
 Carton Labels applied to carton
 Size Requirement on carton label
 Carton placed on P3 conveyor line
 Carton Label Printing Controls
 Reprint Labels
 Start/Stop Label Printer
 Other Advanced Features
 Ship Alones
 Different Label Format
 Labels delivered to pick zone
Monday 11/20/2004 9

10. Zone Routing
 Pick Module Transfers (5)
 Carton Id Barcode Scanned
 Route Determination
 Left, Right, Straight
 Based on assigned pick locations
 Picks sent to PTL when carton divert
confirmed
 Standalone picks are sent to PTL when
carton id label is printed.
Monday 11/20/2004 10

11. P3 PTL Picking
 After Carton/Tote diverted to zone
 Zone is called area on PTL
 Scan Carton Id to Launch
 Using wireless scanner associated to zone
 Bay lights and location lights operate just like P1/P2
 Place carton back on conveyor when picks complete
in area
 Carton goes back to same transfer for next route
determination (left, right, straight)
 Order Confirmed when last pick for last carton
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12. Jackpot Area
 Zone 10 is Jackpot Area
 Transfer Left at Transfer #5
 No Reads
 No Reads
 Missing Picks
 Zone Full
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13. Batch Order Picking
 Single line orders grouped into batches by SKU
 Batches are cartonized to Totes (Large/Small)
 Totes Inducted and Routed to Zone containing picks
 By definition these totes will only go to one area (picks
for only one SKU)
 Use PTL to pick required quantity to satisfy all orders
in the batch.
 Place tote back on conveyor
 Tote delivered to Batch Pick/Sort Area for processing
Monday 11/20/2004 13

14. Batch Pick/Sort
 Select red totes from conveyor
 Scan Carton Id (from tote label)
 Tote contains only 1 item for multiple orders
 Packing Lists generated for each order
 Pack content to carton (or bubble pack) and insert
packing list.
 Apply carton id label from packing list to shipping
container
 Required for scanning at UPS Station
 QC Requirements?
 Carton ready for manifesting
Monday 11/20/2004 14

15. Pack Induction
 Scan Carton Id
 Contents List printed for each carton
 Packing List printed for last picked carton for
order
 Place Documents in Carton
 Carton Ready for QC
Monday 11/20/2004 15

16. QC Operations
 Compare contents of carton to printed carton content list
 Exception Conditions
 Missing Product
 Replace with product from pick location
 Pick was confirmed otherwise carton would be at jackpot
 Excess Product
 Remove excess quantity and replace in pick location
 Right quantity was confirmed in PTL
 Wrong Product
 Remove wrong product to assigned pick location
 Picker confirmed the proper quantity from the assigned pick
location but either picked from wrong location or placed into
wrong carton
Monday 11/20/2004 16

17. Fill & Seal
 Add craft paper and insta-foam as required to
protect carton contents
 Seal carton
 Run through semi-automatic taping machine
 Carton delivered to UPS Station
Monday 11/20/2004 17

18. UPS Station and Shipping
 Place carton on scale
 Scan carton on UPS World Ship station
 Shipping Label printed and applied
 Carton delivered to shipping
 Shipping
 Manual segregation process
Monday 11/20/2004 18

19. Questions
 Questions!!!
 Tour
 More training tomorrow
Monday 11/20/2004 19