Logistics Operations

Order Picking

Standard Operating Procedure

Logistics

Date: November 2015

Issue: Version 1.0

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 M.H. ALSHAYA CO. W.L.L

Retail Distribution Centre Picking SOP

Overview:
This document describes procedures to complete the processing of orders received in the DC and the picking
to fulfil those orders from stock on hand. This procedure provides all details to ensure that the picking
process is as efficient as currently possible, providing maximum outputs / highest KPIs.

Responsibility:
DC Manager, Shift Manager (outbound), WMS Manager, WMS Supervisor, WMS Super Users / Wave
Planners, Warehouse Supervisors (outbound), Team Leaders (outbound), picking teams:
The DC & Shift Managers are responsible for the releasing order waves and ensuring that the required
equipment for picking orders is fully available.
The picking team Supervisors and Team Leaders are responsible for ensuring that all picking team
members maintain the highest picking and accuracy rates. They are also responsible for ensuring that all of
the picking team are trained to fully comply with this SOP.
The WMS Manager / WMS Supervisor / Super Users are responsible for the correct configuration of the
WMS to ensure highest pick rates can be achieved.
The Wave Planners are responsible for analysing orders in the order well so that the outbound Shift
Manager / Supervisor (dependant on DC size) can be advised on the most appropriate picking method to
be used as well as the sequence in which each order should be released from the order well.
The training team are responsible for delivering training on the procedures in this SOP

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Standard Operation Procedure: Logistics Division DC Picking process:
1.0 Processing of orders and picking in the DC:
1.1 Activities undertaken:
1.1.1 Planning the picking method which each order will use
1.1.2 Planning the sequence in which orders will be released (waved).
1.1.3 Releasing the order waves
1.1.4 Picking orders using one of the following methods
1.1.4.1 Discrete order pick
1.1.4.2 Multi store pick
1.1.4.3 Bulk order pick

1.2 Equipment required for picking stock:

1.2.1 Always use any supporting MHE when available
1.2.2 Hand jack / pump truck for moving pallets (see appendix 1)
1.2.3 Pallet riders for moving pallets (see appendix 2)
1.2.4 Trollies for moving cartons / totes (see appendix 3)
1.2.5 There needs to be sufficient equipment to complete Picking
1.2.5.1 Cartons / totes (see appendix 4)
1.2.5.2 Trollies / carts for multi store picking (see appendix 5)
1.2.5.3 RF handsets & shoulder strap (see appendix 6)
1.2.5.4 Pallets for bulk orders / moving cartons / totes (see appendix 7)
1.2.5.5 Sortation tables for bulk picking (see appendix 8)

1.3 Housekeeping Standards:

1.3.1 The floor needs to be kept free of debris at all times

1.4 Pallet Heights:

1.4.1 Pallets of work in the picking / storage area must be a maximum of:
1.4.1.1 5 totes / cartons high OR 2.0 meters high

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 1.5 Moving Pallets:
1.5.1 When moving pallets with cartons / totes on they must be secured by shrink wrapping before
being moved (see appendix 10)
1.5.1.1 Even a single carton / tote on a pallet must be secured using shrink wrapping
ALWAYS ensure loads are safe and secure
1.5.2 Never use broken or damaged pallets. If a pallet is found to be damaged it should be removed
from use immediately
1.5.3 Pallet gates MUST be closed and secured immediately once pallets have been inserted /
removed. NEVER LEAVE PALLET GATES OPEN / UNLOCKED WHEN NOT IN USE
1.5.4 Pallets should not be broken down in front of open pallet gates. If you are required to work in
this area the gate MUST be locked and secured before starting work
1.5.5 Stock MUST never be left unattended in front of open pallet gates
1.5.6 Pallet gates MUST be closed and secured before you leave the area
1.5.7 Any open and unattended pallet gates must be reported to the Supervisor responsible for the
area immediately
1.5.8 Any damaged or defective pallet gates (including locks) must be reported to the Supervisor
responsible for the area immediately

2.0 Priorities:
2.1 By brand forecast:
2.1.1 The brand forecast will drive the primary resource requirement calculation
2.1.2 Achieving each brands outbound forecast is the first priority to apply when determining the
sequence for releasing orders from the order well
2.2 Storage type (by DC):
2.2.1 Type of storage solution should not be used to determine order picking priorities

