Order Segregation Strategies in OTO PACK

In the world of warehouse management, effective order segregation is crucial to ensure accuracy and efficiency. In OTO PACK, segregation refers to the process of gathering items of a single order from a group of items that were picked together. For example, imagine a wave consisting of multiple orders that have been picked using a single trolley or a set of trolleys; segregation ensures that these items are correctly allocated to their respective orders.

OTO PACK offers two primary ways to perform order segregation:

1. Sorting

2. Segregation via Packing Pilot during Packing

Sorting in OTO PACK

Sorting is a structured process designed for efficient segregation in warehouses that have a dedicated Sorting Station. This area includes physical spaces for Sorting Bins, where items from individual orders are placed after sorting. Below are the steps involved in sorting:

Steps for Sorting:

1. Activating Sorting in Waves
   When creating waves, ensure the Sorting Needed toggle is activated. This marks the wave for sorting after picking is completed. Screenshots are shared below both for “Create Wave” and “Create Zone Picking Wave”

2. Navigation to Sorting Stations
   After the picking process is completed for the wave, the system automatically directs the picker to the Sorting Station to place the picked items. Packing status will be updated as “Picked” and Sorting status will be “Ready for Sorting”

3. Scanning Items at Sorting Station
   Warehouse staff responsible for sorting will scan the items brought to the Sorting Station. The system identifies which orders include the scanned item and assigns a Sorting Bin to the order if not already assigned.

4. Placing Items in Sorting Bins
   The sorting staff places the scanned items into the respective Sorting Bins, completing the sorting process for those items.

5. Finalizing Sorting
   Once all items for the orders in the wave have been sorted, the order status becomes ready in the Sorting/Empty page. These orders can now be moved from the Sorting Bin to the Packing Station, where they are ready for packing. When all items have been sorted; Sorting Status is updated as “Sorted”

6. Move to Packing Station
   Select the orders you would like to transfer to the packing stations. Click on Move button on the center. A pop up will appear and lists the packing stations available. After packing station is selected and saved; all bin inventory w    ill be transferred to the selected packing station. Sorting Status will be updated as “Ready For Packing”. The orders will start appearing in Pack Page after this action.

Advantages of Sorting:

• Optimizes segregation for waves with multiple orders.

• Reduces errors in packing by ensuring items are pre-grouped.

Segregation via Packing Pilot during Packing

For warehouses that do not use Sorting Stations, segregation can also be performed directly in the Packing Pilot page during the packing process. This method offers flexibility and eliminates the need for a dedicated physical space for sorting.

Steps for Packing Pilot Segregation:

1. Navigate to Packing Pilot
   Go to OTO PACK → Operations → Packing → Packing Pilot to access the segregation tool.

2. Filter and Select Orders
   Use filters such as warehouse, wave ID, or specific items to locate the group of orders for segregation.

3. Scan Items
   Scan items one by one. The system automatically calculates match rates for the orders that include the scanned items. Select order from the list.

4. Pack Orders Individually
   After selecting the order, continue the packing process as usual. Scan remaining items (if there is), create shipment (if not created before), scan AWB and complete packing.

Advantages of Packing Pilot Segregation:

• Eliminates the need for physical sorting stations.

• Provides a dynamic and flexible segregation option.

Choosing the Right Strategy

The choice between sorting and segregation via packing depends on your warehouse's layout, available resources, and operational goals:

• Sorting is ideal for high-volume warehouses with dedicated physical spaces.

• Packing Pilot Segregation works best for warehouses without sorting stations or for ad-hoc segregation needs.

By leveraging these order segregation strategies in OTO PACK, warehouses can ensure smooth operations, minimize errors, and boost efficiency in order fulfillment.