PRODUCTION INVENTORY … INVENTORY SCANNINGPRODUCTION INVENTORY SCANNING SCANNING ... PROCESS...

PRODUCTION INVENTORYPRODUCTION INVENTORYPRODUCTION INVENTORYPRODUCTION INVENTORY SCANNING SCANNING SCANNING SCANNING

G L O B A L B A K EG L O B A L B A K EG L O B A L B A K EG L O B A L B A K E

PREPARED BY:PREPARED BY:PREPARED BY:PREPARED BY:GLOBALBAKEGLOBALBAKEGLOBALBAKEGLOBALBAKE

1 DECEMBER 20071 DECEMBER 20071 DECEMBER 20071 DECEMBER 2007

Production Inventory Scanning

WWW.GLOBALBAKE.COM PPPP AAAA GGGG EEEE 2222��

CONTENTSCONTENTSCONTENTSCONTENTS

INTRODUCTIONINTRODUCTIONINTRODUCTIONINTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . 3333

OVERV IEWOVERVIEWOVERVIEWOVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4444

SOLUTION DEL IVERYSOLUTION DEL IVERYSOLUTION DEL IVERYSOLUTION DEL IVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 6666

SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

HARDWARE .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

HANDHELD DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

COMMUNICATION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

PALLET BARCODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SCANNING STATIONSSCANNING STATIONSSCANNING STATIONSSCANNING STATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 8888

PROCESS STEPSPROCESS STEPSPROCESS STEPSPROCESS STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . 9999

PALLET PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

FROM FREEZER TO L INE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

PRE FREEZER PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

LOAD OUT .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

PALLET LABELLING .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

PALLET CHANGE .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

INTERNAL PROCESS ING .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

TRUCK MANAGEMENTTRUCK MANAGEMENTTRUCK MANAGEMENTTRUCK MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . 13131313

FRE IGHT COMPANIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

TRUCK LOAD SHEETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

REPORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

P ICK SHEETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

LOAD SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

B ILL OF LADING .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

FUTURE OPTIONSFUTURE OPTIONSFUTURE OPTIONSFUTURE OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . 19191919

RF ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

PALLET BARCODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

WAREHOUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

INWARDS GOODS .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

AWARAWARAWARAWAREHOUSE LOADING PROCEEHOUSE LOADING PROCEEHOUSE LOADING PROCEEHOUSE LOADING PROCE SSSSSSSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20202020

BTRANSFER BETWEEN PABTRANSFER BETWEEN PABTRANSFER BETWEEN PABTRANSFER BETWEEN PA LLETS PROCESSLLETS PROCESSLLETS PROCESSLLETS PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . 23232323

CPICK AND LOAD PROCECPICK AND LOAD PROCECPICK AND LOAD PROCECPICK AND LOAD PROCE SSSSSSSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . .. . . . . . . 26262626



INTRODUCTIONINTRODUCTIONINTRODUCTIONINTRODUCTION

GlobalBake is extending the use of the inventory facilities to include inventory control

through a scanning interface.

The purpose of having improved inventory control is to reduce the difficulties that

occur when production line output, stock in and stock out number do not agree. If the

confirmation of production is not correct the line efficiency may be compromised, if

stock in the warehouse / freezers is not accurate then inventory is uncertain.

Uncertain inventory may mean failure to deliver customer orders which will be

detrimental to their perception of service levels. Additionally errors in inventory may

lead to financial imbalances relative to the value of stock held.

This document outlines the changes and processes being proposed to allow efficient

flow and accurate recording of inventory. The last section covers some options that

will be considered as later extensions, or valuable advantages, to the implementation.



OVERVIEWOVERVIEWOVERVIEWOVERVIEW

In order to achieve efficient inventory control a simple and effective way of tracking

inventory movement needs to be available. The processes outlined in this document,

which are supported by GlobalBake, will improve the ability to perform product recall

in the event of any contamination issues.

Alternative methods for identification of inventory have been considered and this

proposal is based on a barcode scanning solution for pallets of goods. RFID tagging of

pallets was considered and rejected due to the cost of the associated tracking devices

(chips) if they were sent to customers as well. The future section at the end of the

document proposes that pallets may be RFID tagged to allow some automation of stock

taking procedures.

Conceptually there is one entry point to inventory (from the production lines) and one

exit point (to transport) from inventory control. It is at these two points that the initial

focus of improving inventory control is focussed.

