aberon PREPACKER

The aberon PREPACKER application is an avant-garde expansion of aberon WMS that turns the activities relevant to the execution of client orders from reactive processes into proactive processes. This means that, by using aberon PREPACKER, each client order, after being processed, acquires a specific and predetermined structure. Thus, for each order, even before it is picked, the system knows the number of whole pallets, the number of whole cartons and the cartons of mixed content. For each mixed-content carton, the system knows its content in pieces. The a priori knowledge of the order's structure is useful for routing the order and picking the order using other order picking systems, such as voice picking, pick cart, pick-by-light etc. The aberon PREPACKER algorithm is based on complex stereoscopic algorithms formed by Operational Research.

The procedure is as follows:
The orders transferred by ERP via interface to aberon WMS are grouped per client or remain autonomous and are forwarded to aberon PREPACKER for processing. The aberon Prepacker's function is performed automatically or by order waves via a scheduler, or by the user executing the PREPACKING process on selected client orders.

aberon PREPACKER executes the following processes:
1) Split : Each order line belonging to one client order or order group is split into whole pallets, whole cartons and cartons of mixed content (where the order quantities not filling a whole carton are placed)
2) Pre-packing: For order quantities not filling a whole carton, the aberon PREPACKER pre-packing algorithm decides upon which items will be put in which carton. Each mixed-content carton is attributed a unique ID. The algorithm pre-calculates in advance which item is to be put in which packing carton. The pre-packing process takes into account the items' dimensions and weight, the packing cartons available per picking zone, the requirement of vertical placement and the preference for a special carton for the specific item. For aberon PREPACKER to be used in the picking process, it is necessary to comply with the items' parametrical data regarding the dimensions and weight of item pieces and cartons. Other additional information in the item's card is the sign that an item has to be placed in a vertical position and the sign of whether an item is self-packed. The system's parametrical data define the packing cartons, the external and internal dimensions, the weight of an empty carton, as well as which packing carton is to be used in which picking zone.
3) Delivery Service Pre-Palletization: Based on the total number of cartons (whole and mixed ones) and their dimensions, the application performs palletization at delivery service level. For each delivery service, the system calculates the number of pallets required using numbering [Delivery Service / Pallet Serial Number], as well as the content of each delivery service pallet for the order cartons it contains. The Delivery Service Palletization process sees to it that all cartons of an order are on the same pallet. If an order exceeds one pallet, then this order will be placed alone on its own pallets.
4) Label Printing: The order officer, after overviewing the pre-packing and the pre-palletization processes, prints the following carton labels:
- Whole carton or pallet labels
- Labels of mixed cartons on different batches:
- Mixed carton labels
The labels are printed in a heat transfer printer.
5) Delivery Service Pallet Label Printing: For each Delivery Dervice pallet, the particulars of the Delivery Service's pallet and the content of the cartons per client are printed.

The labels of whole-content cartons contain the following data:
- Carton ID
- Date
- Order particulars
- Client particulars
- Item reference and description
- Picking point
- Item lot
- Delivery Service reference and description
- Serial number of Delivery Service pallet, where the carton will be placed
- Serial number of carton from total cartons of the order
- Weight of whole carton

The labels of mixed-content cartons contain the following data:
- Carton ID
- Carton type
- Date
- Order particulars
- Client particulars
- Sign of whether the carton contains only pick-by-light zone items
- Picking and pick-by-light zones which the carton will pass through
- Delivery Service reference and description
- Serial number of Delivery Service pallet, where the carton will be placed
- Serial number of carton from total cartons of the order
- Hypothetical carton weight (net and dead weight)