Picking Operations

The Picking module handles single-order and wave picking workflows, guiding warehouse operators through optimized travel paths to retrieve reserved stock from storage bins.

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Picking Lifecycle & Business Logic

stateDiagram-v2
    [*] --> Pending : Order Confirmed (Stock Allocated)
    Pending --> InProgress : First Item Picked (Auto-Transition)
    InProgress --> Completed : All Lines Fully Picked
    InProgress --> Shortage : Partial Pick / Bin Shortage
    Completed --> Packing : Staged at Packing Station
    Completed --> ScanToDispatch : Direct Barcode Dispatch

1. Pick Sequencing & Path Optimization

• Aisle Travel Optimization: Pick lists are sorted sequentially by warehouse bin coordinates (Aisle → Rack → Shelf → Position) to minimize walking distance across warehouse zones.
• Bin Eligibility: The picker is directed strictly to pickable bin types (storage, pick, bulk) where is_unavailable = false and is_bonded = false.

2. Auto-State Transitions & Stock Ledger

• Automatic Status Transition: When an order is in Confirmed state, recording the first item pick scan immediately updates the sales order state to Picking.
• Perpetual Ledger Deduction: Registering a pick deducts the physical quantity from the storage bin and reclassifies it as staged on the picking cart.

3. Scan-to-Pick Barcodes & Hardware Integration

• Pick sheets and mobile scanners utilize the canonical barcode standard:

  PICK:{orderId}:{lineId}:{binId}:{quantity}

• Scanning the barcode validates the SKU and bin location simultaneously, preventing accidental fulfillment of incorrect items or batch lots.

4. Handling Bin Shortages

• If a storage bin contains fewer physical items than indicated:
  1. The operator enters the actual found count as a Partial Pick.
  2. The system flags a Bin Variance, prompting a cycle count adjustment.
  3. The unpicked balance remains open for fulfillment from an alternate bin or split dispatch.

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Step-by-Step Workflows

1. Picking an Order

1. Go to Inventory → Picking (/inventory/picking).
2. Select an assigned sales order from the queue.
3. Follow the guided sequence to the indicated bins.
4. Scan the Bin Barcode and Product SKU, then confirm the Quantity Picked.
5. When all lines are retrieved, click Complete Picking to transfer items to the packing station (or proceed directly to Scan-to-Dispatch).

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Field Reference

Field	Description
Sales Order	Target customer order being fulfilled.
Bin Location	Shelf/rack coordinate to retrieve items.
Quantity Required	Total allocated units requested on the sales order.
Quantity Picked	Confirmed physical units collected into the pick cart.
Barcode Payload	Encoded scan string (PICK:{orderId}:{lineId}:{binId}:{quantity}).
Status	Pick progress (Pending, In-Progress, Completed, Shortage).