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3.0 The role of Shift Managers:
3.1 Shift Managers or the designated supervisor (dependant on DC size) will control order picking
activities:
3.1.1 Ensuring that there is sufficient equipment for all picking activities
3.1.2 Ensuring that Supervisors and Team Leaders follow this SOP (listed below)
3.1.3 By meeting with Wave Planners on a daily basis to:
3.1.3.1 Decide which picking method will be used for each order
3.1.3.2 Agree the sequence orders will be waved
3.1.3.3 Identify skus which the inbound team need to process as a priority so
that skus can be picked immediately on becoming available
3.1.4 Directing Supervisors / Team Leaders to the orders they will be picking
3.1.5 Releasing of order waves in WMS throughout the shift

3.2 Resource planning:

3.2.1 Sufficient resource needs to be planned to match with forecasted picking volumes by shift:
Forecast volume of skus total units* / Agreed KPI (units per hour)
The length of shift in hours
= The required number of picking team members to fully meet work loads
*NOTE: Whole orders must be processed (do not plan to partially complete picks)
Additional supporting team requirements need to be added (i.e. move pallets etc.)
3.2.2 Expected KPI rates are to be found in section 13.0 of the SOP
3.2.3 When there is insufficient resource available the Shift Manager should:
3.2.3.1 Consider delaying picking certain orders if appropriate
3.2.3.2 Arrange for overtime to occur
3.2.3.3 Possibly use temporary staff (where an agreement to do so exists)
3.2.3.4 If the problem is a common occurrence discussions regarding
recruitment needs to occur to bridge the gap escalate to DOM

4.0 The role of the picking Supervisors and Team Leaders:

4.1 Training:
4.1.1 It is the responsibility of the Supervisors and Team Leaders to ensure that all members of the
team are fully trained and that a record of the training is kept (ALL new and existing team
members). NOTE: The training team deliver the training
4.1.2 Refresher training needs to be given any member of the team who fails to achieve the
minimum KPI rate (units per person, per hour) in the first instance

4.2 Monitoring the performance of picking team members:

4.2.1 Calculations need to be made for each member of the picking teams using accurate timings
and units processed data from the WMS system
4.2.2 All Picking team members need to be aware of their KPI rate (units per hour, by brand) and
their personal achieved processing rate (units per hour)
4.2.3 A board displaying individual performance (KPI rate, by brand) of all picking team members is
to be maintained (see appendix 10)
4.2.4 Calculation of KPI rates see section 13.0 for minimum acceptable

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 4.3 Maximising Output:
4.3.1 A Supervisor or Team Leader needs to be present at all times in the storage areas when picking
is being undertaken to ensure maximum KPI rates.
4.3.2 They need to continuously ensure that the SOP is being followed and that work rates are
maximised.
4.3.3 They need to ensure that members of the picking teams are continually occupied with work

4.4 Shift Preparation:

Supervisors & Team Leaders must ensure the storage area is prepared at the end of the previous
shift, so that work can start at the very beginning of the shift.
4.4.1 Stock of enough:
4.4.1.1 Spare cartons
4.4.1.2 Spare totes
4.4.2 Label the sortation tables used when bulk picking clearly with the required store numbers (see
appendix 8)
Additionally:
4.4.3 That personal KPI rates for the previous shift are being calculated and placed on the picking KPI
notice Board (see appendix 10)

4.5 During the shift:

Supervisors & Team Leaders must ensure:
4.5.1 There is sufficient pallets, cartons / totes for continuous efficient picking of orders
4.5.2 That full cartons / totes are sent for VAS / dispatch to stores as soon as possible

4.6 At the end of the shift:

Supervisors & Team Leaders must ensure:
4.6.1 There are no partially processed orders picking for all individual orders has been competed
4.6.2 Sufficient cartons / totes have been strategically placed around the storage areas to ensure
efficient picking on the next shift

5.0 The role of wave planning:

5.1 Wave Planners will:
5.1.1 Have an excellent level of WMS system knowledge
5.1.2 Have good levels of analytical skills and an understanding of the possible methods that can be
used to pick different orders
5.1.3 Be able to determine which picking method will ensure orders are processed with the highest
KPI rate

