Order Fulfillment Procedures

Physical Inventory Counts
Order Import
Selection of Inventory
Picking Orders and Bill of Material Processing
Verifying/Quality Checking Orders
Packing
Shipping

Physical Inventory Counts

Operators print Inventory Count forms containing areas for recording location, product number, quantity, description, lot/batch number, and unit of measure.

One Inventory Count Form is physically attached to each location.

Orders in the warehouse that have been selected (inventory allocated to them) for picking are picked, and confirmed.

Inventory items being counted are "frozen" by setting the Inventory Freeze flag on all products. (This automatically stops inventory from being allocated to orders during counting.)

As items are counted, the operator records the location, product number, description, quantity counted, and the unit of measure (case, each, drum, etc). This is done until all items have been physically counted and recorded on the count sheets.

Using the COREflex™ product lookup screen and the count sheet, the operator looks up the quantities on COREflex™ and compares it to the counted quantity.

If quantities match, the count sheet is approved and no adjustments are made.

If the counts do not match, a recount can be performed or if the variance is acceptable, an Inventory Count adjustment is made using the Physical Inventory Adjustment screen.

COREflex™ inventory reduces or increases inventory to the adjusted location as requested and history records are updated to reflect the activity for tracking purposes.

After all adjustments are completed, all inventory items are "un-frozen" and inventory allocations for order picking automatically resume.

Order Import

Invoices / Orders are entered into QuickBooksPro™ and are marked as pending.

Using COREflex™ Import, all pending invoices are electronically transferred to the COREflex™ database.

COREflex™ maintains copies of the pending QuickBooksPro™ invoices. These invoices are called Customer Orders in the COREflex™ system.

History records are updated to reflect the activity for tracking purposes.

Selection of Inventory

Using COREflex™ Selection, the operator initiates the inventory allocation process that will select the bins from which each item will be picked.

During this process, all order items are compared to the inventory quantities and locations maintained in the warehouse.

As inventory quantities and bins are found sufficient to pick an order complete, COREflex™ allocates the inventory to the specific order.

If there is not sufficient inventory for an order, the order goes back into the queue and waits for the next time the Selection process is run.

History records are updated to reflect the activity for tracking purposes.

Picking Orders and Bill of Material Processing

Using COREflex™ Picking, one pick sheet work order is printed for each order that contains product numbers, quantity to pick, descriptions, units of measure, and inventory locations of each item to be picked. USPS shipping labels are also printed.

Items are printed on the pick sheet in the most efficient walking sequence in order to minimize the time required to pick an order.

Guided by the picking sheet, operators walk to each bin and physically pick the items from inventory as indicated on the pick sheets. As each item is picked, the operator "checks-off" the item on the pick sheet.

Using COREflex™ Picking Confirmation, the operators enters the order number and the system displays the order header and detail information.

Lot control and batch control specific information is entered into the comment field for later reference if required.

If all items have been picked complete, the operator clicks the "Pick Complete" button and the system accepts all quantities to pick as the quantity picked.

If an item has not been picked complete, the operator selects the specific line item and enters the actual quantity picked.

Upon completion of entering all short picks, the operator clicks the "Pick Complete" button and the system accepts the short picked quantities that were entered as the quantities picked.

At this point, COREflex™ inventory reflects all items and quantities picked as being removed from picking locations and added to the individual customer's order.

History records are updated to reflect the activity for tracking purposes.

The order pick sheet is forwarded to accounting for use in updating Quick Books Pro ™.

Using the QuickBooks Pro™ invoice screen, the invoice is retrieved by the book-keeper by entering the invoice number. The order is then recorded as being shipped for accounting purposes. Picking comments can be entered into the memo for the customer to see.

Verifying/Quality Checking Orders

QC operators visually compare the product picked to the items on the order pick sheet. As each item is verified, the operator "checks-off" the item on the pick sheet. If an item is not correct, the operator indicates this by circling either the quantity or item number.

After all items have been verified, the operator uses the COREflex™ Order Status Update screen to enter the order number. The system displays the order header and order detail information.

If all items are correct, the operator clicks the "Verified" button and the system changes the orders status to Verified.

If all items are not correct, the operator clicks the "Verification Failed" button and the system changes the orders status to Failed Verification.

Orders failing verification are manually corrected and any inventory adjustments are made using the COREflex™ Inventory Adjustment Screen.

Once corrected, the order can be processes through Verification again.

History records are updated to reflect the activity for tracking purposes.

Packing

Packing operators physically pack the items for shipment.

After all items have been packed, using the COREflex™ Order Status Update screen, the operator enters the order number and the system displays the order header and detail information.

The operator clicks the "Order Packed" button and the system changes the orders status to Packed.

History records are updated to reflect the activity for tracking purposes.

Shipping

Shipping operators tape the carton and apply the pick-sheet shipping label to the carton.

Using the COREflex™ Order Status Update screen, the operator enters the order number and the system displays the order header and detail information.

If barcode labels are required, the operator prints them at this time and applies them to the shipping carton.

Once shipped, the operator clicks the "Order Shipped" button and the system changes the orders status to Shipped.

History records are updated to reflect the activity for tracking purposes.