To track product that is to enter inventory a scan is made prior to entry into the

freezers. This scan will also be used to confirm production for the shift which will

improve the accuracy of data recorded at this point and will help to track production

efficiency.

The other scanning point in the system will be at the point of exit to transport for

delivery to customer premises. At this point the transport device and purchase order

are known and will be recorded against the pallet as it exits. Cross checks can be done

at this time to ensure that the scan is appropriate, for example that the pallet’s

contents are appropriate for the Customer / Purchase Order being transported. This is

the point that inventory will be debited with the items on the pallet.

Samples removed from a pallet will continue to be processed as orders from a customer

and accounted for in that manner. The final destination of samples will need to be

recorded by the shipper / deliverer of those items to their final real address for recall

compliance.



SOLUTION DELIVERYSOLUTION DELIVERYSOLUTION DELIVERYSOLUTION DELIVERY

S O F T W A R ES O F T W A R ES O F T W A R ES O F T W A R E

The scanning solution will be delivered in a browser based format. Whilst this format is

not as rich as a more specifically written application it allows faster change, requires

no software on the handheld device and can subsequently be implemented in a quicker

timeframe.

The use of this technology, in conjunction with suitable handheld devices, will allow for

future development to be created that can enhance the interface. This can be done on

an as needed / required basis.

H A R D W A R EH A R D W A R EH A R D W A R EH A R D W A R E

H A N D H E L D D E V I C EH A N D H E L D D E V I C EH A N D H E L D D E V I C EH A N D H E L D D E V I C E

The chosen handheld device must run Windows Mobile 5 or later to support a future

option of Jade based application in subsequent developments. These JADE facilities

will be possible in late 2007 with new releases of the JADE software underlying

GlobalBake.

− The device must support a Microsoft Internet Explorer compatible browser

which will be the target environment for the solution. With Windows Mobile

5 this is implicit.

− A communications interface must be supported to allow the internet browser to

connect in real time to the GlobalBake solution.

− The device must be able to scan a barcode and place the data into a browser

field and enter or tab to the next field on the form. The action required to

submit a completed form to the server must be easy to be carried out in a

freezer environment e.g. possible for an operator wearing gloves.

− The device must be able to scan over a distance that is appropriate for the

distances likely to be involved. If load-out scanning is done from a forklift

then that should be an acceptable scanning distance from the device.

− The supported barcodes must be adequate for the needs of the solution as it

will be implemented.

− Suitable operating parameters of the device must be supported to allow for

temperature and handling issues. Devices investigated have shown

operating temperatures down to 10° Fahrenheit and an ability to cope with

multiple 4 foot drops to polished concrete



C O M M U N I C A T I O NC O M M U N I C A T I O NC O M M U N I C A T I O NC O M M U N I C A T I O N

As noted above the handheld devices must be able to communicate with GlobalBake in

real-time for validation of the data entry at each point. If any proposed scanning

stations do not already have suitable communications then additional devices, and

infrastructure, will be required to be installed. This requirement will depend on the

operating characteristics of the handheld device. Note that as well as hardware to

support the communication there may also be infrastructure to support the

communication back to the web server delivering the application.

P A L L E T B A RP A L L E T B A RP A L L E T B A RP A L L E T B A R C O D E SC O D E SC O D E SC O D E S

In order to identify each pallet as they are scanned at the end of the production lines

pre-printed barcodes must be affixed to the pallets during the pallet packing phase at

the end of the production line. All pallets that are stored in the inventory (freezers

and any other storage spaces) must have an attached pallet number in the form of, at

least, an attached barcode. The attachment of the barcodes will need to be in a

manner and place that ensures:

− The barcodes cannot be accidentally removed during handling.

− They can be easily scanned, probably from a variety of locations at the desired

distance.

Pallet numbers should be serial and pre-printed in order to speed the process at the

production line end.



SCANNING STATIONSSCANNING STATIONSSCANNING STATIONSSCANNING STATIONS

The number of scanning stations that will be implemented may change over time as

additional functionality is introduced and this section proposes an initial configuration

based on the previous details.

The initial scan will be done at the end of the production lines to confirm production.

The exact point this occurs in the packing process will depend on each clients internal;

processes, choice of barcode attachment and labour issues.