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6.0 WMS picking types to ensure the most efficient picking of orders, 3 different methods of picking
can be used in WMS:
6.1.1 Discrete order picking:
6.1.1.1 This is the picking method used most frequently in smaller DCs and
for small numbers of stores
6.1.1.2 Does not require any sortation of skus
6.1.1.3 Picking is done for a single store at a time
6.1.1.4 Use the following equipment:
6.1.1.5 RF Handset with strap
6.1.1.6 Trolley
6.1.1.7 Cartons / totes

6.1.2 Multi store picking:

6.1.2.1 Requires a bespoke picking trolley to be used during picking with
several slots for the different stores, this limits the numbers of stores combined
together in the pick
6.1.2.2 Used when the pick length of travel is high
Requires a level of commonality (small sku m3 = 60%+ medium sku m3 = 80 %+) of
the skus to be picked across the stores in the order
6.1.2.3 The segregation of sku units to individual stores is done during picking
6.1.2.4 Use the following equipment:
6.1.2.5 RF handset with strap
6.1.2.6 Multi store picking trolley
6.1.2.7 Cartons / totes

6.1.3 Bulk order picking:

6.1.3.1 Picking for many stores at a time
6.1.3.2 More commonly used in large DCs where orders are for large
numbers of stores
6.1.3.3 Involves two distinct steps: a picking step, then a sortation step
6.1.3.4 Requires a high level of commonality (80%+) of the skus to be picked
across all the stores included in the order
6.1.3.5 Use the following equipment:
6.1.3.6 RF handset with strap
6.1.3.7 Trolley
6.1.3.8 Cartons / totes
6.1.3.9 Sortation tables with store labels clearly visible

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 6.2 Factors influencing which picking method to use:
6.2.1 See the grid on the following page (Figure 1 on the following page)
6.2.2 Sku size (m3):
6.2.2.1 The physical size of the sku used to determine which picking method
will be to the category level (i.e. by brand / by category)
6.2.3 Number of Stores on the order:
6.2.3.1 Orders with more than one store, the number of skus in common to
the stores included in the orders will determine the type of picking
method to be used (multi store picking or bulk picking)
6.2.4 Type of order: (allocation & MINS replenishment) has an influence on the type of method to
be selected
6.2.4.1 MINS one to one replenishment orders often have low commonality
of skus across the order
6.2.4.2 Allocation orders often have high levels of commonality
6.2.4.3 Refer to section 7 if the combining of orders (allocation & MINS
replenishment) is being considered

7.0 Preparation with brands:

7.1 Prior permission from brands needs to be obtained if MINS replenishment and allocation orders
are going to be combined
7.1.1 Analyse which brands are likely to benefit from having their orders combined
7.1.2 SDOMs / DOMs will arrange agreement with the brands for combining orders
7.2 Agreement with brands needs to be obtained for stores which do not have a daily delivery to
have their orders saved and combined then picked in time to match their delivery schedule

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Picking method:
Discrete Order Picking: Multi Order Picking: Bulk Order Picking:
Is a form of bulk picking but with will require a dedicated area to
Will be used on the majority of
limited numbers of Stores separate the pick into store
occasions (85%-95%)
included in the order wave delivery containers
General:
Sku size (M3) Small, Medium or Large Small Small, Medium or Large
Minimum store number 1 store 2 stores 6 stores *
6 stores N.B. Picking Equipment is
Maximum store number None the limiting factor * None
Commonality of SKU's in the
order must be N/A Medium (60%+) or High (80%+) High (80%+)
Use for Replenishment Order most likely likely unlikely
Use for Allocation Order likely more likely most likely
Use for Replenishment Order
Combined with Allocation Order Most likely for High M3 most likely for Small M3 most likely
Order size Medium or High low High
Figure 1: Criteria of the different picking methods

limiting factors None av Sku per carton influences this None

Minimum Order / total units None 25 -100 500
Maximum order / total units None 50 -250 None
Pick length Small to Large Small to Large Small to Medium
Sku size (M3)
Category: Small Medium Large
Footware Yes Yes
Accessories Yes
Lingerie Yes Yes
Fashion Yes Yes - winter coats
Home Yes Yes Yes
Cosmetics Yes
* the picking equipment will determine how many stores can be picked for at a time
- a standard trolley will only allow space for two totes / cartons side by side
- bespoke trollies will allow for higher numbers of stores to be picked
8.0 WMS configuration:
8.1 WMS needs to be configured to allow all three picking types to be used
8.1.1 Liaise with the central WMS application team to enable all picking methods
8.2 A wave master template for each brand / picking type will need to be set up in advance within
WMS (see appendix 10)
8.3 For picking setting the work unit number within WMS to ideally 200 units as this generates the
highest KPI rates

