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Section:  Supervisor and Operator Guide
Topic:  Unplanned Cycle Counts

Procedure Number: 09-123

Summary

DoveTrack WMS has been configured to automatically create a cycle count for a location whenever a carousel or flow rack operator performs a short pick. The creation of a short pick cycle count prevents DoveTrack from going back to the same location over and over when creating picks for orders.

Tree of Life has SOPs in place to perform priority replenishments to bring cases of short product into DoveTrack. Once these priority replenishments are performed, the inventory is immediately availble for picking.



Procedure

1. Handle unexpected shortages found during picking, Creation of Short Pick Cycle Counts.
2. Perform Cycle Counts that were generated during short picks.
3. Process Cycle Counts
4. Apply short pick Cycle Counts.



1. Creation of Short Pick Cycle Counts

DoveTrack WMS has been configured to automatically create a cycle count for a location whenever a carousel or flow rack operator performs a short pick. The creation of a short pick cycle count prevents DoveTrack from going back to the same location over and over when creating picks for orders.

See figure 1.


Figure 1.

2. Performing Cycle Counts (Daily and/or Short Pick Generated)

Cycle counts are performed by one of the following methods:

  1. For carousel locations, use the program Process Cycle Counts on the Carousel menu.
  2. For flow rack locations, use the program Print Flow Rack Cycle Counts on the Flow Rack menu to print a list of cycle counts to be completed. Then use the Cycle Count program on the RF Main Menu to complete the counts.

    Operators at Carousel and Flowrack stations will process cycle counts after each batch. Once All Cycle Counts have been processed the carousel and flowrack operators will notify the supervisor that all counts have been performed. Supervisor will Apply cycle counts (see below) before the next order drop is performed on NTS. This will ensure that all locations are available to be allocated.

    During the processing and applying of cycle counts, no operator should be performing putaways. If an operator processes a cycle counts for a location and before that cycle count is applied, another operator stocks more product into that location, when the supervisor applies the cycle count, the quantity on hand will not be correct.

    See figure 2.


Figure 2.

3. Process Cycle Counts

When this function is selected, the carousels will rotate and the cycle counts are presented to the operator.
The operator is prompted to enter the quantity counted.


The operator may quit the cycle count batch by clicking on the Quit Batch button on the screen.

The operator may skip a count by clicking on the Skip This Count button on the screen.

If a carousel fails to rotate properly, the operator may press the Retry Rotate button or Shift F1.


Note If the part number in the location does not match the part number on the screen:

  1. Make a note of the location, the part number on the scrren, the part number in the location, and the quantity in the location. Give this information to a supervisor
  2. Skip the cycle count

See figure 3.


Figure 3.



If the quantity is not what is expected by DoveTrack the operator is prompted to recount.
See figure 4.


Figure 4.



The 2nd counted quantity is accepted and the next count is presented.
Repeat the above steps until all cycle counts are complete or you may quit cycle counts.
See figure 5.


Figure 5.



Note
If you receive a warning message No cycle counts for this zone please see your Supervisor.
See figure 6.


Figure 6.

4. Applying and Uploading Cycle Counts

A Cycle Count must be reviewed and applied by the Supervisor to free up that location; i.e. allow picks for location.

Cycle counts are applied and uploaded when a supervisor runs the "Apply" option in the Review Cycle Counts program found on the Supervisor menu. When cycle counts are applied, the database quantity is updated with the quantity counted when the cycle count was performed. The difference between the counted quantity and the database quantity is uploaded to the host as an adjustment in the FCARCYCL table.

Applying cycle counts deletes all cycle counts. The locations for any cycle counts that have not been completed are saved in table cyclecount_locations. Cycle counts for these locations are recreated the next time that Create Cycle Counts by Location is run.

The supervisor can Apply a single Cycle Count by filling in the checkbox next to the cycle count record and Pressing the Apply Single button. This will upload an adjustment to the host and change the WMS QOH accordingly for that single cycle count while leaving the rest of the cycle counts intact.


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