Cost savings, in the number of devices, can be achieved by scanning at a central point

if multiple production lines exist but this can have the difficulty of identification of

final product and source.

The other initial scanning point will be as the inventory is loaded onto trucks and at this

point the load-out will be related to a specific truck and customer / purchase order.

The number of physical devices required at these locations will depend on the

processes in place there for loading of trucks.



PROCESS STEPSPROCESS STEPSPROCESS STEPSPROCESS STEPS

This section identifies the sequence of events that a pallet will take through its life as

inventory. Assumptions made are:

− Pallets re-entering packing at the end of the production line would require

slightly different handling to cater for this process since GlobalBake already

knows about it and it has existing cartons on the pallet.

− Pallet re-packing, or creation, will be a scanning function. When two partial

pallets are merged for an order or for storage requirements then a

GlobalBake transaction will need to be entered to record the merge results.

P A L L E T P R O C E S SP A L L E T P R O C E S SP A L L E T P R O C E S SP A L L E T P R O C E S S

At some point in the process the pallet identification information must be attached to

the pallet. This could be done at any suitable point, for example as the pallet is placed

at the end of the line for stacking or before the pallets are made available to the end

of the line. This choice is one that the client can make relative to the internal

processes, skills and resources. The pallet must have an identifying barcode prior to it

being scanned at the end of the line or on entry to warehousing.

F R O M F R E E Z E R T O L I N EF R O M F R E E Z E R T O L I N EF R O M F R E E Z E R T O L I N EF R O M F R E E Z E R T O L I N E

When a pallet is taken from inventory to be stacked with additional product from the

line it will be scanned to confirm that the carton count in GlobalBake matches what is

on the pallet. This is to ensure first that the pallet count is accurate and secondly to

ensure that the correct number of cartons will be added from the line. If the count is

wrong then the handheld operator will need to be able to correct the count causing a

stock take loss/gain.

P R E F R E E Z E R P R O C E S SP R E F R E E Z E R P R O C E S SP R E F R E E Z E R P R O C E S SP R E F R E E Z E R P R O C E S S

As each pallet is has been wrapped and is ready to be moved into the freezer the

warehouse person will be required to scan all the information necessary for GlobalBake

to manage the pallet from that point.

Once the pallet is full, and any additional barcodes are attached for ease of

identification, the following scan will be done to update GlobalBake:

− From the production sheet scan the product produced. This scan will include

information that includes any line identifier, the date and the Product

Code.

− Pallet identifier from attached barcode.



− The number of cartons on the pallet. Note that this will default to a full pallet

unless overridden such as at product change or end of shift.

Once this process is complete the pallet can proceed to the freezer.

The response from scans here will be OK or error. If the process is running smoothly

then errors should be minimal if not negligible. The kinds of errors are that the date is

wrong in the production barcode for the current day, too many cartons of the scanned

product have been produced or the pallet identifier is not valid etc.

L O A D O U TL O A D O U TL O A D O U TL O A D O U T

As each pallet is placed onto a truck the following scans will be done to update the

inventory held in GlobalBake:

− Truck identifier from truck load sheet.

− Purchase order identifier from truck load sheet.

− Pallet id from barcode on the pallet.

Errors that may be reported for this transaction include:

− Pallet not currently included in inventory.

− Purchase order not scheduled for truck.

− Pallet contents invalid for purchase order.

− Out of order load for customer / PO being loaded.

P A L L E T L A B E L L I N GP A L L E T L A B E L L I N GP A L L E T L A B E L L I N GP A L L E T L A B E L L I N G

Once a customer / purchase order is completely loaded on a truck sheets can be

printed to identify the end of that order. They are then attached to the pallets in the

truck and then the next order can be loaded.

Whether these are printed at the loading dock area or elsewhere are choices for the

client to make relative to their processes.

P A L L E T C H A N G EP A L L E T C H A N G EP A L L E T C H A N G EP A L L E T C H A N G E

In circumstances where the contents of one pallet are placed on another then there

will be a process to record this change of pallet by transfer. Possible scenarios when


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this will occur are to merge two partial pallets or to pick an order that includes partial

pallet size order lines.

The information that will be recorded for this transaction are:

− Source pallet or null if this is a stock-take adjustment to a pallet.

− Number of cartons.

− Lot identifier of cartons.

− Target pallet, if this is a merge or Purchase Order if this is a picking function.