9.0 DC specific data required for planning process:

9.1 Data to be maintained on a period basis to assist in determining picking method:
9.1.1 Having this data current and in a single folder / file will greatly speed up the analysis of orders
9.1.2 Brand Store list grouped / filterable
9.1.2.1 Categories supplied to the store (highlight exclusions if they occur)
9.1.2.2 Av. total units volume a day by day
9.1.2.3 MINS one to one replenishment Av. a day
9.1.2.4 Delivery schedules to stores
9.1.3 Brand category breakdown list of classes
9.1.4 Average skus per carton by brand, by category
9.1.5 The pick distance through storage by brand, by category (i.e. the number of aisles x aisle
length)

10.0 The wave planning process:

10.1 Orders containing skus received into DC SOH but awaiting put away:
10.1.1 Firstly run the WMS report Alshaya_WMS_SOH_Transfer to determine skus
that are currently unavailable in the storage, but which are received into the
dummy receiving area. (See appendix 11)
10.1.2 Highlight these skus to the receiving & put away team for immediate priority
Put away.
10.1.3 Ensure that the put away team informs the Wave Planners when these skus
Are put away into storage and are available to be picked.
10.1.4 Wave Planners can now advise the Shift Manager that the affected order(s)
Can be released NOTE: determine picking method as below.

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10.2 Analysis of orders:
10.2.1 Determining which picking method to use:
10.2.2 Discrete order picks are the most commonly used method (85%+)
10.2.2.1 Determine multi store picking and bulk order picking methods are not
suitable as soon as possible
10.2.3 Assess sku m3 is this a range or a consistent size across the order
10.2.4 Determine the range of stores across the order(s)
10.2.5 If it is likely that multi store or bulk picking methods will result in the highest
picking KPI (after checking the criteria of the order use figure 1)
10.2.5.1 Export the order details into excel
10.2.5.2 Add filters analyse how many skus are common across various stores.
10.2.5.3 Sorting will quickly highlight skus which are common to a number of
stores
10.2.5.4 Group stores in different ways to find those with commonality
10.2.6 It may be that some stores need to be excluded and picked as discrete order picks whilst the
majority can be picked using bulk order / multi store picking
10.2.7 Model combining MINS & allocation (where available) orders for the same brand / category is
there greater % commonality
10.2.7.1 If threshold for multi store or bulk order picking is achieved
recommend these picking methods to Shift Manager at the wave
planning meeting
10.2.8 Use WMS wave master templates as previously set up by brand / picking method type

10.3 The daily / shift wave planning meeting (For an example DILO see appendix 12):
10.3.1 Wave Planners and Shift Manager meet to confirm the shifts picking plan
10.3.1.1 The picking methods to be used for each order
10.3.1.2 Work units in the orders need to be ideally divided up into 200 units
10.3.1.3 The number of the picking team required to complete each order
10.3.1.4 Orders with skus requiring immediate put away have been identified
and inbound team requested to priorities and inform when complete
10.3.1.5 Calculated time to complete each order
10.3.1.6 Which orders will be potentially held
10.3.1.7 Recommendations for release
10.3.1.8 Agree when the next meeting will occur

10.4 Release of Orders from the well:

10.4.1 The Shift Manager will meet and go through the picking plan with Supervisors & Team Leaders
10.4.1.1 Agree which pickers will pick which orders
10.4.2 The Shift Manager will release the orders from the well
10.4.3 Supervisors will advise pickers which storage location area to go to
10.4.4 Supervisors will ensure that the sortation tables are configured for any bulk order picks
10.4.4.1 Store numbers are clearly labelled on the sortation table(s)

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11.0 Picking Process:
11.1 Preparation:
11.1.1 Ensure there are enough cartons / totes spaced regularly throughout the storage area
11.1.1.1 lowering the time taken to replenish these during the picking process
by placing them in a suitable position (i.e. aisle ends)
11.1.1.2 Replenish stocks of cartons / totes throughout the shift as required
11.1.2 Check any MHE used to move cartons / totes through the DC is operating
11.1.2.1 Use manual handling contingency if equipment is malfunctioning
11.1.3 There need to be enough RF handsets with shoulder straps for each picker
11.1.3.1 The RF handsets need to be fully charged (see appendix 6)
11.1.4 There need to be enough trollies for picking requirements
11.1.4.1 Standard trolley for discrete order picking and bulk order picking (see Appendix 3)
11.1.4.2 Bespoke trolley for multi store picking which has carton / tote sized
hoppers for between 2 and 6 stores (for examples see appendix 5)
11.1.5 Sortation tables are available for bulk order picking (see appendix 8)
11.1.5.1 The sortation table need to be clearly marked with the store numbers
11.1.5.2 There need to be enough cartons / totes available to meet the
requirement of the orders

