processing warehouse orders for pinnacle auto parts

Processing Warehouse Orders for Pinnacle Auto Parts

WelcomeWhy is this important?

Universal changed how it pulls orders for Pinnacle Auto Parts. We’re using different part numbers, different warehouse space, different paperwork, and different packaging. It seemed a good time for a different way to train our employees. This lesson should clarify what you have to do to complete an order for Pinnacle.

To get through this program, you just need the arrow keys shown here. They’re at the bottom right corner of your keyboard.

Left goes back. Right goes forward. Try pushing the right arrow now to go to the next page.

Introduction

What You’ll LearnThis lesson covers the entire order fill process from start to finish.You’ll Learn:

What Makes a Good Pallet

How to Pull the Order

How to Package the Shipment

How to Ship the Order

Introduction

What You’ll LearnThis lesson covers the entire order fill process from start to finish.You’ll Learn:


Building the Order



Introduction

Lesson GoalsAt the end of the lesson, you will process an actual order. You’ll demonstrate what you’ve learned to:

Pick a good pallet

Pull the correct parts with correct labels

Pack the order on a skid

Complete the paperwork

Inform the Shipping Manager You’re Finished


Building the Order



Introduction

Work from the Bottom UpYou will “build” an order from the bottom up. Think of a shipment like a house: it’s as strong as its foundation. Build on a strong foundation by choosing a good pallet.

So what makes a good pallet?






Pallet StructureRecall the parts of a pallet

Pallet Truck Openings

Forklift Openings

Stringer






Pallet StructureRecall the parts of a pallet

Top Board

Bottom Center Boards






A Good PalletA good pallet must have all of the following features:

4-Way Entry

Solid Stringers

Made from Hardwood

About 48” x 40” on top

7 Boards on Top

3 Center Boards on Bottom






A Good Pallet in Detail4-Way Entry

Solid Stringers

Made from Hardwood

Openings on all four sides so the pallet can be lifted by a pallet truck or forklift

No splits along the length of the stringer or chunks missing

No pallets built from plywood or non-wood materials






A Good Pallet in Detail (cont.)


7 Top Boards

3 Center Bottom Boards

The most common pallet size in the plant

7 planks running between stringers on the upper side of the palette

3 planks running between the middle of the stringers on the under side of the palette






The Perfect PalletDo you see all the required elements?

4-Way Entry

Solid Stringer

Made from Hardwood


7 Boards on Top

3 Center Bottom Boards

48”40”






A Bad PalletWhat is right and wrong with this pallet?

Right:4-Way EntryProbably the right size

Wrong:Made of PlywoodNo Center BoardsNo Bottom Center BoardsDoesn’t have Stringers






Pallet ExercisesRefer to your exercise manual. Answer problems 1-6. Do not click to the next slide until you have completed the exercises.

Did you finish problems 1-6? If so, click to the next slide to check your answers.






Pallet Exercise 1 AnswerIs this a good pallet? If it is not a good pallet, why?

Not a good pallet. It does not have 4-way entry.






Pallet Exercise 2 Answer

Not a good pallet. Does not have 4-way entry. It does not have three center boards on the bottom.

Is this a good pallet? If it is not a good pallet, why?







Not a good pallet. It has 4-way entry and is hardwood butOnly 6 of 7 top boards1 instead of 3 center bottom boards.








Not good pallets. Has 4-way entry but:Made of cardboard, not hardwood

Are these good pallets? If they are not good pallets, why?







Not a good pallet. It has 4-way entry, solid stringers, and is made of hardwood butDoes not have 7 top boardDoes not have 3 center bottom boards.







Pallet Exercise 6 AnswerWhat Makes a Good Pallet



How to Ship the Order Not a good pallet. It has 4-way entry and is made of hardwood

butIt only has 6 of 7 required top boardsIt has no bottom boards



Add up the number of exercises you got right. Did your reasons match the answers? Did you get all six right?

If not, take a few moments to review this section and make sure you understand why the pictures were examples of good or bad pallets.

If you got all six right, you’re ready to move on to pulling the order.






How Did You Do?

Pulling the OrderPinnacle will only order 86 possible part numbers for their stock orders.