Errors that may be reported for this transaction include:

− Source or target pallet not currently included in inventory.

− Lot number not in source pallet.

− Cartons exceed recorded number on source pallet.

− Target pallet has more cartons than maximum.

I N T E R N A L P R O C E S S I N GI N T E R N A L P R O C E S S I N GI N T E R N A L P R O C E S S I N GI N T E R N A L P R O C E S S I N G

To allow for the handheld systems being disabled for some reason it is also possible to

perform the pallet processes from within GlobalBake as per the below screen image.

Figure Figure Figure Figure 1111 Pallet Processes Screen Pallet Processes Screen Pallet Processes Screen Pallet Processes Screen



TRUCK MANAGEMENTTRUCK MANAGEMENTTRUCK MANAGEMENTTRUCK MANAGEMENT

Truck Management allows the shipping/distribution department to plan for the

deliveries that are to be shipped.

F R E I G H T C O M P A N I E SF R E I G H T C O M P A N I E SF R E I G H T C O M P A N I E SF R E I G H T C O M P A N I E S

At the highest level in the truck management are definitions of freight companies.

These definitions are primarily as a grouping to allow different trucking companies to

be represented and all the associated trucks can be grouped under the company.


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T R U C K L O A D S H E E T ST R U C K L O A D S H E E T ST R U C K L O A D S H E E T ST R U C K L O A D S H E E T S

Within each of the freight companies are the definitions of the associated trucks as

seen below.

Figure Figure Figure Figure 2222 Truck Load Sheet Form Truck Load Sheet Form Truck Load Sheet Form Truck Load Sheet Form

Note that multiple orders can be loaded for a customer and multiple customers can be

loaded on the truck if required. Where multiple customers are loaded then load labels

can be printed to be affixed to pallets to clearly identify the different delivery

boundaries in the truck. Seal numbers can be recorded if used for transport security.



As pallets are loaded via the handheld interface they appear in the loaded list as per

below:


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R E P O R T SR E P O R T SR E P O R T SR E P O R T S

To facilitate the loading process using handhelds the truck load sheet can produce

reports that will be used during the loading process.

P I C K S H E E T SP I C K S H E E T SP I C K S H E E T SP I C K S H E E T S

The pick sheet is used to tell loaders which products need to be loaded to a particular

truck.

Figure Figure Figure Figure 3333 Pick Sheet Pick Sheet Pick Sheet Pick Sheet



L O A D S H E E TL O A D S H E E TL O A D S H E E TL O A D S H E E T

The load sheet is used to identify the truck being loaded and can also be used for

manual recording in the event the handheld interface is unavailable.

Figure Figure Figure Figure 4444 Load Sheet Load Sheet Load Sheet Load Sheet


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B I L L O F L A D I N GB I L L O F L A D I N GB I L L O F L A D I N GB I L L O F L A D I N G

Once the truck load is complete a bill of lading can be printed for the driver.

Figure Figure Figure Figure 5555 Bill of lading Bill of lading Bill of lading Bill of lading


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FUTURE OPTIONSFUTURE OPTIONSFUTURE OPTIONSFUTURE OPTIONS

R F I DR F I DR F I DR F I D

RFID tags on pallets placed at end of line, removed at load out can be used to

accelerate stock-take at pallet level since all pallets can be easily identified in the

inventory. Options here include:

− Automation in stock-take using scanning device to find all inventory pallets.

− Passive tags with pure pallet identity.

− Passive tags with identity and product information.

− Active tags for the two scenarios above.

− Automatic scanning at entry/exit points in the warehouse/freezer.

− Alarms for inappropriate action from automatic scanners.

Active tags have an integrated battery and can be scanned from greater distance.

Passive tags rely on the radio signal to generate their response and the distance the

scan works from is much less.

P A L L E T B A R C O D E SP A L L E T B A R C O D E SP A L L E T B A R C O D E SP A L L E T B A R C O D E S

If suitable media can be found it would be possible to print these labels directly from

GlobalBake and this might add an additional opportunity for checking. Indeed the

pallet barcode, rather than being purely a serial number, could be encoded to include

some details such as date, line, shift etc.

W A R E H O U S EW A R E H O U S EW A R E H O U S EW A R E H O U S E

Warehouse locations recorded for inventory control. All movements inside the

warehouse recorded in the system so that every location’s contents are known at all

times.