11.2 Discrete order picking:

11.2.1 As per full instructions in (See Appendix 13)
11.2.2 The size of the work units in WMS ideally needs to be set at 200 units
11.2.3 Picker logs into RF handset & scans the nearest location barcode
11.2.4 WMS directs picker to a picking location (at the start of the picking route)
11.2.5 Picker opens carton / tote by scanning barcode
11.2.6 Picker selects the correct number of units enters number into RF handset
11.2.6.1 Short picks Supervisor confirms zero units in the location
11.2.7 WMS directs picker to the next storage location and number of units to pick
11.2.8 Once carton / tote is full picker closes it on the RF Handset and opens new Tote / Carton
11.2.8.1 Fill cartons / totes leaving 2 fingers width of space at the top
11.2.8.2 If VAS is to be applied fill cartons / totes leaving 5 fingers width of
space at the top
11.2.8.3 Ensure garment care standards by folding fashion skus carefully
before placing them in the carton / tote
11.2.9 Picker completes the full work order
11.2.10 Back to point 11.2.3 until shift ends

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11.3 Multi store picking:
11.3.1 As per full instructions in (See Appendix 14)
11.3.2 Picker logs into RF handset
11.3.3 Picker scans nearest location barcode
11.3.4 WMS directs picker to a picking location (The start of the picking route)
11.3.5 Picker opens carton / tote by scanning barcode
11.3.6 Picker selects the correct number of units enters number into RF handset
11.3.6.1 Short picks Supervisor confirms zero units in the location
11.3.7 Picker scans sku barcode and selects put to store option
11.3.7.1 Picker places correct number of units in carton / tote as directed by
RF handset
11.3.8 WMS directs picker to the next storage location and number of units to pick
11.3.9 Once carton / tote is full picker closes it on the RF Handset and opens new carton / tote
11.3.9.1 Fill cartons / totes leaving 2 fingers width of space at the top
11.3.9.2 If VAS is to be applied fill cartons / totes leaving 5 fingers width of
space at the top
11.3.9.3 Ensure garment care standards by folding fashion skus carefully
before placing them in the carton / tote
11.3.10 Picker completes the full work order
11.3.11 Back to point 11.3.3 until shift end

11.4 Bulk order picking:

11.4.1 Picking
11.4.2 As per full instructions in (see appendix 15)
11.4.3 Picker logs into RF handset
11.4.4 Picker scans nearest location barcode
11.4.5 WMS directs picker to a picking location (at the start of the picking route)
11.4.6 Picker opens carton / tote by scanning barcode
11.4.7 Picker selects the correct number of units enters number into RF handset
11.4.7.1 Short picks Supervisor confirms zero units in the location
11.4.8 Picker selects put to store
11.4.9 Picker places correct number of units in cartons / totes as directed by RF handset
11.4.10 WMS directs picker to the next storage location and number of units to pick
11.4.11 Once carton / tote is full picker closes it on the RF Handset and opens new tote / carton
11.4.11.1 One sku per carton / tote
11.4.12 Once trolley is full picker moves to the bulk order sortation area

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 11.4.13 Sortation:
11.4.14 Set the sortation table up labelling the store numbers clearly before picking commences
(see appendix 8)
11.4.15 Picker scans sku barcode and selects put to store option
11.4.16 Picker places correct number of units into cartons / totes as directed by RF handset
11.4.16.1 Fill cartons / totes leaving 2 fingers width of space at the top
11.4.16.2 If VAS is to be applied fill cartons / totes leaving 5 fingers width of
space at the top
11.4.16.3 Ensure garment care standards by folding fashion skus carefully
before placing them in the carton / tote
11.4.17 Picker goes back to point 11.4.4
11.4.18 Picker completes the full work order