Since Pinnacle requires special labels with their own part numbers, the 86 part numbers are located in a separate part of the warehouse and stocked by Pinnacle number.

Each Pinnacle number matches a location number. Your pick list will always sort part numbers from lowest location number to highest.

The map on the next screen shows locations.






Pulling the Order (cont.)

This is the map of the warehouse layout. Copies of this map are posted in the warehouse to help you find your way.






You will be given a pick list to use as a worksheet. The pick list, shown below, has a lot of information that you can ignore. When pulling the order, focus only on the quantity ordered and part number.

Qty. Ord. Shipped B/O

Part Number Description

Exchange Each

Core Each

Core Total

Ext. Total

5 5 0 1-165 RMFG CARB 5 5 0 10-325A RMFG CARB

7 7 0 10-344 RMFG CARB 5 5 0 10-345 RMFG CARB 5 5 0 14-107 RMFG CARB







You will start with the LAST number on the pick list and pull backwards in order until you reach the first number on the list. This is to keep the part numbers in ascending order on the skid.

To find the location of the last part number on your pick list, start at location 86, walk in the direction of the arrows on the map, and look for the Advance number 7-7587. In this case it is location 76.







Exchange Each

Core Each

Core Total

Ext. Total

1 1 0 9-222 RMFG CARB 3 4 0 9-224 RMFG CARB 3 3 0 9-226 RMFG CARB 5 5 0 9-75 RMFG CARB 7 7 0 7-7587 RMFG CARB



Once you have found the right location, your pick slip tells you to pull 7 carburetors with that part number. As you pull boxes, you need to verify three things:

Each box has two labels: Universal and Pinnacle.

The Pinnacle number on each box matches the part number ordered

The barcodes on the Universal and Pinnacle labels will scan with a barcode reader.







Label CheckEach carburetor box that you pull should have two labels, as shown below.

As you pull, check for:

Both Universal and Pinncle labelsClear barcodes – not smeared, broken, or rubbed offCorrect part number compared to location sign and pick slip






Label Check (cont.)Since Pinnacle scans everything they check in to their warehouse, you need to make sure the barcodes on the labels are clearly printed and complete.

This is a bad barcode because it is ripped and will not scan. Replace it with a new label.






Label Check (cont.)Both Universal and Pinnacle labels

Clear barcodes

The part matches the location sign and the number on the order

If both labels aren’t presentCheck for an “x” which means it needs a gasket. Pull one from the gasket area of the warehouseIf there’s no “x”, get a label.

If barcodes aren’t clear, get a new label printed

If it does not match, relocate the part to its correct location using the interchange provided.






Loading the PalletYou will load boxes into a cardboard gaylord on the pallet. As you load the pallet, stack boxes from back to front and left to right with all labels facing you. This will make it easier to keep track of what you already pulled.





This is a top view of the pallet showing the pallet loading order.


Loading the Pallet (cont.)What Makes a Good Pallet




As you stack boxes, insert a piece of cardboard about the size of the gaylord between the second and third layer to add support.

Then continue stacking until you reach five layers high. To ensure stability, no pallets will be loaded higher than five layers.


Once you have checked the labels, barcodes, and part numbers of all 7 carburetors for part number 7-7587, it is time to take notes on the pick list.

It is important that employees used standard notes. These notes communicate information to the office and other employees. Uniform notes reduce confusion and mistakes.





Notes on Your Paperwork


Notes (cont.)Once you’ve checked the labels, you need to take notes on the pick list.

Quantity PulledIf you pulled the entire quantity ordered, put a “-” next to the number in the “Shipped” column.If you pulled less than the entire quantity ordered, write the quantity you actually pulled and a “-” next to the number in the “Shipped” column.

Skid NumberIn the “Exchange Each” column, write the number of the skid that the part is packed on.






Notes (cont.)What Makes a Good Pallet




Lets see what the notes look like on the sample pick list below.



Exchange Each

Core Each

Core Total

Ext. Total

1 1 0 9-222 RMFG CARB 3 4 0 9-224 RMFG CARB 3 3 0 9-226 RMFG CARB 5 5 0 9-75 RMFG CARB 7 7 0 7-7587 RMFG CARB

Let’s say you were able to pull all 7 of the 7-7587. Then you would mark the paperwork as shown below.

