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Set up the order and pick processes as part of building a real-world scenario of an order fulfillment center.
Any referenced datasets can be downloaded from "Module downloads" in the module overview.
Transcript
00:03
The first step in simulating order consolidation in a warehouse
00:08
is to build the logic for the order and pick processes using a combination of activities, objects, labels, and lists.
00:16
Here, a 3D model is already created and running.
00:20
Orders arrive, with a variable number of items per order, which are picked from different points in a fulfillment center.
00:28
Items travel from a pick area to the conveyor, and then to a pack area.
00:34
The items are colored, and each color denotes an order.
00:39
At the pack stations, the orders are packed once all items for an order arrive at the rack, or put wall.
00:47
The items are placed in a colored tote that corresponds to the designated order color.
00:52
In Properties, select Show Connections to view the connections between objects in the 3D model,
00:58
like the conveyor and its corresponding rack, or the rack and its pack table.
01:04
Keep in mind that these connections, as well as the specific object settings, need to be applied when building your 3D model.
01:13
This ensures that the process functions as planned.
01:17
For example, select the Rack, and in Properties, you can see that it has a Station Label of 1.
01:24
Since there are multiple racks, this identifies the specific rack.
01:29
Additionally, under Output, Do Not Release Item is selected for this rack.
01:36
This ensures items do not immediately release from the Rack to the pack table, allowing you to retain control over the release of items.
01:45
Similarly, select the pack table.
01:49
In Properties, under Output, Do Not Release Item is selected.
01:55
This option allows you to control the release of the tote.
01:60
If it were not selected, then the pack totes would proceed to the conveyor before all the items are packed.
02:07
This is why it is important to apply the appropriate settings to objects in your model before building the logic in your process flow.
02:15
Next, an existing process flow is accessed by selecting Process Flow > General > Process Flow.
02:26
Here, the logic that drives the model is broken down into two main parts, Order logic and Pick logic.
02:34
Process containers and boxes are used to separate the different areas of logic.
02:40
This is a recommended best practice to help you better organize the steps in your process flow.
02:47
Zoom in on the Orders area and look at the first step in the process, Create Order and Reserve PutWall Slot.
02:55
This activity block is meant to generate and set up the orders so that they can be easily tracked throughout the flow.
03:03
Click the Source, Order Arrivals.
03:07
Here, a Date Time Source controls the arrival of items.
03:11
Click Edit Arrivals.
03:15
In the dialog, a Quantity of “200” items arrive over the course of one full day.
03:21
To repeat the arrivals, expand Repeat Interval and select Daily.
03:27
For the Arrival Spacing, Randomly spaced is selected to spread the arrivals over the course of the day.
03:34
Exit the dialog.
03:37
Next, an Assign Labels activity, called Order Size, is used to create a Label on each order called Picks.
03:46
In this case, the Picks label is set up with a uniform distribution between 1 and 12 to determine how many items are in the order.
03:55
Then, a second Label is added to each order called OrderNumber.
04:01
This label finds the arrival number of the order and applies the corresponding label to the order token.
04:08
For example, the first order will receive a label of 1, the second, a label of 2, the third, a label of 3, and so on.
04:19
This label not only identifies the order number but is also used to apply a color to the order,
04:25
which makes it easier to identify it throughout the simulation.
04:30
In the ProcessFlow, the next several steps in this activity block pertain to the put wall.
04:37
Prior to creating picks, it is important to include the put wall slot reservation steps here,
04:43
so that you can appropriately assign each order along with its picks to a put wall slot.
04:48
This will be reviewed in more detail later in the course.
04:53
Next, create the pick tokens for the order using a Create Tokens activity, here, called Create Pick Tokens.
05:02
Remember, in Order Size, you created a label called Picks with a uniform distribution between 1 and 12
05:09
to randomly assign a number of items to the order token.
05:13
In Create Pick Tokens, in the Quantity field, you reference this number with “token.Picks”
05:20
so that the number of pick tokens created matches the number of items in the order.
05:25
Set Create As to “Child Tokens” to associate each pick with its parent token, the order.
05:33
Under Parent Label Access, select Read to allow parent tokens to read child labels.
05:40
Ensure Label Access on Parent Only is disabled.
05:45
This allows you to apply labels to Child Tokens.
05:49
Add a new label.
05:52
For the Name, input “PickNum”, and then set the Value to creationRank.
06:02
This creates a label on each pick token with a number based on its creation so that you can easily identify each pick token within an order.
06:11
Next, navigate to the Picks logic of the process flow.
06:16
Once your pick tokens are created, they need to undergo additional steps.
06:22
For example, a Delay activity is used to represent a Time to Pick, and then pick tokens are assigned a Pick Area,
06:30
which determines where the corresponding item arrives within the 3D model.
06:35
Reset and then Right-click in the model.
06:39
Select Object Groups > Select Picking Areas.
06:45
The picking areas are Queues and are highlighted in the model by the red boxes.