12.0 Partial Pre Allocation Orders (for full details refer to the Partial pre allocation SOP):
12.1 Is the process of receiving picking & placing remaining stock into storage all at the same time
12.2 Orders for the required skus need to be interfaced at the same time as the ASN data is interfaced
12.3 To activate the picking the order needs to be run before any receiving has started
12.3.1 Use a pre allocation wave master
12.3.2 Once received the skus in the order wave are automatically cross docked to
the corresponding store locations
12.4 This will require an additional step to the receiving sortation process (Refer to the receiving / put
away SOP section 10.6)
12.4.1 After sortation of skus has occurred and as part of the receiving process
directed by the RF handset further sortation into store cartons / totes
12.4.2 There will be a need for additional cartons / totes in the sortation / receiving area

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13.0 KPI Rates:
13.1 The minimum acceptable units per hour KPI (by activity receiving / checking and putting away)
are shown below: figure 2
13.2 The KPI figures are a base starting point: they should be reviewed regularly and increased as the
receiver / checker and put away operatives performance improves
13.3 Supervisors and Team Leaders need to ensure that all their team members are achieving the
target KPIs
13.4 SDOMs and DOMs should review their target KPI rates monthly:
13.4.1.1 Once minimum acceptable rates have been achieved increases should
be considered
13.5 All KPI rates can be calculated using data available from the WMS system

Figure 2: Picking KPI rates

Picking KPI Rates Minimum Acceptable:
Sku Class Discrete Order Multi Store Bulk
Footwear 110 130 135
Fashion 160 175 200
Cosmetics 200 220 240
Picking KPI Rates Average:
Sku Class Discrete Order Multi Store Bulk
Footwear 140 160 170
Fashion 200 220 250
Cosmetics 250 275 300

14.0 Implementation:
14.1 To assist in implementation please use the self-audit checklist (see appendix 16)
14.2 Refer to Implementation briefing documents

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Table of contents
SECTION #3- APPENDIXES

APPENDIXES DOCUMENTS PAGE

Appendix-1 Hand Pallet Jack 18
Appendix-2 Pallet Riders 18
Appendix-3 Trollies for moving Totes & Cartons 19
Appendix-4 Totes & Cartons 19
Appendix-5 Multi Store Picking Trolley 20
Appendix-6 RF Handset & Shoulder strap 20
Appendix-7 Pallets 21
Appendix-8 Sortation table 22
Appendix-9 Colleague KPI rate display board 23
Appendix-10 WMS wave master template example 24
Appendix-11 WMS report Alshaya_WMS_SOH_Transfer 24
Appendix-12 Example single shift operation DILO 25
Appendix-13 WMS Discrete Store Picking process 26
Appendix-14 WMS Multi Store Picking Process 30
Appendix-15 WMS Bulk Picking Process 34
Appendix-16 Self-Audit Checklist 38
Glossary of common terms & abbreviations 40

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Appendix 1: Hand Pallet Jack

Appendix 2: Pallet rider

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Appendix 3: Trolley for moving Cartons / Totes

Dimensions 1.0 m long 0.65 m wide 0.9 m high

Appendix 4: Totes & Cartons
Totes:

Cartons:

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Appendix 5: Multi Store picking trollies

Appendix 6: RF Handset with Strap

The belt needs to have sturdy attachment clips

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Appendix 7: Pallets

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Appendix 8: Sortation Table Front View

Side View

Dimensions:
Width 2.45m
Depth 1.26 m
Height 1.04 m plus wheel height
NOTE: 12 LOGIX Cartons or 12 Totes will fill the table

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Appendix 9: Colleague KPI rate display board

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Appendix 10: Wave master template

Appendix 11: Alshaya_WMS_SOH_Transfer report

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Appendix 12: Example one shift operation DILO
WMS Super Users /
Inventory
Time: Inbound Activities: Outbound Activities WMS Activities Wave Planners /
Activities
Space Planners

Deliveries commence Orders Interfaces Start to analyse all

0600
with WMS orders
Space maintenance
activities
Dispatch Analyse all orders make
-consolidation
- " golden zone" recommendations for
0630 Deliveries Picking method to be
Sortation / receiving used and sequence for
release