I N W A R D S G O O D SI N W A R D S G O O D SI N W A R D S G O O D SI N W A R D S G O O D S

Implement scanning at the receipt positions of bulk supplies to track receipt of

ingredients.


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AAAA WAREHOUSE LOADING PRWAREHOUSE LOADING PRWAREHOUSE LOADING PRWAREHOUSE LOADING PROCESSOCESSOCESSOCESS

The Pallet Management system is designed to record the cartons/cases as they are

transferred from the end of the production lines to the warehouse. This record is to

both confirm what has been produced and also for inventory control in the warehouse.

The device will beep if an error is detected (and the sound is turned on!).



SHIFT START

From the ‘Load Production’ screen scan the printed

barcode for the line/product.

If you scan anything else here an error will be

reported and the screen will remain unchanged.

Get the scanning device from power charger.

Ensure Pallet Management application is running on the

device and get to the production application.

Ensure correct production line barcodes are in place.

Know if a partial pallet is being loaded.

If the pallet from the line is NOT a partial pallet that

already has a barcode label on it take the next barcode

and apply to the pallet.

CLICK

YOU ARE NOW READY TO START

CLICK


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If a ‘full’ pallet label is scanned for a second time

then the system will report an error.

Assuming you have scanned a valid production line

barcode then the screen will show the line, shift and

product information. If this is NOT correct then correct

the production line scan by clicking the ‘pallet

management’ link and getting to the production scan

screen again. Once correct the screen will be ready for

the pallet scan.

Enter the number of cartons made on THIS shift. Normally

this will be the number on the screen (calculated for

expected product) but for the first or last pallet of a

product this may be different.

Once entered press the RETURN key and the system will

return to the production line scan screen and show the

last action.

Scan the pallet barcode and the screen will show the

pallet number and be ready for carton count entry.


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BBBB TRANSFER BETWEEN TRANSFER BETWEEN TRANSFER BETWEEN TRANSFER BETWEEN PALLETS PROCESSPALLETS PROCESSPALLETS PROCESSPALLETS PROCESS

The Pallet Management system is designed to record the pallet location of all

cartons/cases of finished product in inventory. This tracking allows inventory to be

understood and to help accurate movement of pallets to trucks etc .

At times it will be necessary to transfer some cartons/cases from one pallet to another

and the transfer function is used to perform that transfer. If the system does not know

of a transfer then it will create serious issues when those pallets are used elsewhere.



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SHIFT START

From the ‘Pallet Transfer’ screen scan the printed

barcode of the pallet that is having product

REMOVED, the ‘from’ pallet.

If you do not scan a valid pallet barcode here an

error will be reported.



device and get to the Pallet Transfer application.

CLICK

YOU ARE NOW READY TO START

TRANSFERRING BETWEEN PALLETS

CLICK



The next screen initially shows the maximum

number of cartons/cases available for transfer

from the batch that you selected. Using the

keypad enter the number of cartons/cases that are

being removed from the pallet, for example 10.

Assuming you have scanned a valid pallet then the

system will respond with a list of the system’s expected

contents of the pallet. Select the line that contains the

products and batch of cartons/cases that are to be

removed from the pallet.

Click the OK button or press Return on the keypad to

continue.

Once the transfer is complete the system will now be

ready for another transfer and it will show the details of

the transfer you have just completed.

Scan the pallet barcode of the pallet having product

ADDED to it, the ‘to’ pallet that is to receive the

cartons/cases.



CCCC P ICK AND LOAD PROCESP ICK AND LOAD PROCESP ICK AND LOAD PROCESP ICK AND LOAD PROCESSSSS

The Pallet Management system is designed to record the pallets and hence

cartons/cases as they are transferred from the warehouse onto a truck.




SHIFT START

From the ‘Pick and Load’ screen scan the printed

barcode for the truck.

If you scan anything else here an error will be

reported and the screen will remain unchanged.



device and get to the Pick and Load application.

Ensure correct truck load barcodes are in place.

CLICK

YOU ARE NOW READY TO START LOADING A TRUCK

CLICK


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Validate that the pallet cartons are correct for the

order and scan the pallet id onto the truck as it is

loaded.

The system will validate that the pallet is OK and

report the pallet as loaded.

Assuming you have scanned a valid truck load sheet check

that the display shows the correct information.

If the system

determines that the

pallet is not correct

for the truck then an

error will be reported.

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