Thanks @JayRam Jay. I was thinking about it after I posted on the forum and I arrived to similar kind of work flow as yours.
Make new DocType (lets say Racking System) The Bin Tree would be like this
Warehouse (Make warehouse 1st in Warehouse Tree) > Zone> Aisle> Rack> Shelf> Bin
The DocType needs to capture physical layout of the Warehouse. Example 5 Aisles, 10 Racks, 400 Shelves,
Pick List is there in V12 but needs refinement to large extent to manage what I am proposing below.
I would break down this project in 4 Phases for development and testing.
When stock is entered it is captured in default warehouse. From here user links the stock location without moving the stock in the warehouse. We can work out auto assignment in Phase 3.
- Sales Order is created followed by Pick List.
- The Pick List will pull all the information of Sales Order and against it populate the item location as mentioned above.
- User goes around picking the item and scanning it on the Pick List. Carries a phone with barcode scanner attached to it.
- A pop-up window will appear for user to confirm the number of units retrieved. Maybe there are lesser number of units available than the pick list. Or if the item is not part of Pick List a warning message is shown in the Pop Up like “Item not part of Pick List”. This also ensure that user has picked the correct item.
- Pick List is submitted and converted to Delivery Note.
NOTE: For business that have products with expiry date when the item is scanned the pop-up should warn the picker that item has passed expiry date. We can use the batch management system for warning message.
- Logic needs to be written to allow system to work out the best route the picker takes to pick item in the shorted period of time.
- The list is auto sorted in descending order. User starts picking the first item and moves to the 2nd item.
- Rest of steps similar to the PHASE 1
ZONING & SPLIT PICK LIST
Very large warehouses are split into zones. Each zone has one or more dedicated picker.
- Master pick list is created.
- It is split by zones.
- Zone pick list is sorted as per the best route for picking.
- Each pick list is assigned to zone staff for picking items.
- After all zones have completed respective pick list is regrouped in one Delivery Note.
CUSTOMER SPECIAL REQUIREMENTS
Some customer have special requirements. Example few hypermarkets do not accept items which have passed x% of sell by date. Example Reliance Fresh will only accept if item has 50% of balance validity date. Item produced on 1st Jan 2019 with expiry of 31 Dec 2020. 50% threshold will pass on 1st Jan 2020. The item can be shipped anytime before 31st Dec 2019 but wont be accepted by Reliance on 1st Jan 2020. Maybe there would be other types of special requirement like this.
Here the world best Warehouse Management System. They have too many features but we can learn few things from them. https://wamas.com/
If my client is happy to invest I would be able to support the development through my developers. We can also look at collaborating on it. I think I captured all that I could think of. Please feel free to add anything more.