Maintenance Picking Planning Picking Planning

0700
complete meeting meeting
Ensure that there is no
Sortation table Release first
0730 overlap of activities
preparation (Bulk waves
Deliveries -picking
picking)
Sortation / receiving -put away
Picking first wave -storage maintenace
0800 Put away in storage in
commences must be staggered
0830 which there is no
0900 picking
0930 Space
Storage space analysis
1000 configuration
1030
Picking wave 1
Sortation / receiving
1100 Prepare update for
Put away in storage in
inbound planning
which there is no Release second
1130 meeting
picking wave
Inbound planning
meeting
Sortation / receiving Picking second wave Inbound planning
1200
Put away in storage in commences meeting
which there is no
picking
1230
1300
Sortation / receiving
ASN download Plan shipment space
Put away in storage in Picking wave 2
1330 information requirements
which there is no
1400 picking

Assign space to
1430 Sortation / receiving Storage Storage area
Assign & exception sku's &
Put away in storage maintenance and consumable
unassign space to unassign space
preparation for replenishment
Prepare sortation / exception sku's asignments / resolve
1500 shipments VAS / dispatch
receiving area space issues

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Appendix 13: Wave Master Discrete Order Picking
Discrete Store Picking Process
A complete outbound process begins from order planning to load confirmation in warehouse in WMS. Pick files
are interfaced in WMS System or created manually by WMS Team (sometimes to support business). Forecast for
the business week is forwarded to Operation/support team by Help Desk and then operations work to achieve
that target and plan accordingly. Stores are prioritized on delivery by Fleet Team so that stocks delivery can be
managed.

Below is the STEP BY STEP process WMS Team follows from initial wave processing through to load confirmation.

Go to wave explorer select wave where we have pick files that are to be processed. Select any shipment &
add to wave Rep store Pick as shown in below followed screenshot

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 Rep store Pick as shown in below followed screenshot a wave will be created.

Once pick file is added to wave, Run Wave as shown below. As the stock gets allocated, wave comes under
complete wave. Release wave and click OK in confirmation window.

Once Release the wave then RF work begins and in Shipment Explorer load will be visible for that
shipment.
Log in to your RF Device and select WORK from next window.

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 Select your work type from below Work profile as Store picking. Press OK in 2nd window.

Below window will open where Location is visible, go to location scan item put qty and scan carton # in
required field.

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 Select Your cotainer Type as carton and press OK. In next window repeat same untill work completed.

As below Carton is created in shipment Explorer. Print essential Documents (Packing Lists & Zebra Label)
close carton and confirm load to dispatch stock.

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Appendix 14: Wave Master: Multi store picking.
Files are added in wave using wave master MULTI STORE PICKING as below. Process wave and work will be created.

Number of WORK UNITS is 656. Each work unit have unique location.

Now open your RF windows go to WORK and select Multi store picking from list. And press ok.

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 Below window will visible where location and total qty of work unit will visible. Go to location pick item put qty and
Carton# and press OK

NOTE: Item scan option should be visible in above window instead just pick from location.

In This window give qty carton #. Once item picked Next window will be Put away confirmation as below where
shipment ID is visible and required qty also. Just put required qty give carton and press OK.

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 After confirmation again Put away confirmation window will open for next Location.
This process will continue untill all picked qty segragated in desired locations.

Once all Put away is done again below window will visible Press OK and pick new WORK UNIT.

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 Then again segregation will start in Put away confirmation window where shipment ID is visible to put stock.

NOTE: Same Put away cartons can be used until qty. is full in it.

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Appendix 15
BULK PICKING PROCESS FLOW (Also for ECOMS ORDERS)

Interfaced 2 shipments for same store 105 with 2 item each.

Added both shipments to New wave [Bulk Pick Com] and released.

Select work profile Bulk Picking.

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System shows consolidated item Qty. From both shipments for Item 1 and Item 2 and was picked to Transport container
BLKTST1.

Select work Profile RF bulk Put away.

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Entered work Unit [Transport Container]:

Item1:MU43124
Total Requested and picked: 17
Put away screen shows split of items Qty. Based on shipments.

Item2:MQAV023 CARD
Total Requested and picked: 11
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Put away screen shows split of items Qty. Based on shipments.