On the next number, you were only able to pull 3 of the 9-75. Then you would mark the paperwork as shown below.

113-

-

Now let’s say there are no 9-226. You would not write anything in the “shipped” or “exchange each” columns.


Notes ExercisesRefer to your exercise manual. Answer problem 7-9. Do not click to the next slide until you have completed the exercises.

Did you finish problems 7-9? If so, click to the next slide to check your answers.






Notes Exercise AnswerWhat Makes a Good Pallet




7. How many total parts were pulled from this order?

8. Are there any mistakes in the notes? If so, where?



Exchange Each

Core Each

Core Total

Ext. Total

1 1 0 9-222 RMFG CARB 3 4 0 9-224 RMFG CARB 3 3 0 9-226 RMFG CARB 5 5 0 9-75 RMFG CARB 7 7 0 7-7587 RMFG CARB 1

1-4-

-1

2

21-

14

There should only be a “-” next to the 1 in the first row. The 2 in the “core each” column should be in the “exchange each” column. There should not be a skid number for the third row listed since no parts were pulled.


Notes Exercise AnswerWhat Makes a Good Pallet




9. Which part number would you expect to find on the bottom of the first skid?



Exchange Each

Core Each

Core Total

Ext. Total

1 1 0 9-222 RMFG CARB 3 4 0 9-224 RMFG CARB 3 3 0 9-226 RMFG CARB 5 5 0 9-75 RMFG CARB 7 7 0 7-7587 RMFG CARB 1

1-4-

-1

2

21-

7-7587


From Pick List toPacking Slip





Once you have the entire order pulled and your notes on the pick slip are complete, take the paperwork to the office. They will convert the pick list into a packing slip.

While the office is making the packing slip, you can move on to finalizing packaging for shipment.


Packaging the ShipmentWhat Makes a Good Pallet




EACH pallet shipped should be:

Tightly shrink-wrapped around gaylord to avoid shiftingLabeled with a “Mixed” sign and skid number

The LAST pallet in each shipment should:

Labeled with the white copy of the packing slip (the office keeps pink and yellow)


Packaging DetailsWhat Makes a Good Pallet




Using the shrink-wrap roll, tie the end to the pallet. Walk around the pallet clockwise several times, working from the bottom up. Pull tightly as you go. When you reach the top, tape the mixed and skid number signs to the pallet and shrink wrap over them. When all boxes are secured, cut the wrap and tuck in the loose end.


Packaging Details (cont.)What Makes a Good Pallet




Now that the order is pulled and packaged, it is time to notify the shipping manager that the order is ready to ship.

It is important to notify the manager immediately so that Pinnacle will receive the product as soon as possible.

The Shipping Manager will arrange shipping with a freight truck company and create the freight paperwork (known as a Bill of Lading). Attach the bill of lading to the packing slip.


Your role in final shipment is to make sure that the last pallet loaded on the truck is the one with the packing slip. That way, Pinnacle will have the paperwork as soon as they start unloading the truck.

Shipping the OrderWhat Makes a Good Pallet




Mixed1 of 3

Mixed2of 3

Mixed3 of 3Pack

Slip


Order CompleteWhat Makes a Good Pallet




Once the parts are on the truck, your done with the shipment.

Following the methods discussed here, you have done your part to ship carburetors correctly, quickly, and in good condition.

When Pinnacle receives the right parts in a timely manner and in good condition, it helps them sell our parts faster. The faster Pinnacle sells our products, the quicker they will reorder from us.

So you see that doing your job right every time really does make a difference. Keep in mind what you’ve learned as you work and let your manager know if you’d like to refresh your memory with this program in the future.

Ready To Try It Yourself?





You’ve come to the end of the lesson. Take a moment to assess how well you could process an Pinnacle order. If you need to, go back and review.

When you think you’re ready, inform the manager that you would like to pull a “test” order.

processing warehouse orders for pinnacle auto parts

Documents

good pallethow

good palletbuilding

good palletpull

good time

different way

entire order

actual order

common pallet size