Below Screen shot from Shipment explorer after picking:

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Appendix 16: Picking Self-Audit checklist
Score 5, 3, 2, 0r
Date: Country: DC Name: 1= correct 0 = Available
Coments: incorrect (see Score:
Audit Ref: Description: Measure: Yes / No /NA available score)
Equipment
1.2.4 Picking trolley present to spec Y/N 1
1.2.5.2 Multi store picking trolley present to spec Y/N 5
1.2.5.5 Sortation table present to spec Y/N 5
1.5 Housekeeping standards Floor clear of debris Y/N 3
1.4 Pallet heights Not exceeding specification limit Y/N 3
1.5 Moving pallets Pallets securely wrapped Y/N 5
Management
4.1 Picking method training All team members trained Y/N 5
A record of all team members training
4.1 Training records Y/N
kept 3
4.2.1 KPI rate calculated for all team members Y/N 3
4.2.2 KPI rate communicated All team members know KPI rate Y/N 5
4.2.3 KPI rate communicated KPI rate board in constant use Y/N 3
WMS Picking configuration
WMS configured to allow the three
8.1 Picking method configuration Y/N
picking methods 5
Wave master templates set up by brand WMS configured with wave master
8.2 Y/N
by picking method templates set up 5
Planning Data
9.1.2 Brand store list Available in a folder for wave planners Y/N 3
Store category lists and exclusions
9.1.2.1 Available in a folder for wave planners Y/N
highlighted 3
9.1.2.2 Total av. Daily volume Available in a folder for wave planners Y/N 3
9.1.2.3 MINS av. Daily volume Available in a folder for wave planners Y/N 3
9.1.2.4 Store delivery schedules Available in a folder for wave planners Y/N 3
9.1.3 Brand category breakdown Available in a folder for wave planners Y/N 3
9.1.4 Av sku's per carton / tote by class Available in a folder for wave planners Y/N 3
9.1.5 Pick distances by brand, by class Available in a folder for wave planners Y/N 3
Wave planning
figure 1 Orders analysed against criteria Wave planning occuring Y/N 5
10.1.1 WMS report report being run against orders Y/N 3
Inbound team prioritising missing sku's
10.1.2 Inbound team actioning priority put away Y/N
for put away 3
Analysis of orders to determine correct
10.2.1 Different picking methods identified Y/N
picking method 5
Daily / shift pick planning meeting
10.3 meeting taking place Y/N
occuring 5
10.3.1.1 Different picking methods suggested Different picking methods in use Y/N 5
Number of pickers required for an order
10.3.1.3 Calculate number of pickers needed Y/N
know 5
10.3.1.5 Calculate time needed for picking order Time required for order to be picked know Y/N 5

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Date: Country: DC Name: Score 5, 3, 2, 0r
1= correct 0 = Available
Coments: incorrect (see Score:
Audit Ref: Description: Measure: Yes / No /NA available score)

Preparation for order picking

11.1.1 Cartons / totes strategically placed Additional cartons totes available Y/N 5
11.1.2 MHE used to transport cartons / totes MHE in use Y/N or N/A 1
11.1.3 RF handsets have shoulder strap Present to spec Y/N 3
11.1.4.2 Multi store picking trolley used correctly Used for multi store picks Y/N 5
11.1.5 Bulk picking sortation tables prepared Store labels on sortation table Y/N 5
Picking
11.2 Discrete order picking correctly follow the WMS process Y/N 5
11.3 Multi store picking correctly follow the WMS process Y/N 5
11.4 Bulk picking correctly follow the WMS process Y/N 5
12 Partial pre allocation follow the SOP Y/N or N/A 5
Information
KPI rate achieved: Discrete order picking
KPI rate achieved: Multi store picking
KPI rate achieved: Bulk picking
KPI rate achieved: Partial pre allocation
Number of pickers in the team
TOTAL SCORE: 0
Shift manager Signature Shift manager TOTAL AVAIlABLE: 150
Self-auditor Signature Self-Auditor % rate: 0%
N/A items give the full score when calculating

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 Logistics operations SOP glossary of terms &
abbreviations:
Description:
Allocation Allocation order created by the brand team
ASN Advance Shipping Note
DC Distribution centre
DILO Day in life of (operational clock)
DOM Distribution Operations Manager
GRN Goods Received Note
LDC Local distribution centre
LP Loss Prevention
MHE Mechanical handling equipment
MINS One to one replenishment orders generated from store sales
m3 Cubic size (of a sku =height x width x depth) dimensions in cubic meters
RDC Regional distribution centre
SDOM Senior Distribution Operations Manager
Shroud Plastic film covering that protects products
Sku Stock keeping unit a single product
SOH Stock on hand sku amount data in WMS
UPMH Units per man hour
VAS Value added services
WMS Warehouse management system

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