06:51
In Toolbox > Groups > Picking Areas, the six pick areas are listed in the Group Properties dialog.
07:02
In the ProcessFlow, open the Assign Labels activity, called Pick Area.
07:09
The PickArea label is set to a uniform distribution between 1 and 6
07:13
so that one of the pick areas will be randomly assigned to each pick token.
07:19
Next, a Create Object activity, here called Create Pick, is used to create the corresponding pick item in the model.
07:27
Select Object > FlowItems > Pick to define the object that will be created.
07:36
Note that Pick is not a default flowitem option, this is a custom flowitem created for this model.
07:43
Then, set up where the object will be created, in this case, the picking area.
07:51
Additionally, add a Label to the picks called “StationNum”, with a Value of “token.StationNum”.
07:59
Remember that each rack was assigned a Station Number when it was set up in the 3D model;
08:05
this label will identify which rack the item travels to.
08:09
Next, define the logic for the picks to join with their order.
08:14
Here, a Pull from List activity is used for the order token to wait for its picks, called “Wait for all Picks to arrive in PutWall”.
08:24
The pick tokens arrive at a Push to List activity, called “Notify Order of Arrival”, and are pushed to the Arrived Picks list.
08:34
Once all tokens arrive at the list for an order, the Order token will remove the picks from the list, advancing them in the process.
08:43
For the Pull from List activity, the Request and Require Number are set to “token.Picks”.
08:51
This references the total number of picks assigned to the order,
08:55
ensuring that all items are required to arrive before the order token can pull the picks from the list.
09:01
The Partition ID is set to “token” to ensure the order token pulls only those pick tokens whose Partition ID matches the Order,
09:10
or parent, token.
09:12
Similarly, for the Push to List activity, the Partition ID is set to “token.parent” to partition the picks by their parent token.
09:22
Setting up the List activities in this way and appropriately partitioning the tokens
09:27
allows you to ensure that all picks will be matched with their parent order.
09:32
The initial logic to create, and then consolidate, your order tokens and pick tokens is now set up,
09:39
and you are ready to create the logic for the put wall reservation slots.
Video transcript
00:03
The first step in simulating order consolidation in a warehouse
00:08
is to build the logic for the order and pick processes using a combination of activities, objects, labels, and lists.
00:16
Here, a 3D model is already created and running.
00:20
Orders arrive, with a variable number of items per order, which are picked from different points in a fulfillment center.
00:28
Items travel from a pick area to the conveyor, and then to a pack area.
00:34
The items are colored, and each color denotes an order.
00:39
At the pack stations, the orders are packed once all items for an order arrive at the rack, or put wall.
00:47
The items are placed in a colored tote that corresponds to the designated order color.
00:52
In Properties, select Show Connections to view the connections between objects in the 3D model,
00:58
like the conveyor and its corresponding rack, or the rack and its pack table.
01:04
Keep in mind that these connections, as well as the specific object settings, need to be applied when building your 3D model.
01:13
This ensures that the process functions as planned.
01:17
For example, select the Rack, and in Properties, you can see that it has a Station Label of 1.
01:24
Since there are multiple racks, this identifies the specific rack.
01:29
Additionally, under Output, Do Not Release Item is selected for this rack.
01:36
This ensures items do not immediately release from the Rack to the pack table, allowing you to retain control over the release of items.
01:45
Similarly, select the pack table.
01:49
In Properties, under Output, Do Not Release Item is selected.
01:55
This option allows you to control the release of the tote.
01:60
If it were not selected, then the pack totes would proceed to the conveyor before all the items are packed.
02:07
This is why it is important to apply the appropriate settings to objects in your model before building the logic in your process flow.
02:15
Next, an existing process flow is accessed by selecting Process Flow > General > Process Flow.
02:26
Here, the logic that drives the model is broken down into two main parts, Order logic and Pick logic.
02:34
Process containers and boxes are used to separate the different areas of logic.
02:40
This is a recommended best practice to help you better organize the steps in your process flow.
02:47
Zoom in on the Orders area and look at the first step in the process, Create Order and Reserve PutWall Slot.
02:55
This activity block is meant to generate and set up the orders so that they can be easily tracked throughout the flow.
03:03
Click the Source, Order Arrivals.
03:07
Here, a Date Time Source controls the arrival of items.
03:11
Click Edit Arrivals.
03:15
In the dialog, a Quantity of “200” items arrive over the course of one full day.
03:21
To repeat the arrivals, expand Repeat Interval and select Daily.
03:27
For the Arrival Spacing, Randomly spaced is selected to spread the arrivals over the course of the day.
03:34
Exit the dialog.
03:37
Next, an Assign Labels activity, called Order Size, is used to create a Label on each order called Picks.
03:46
In this case, the Picks label is set up with a uniform distribution between 1 and 12 to determine how many items are in the order.
03:55
Then, a second Label is added to each order called OrderNumber.
04:01
This label finds the arrival number of the order and applies the corresponding label to the order token.
04:08
For example, the first order will receive a label of 1, the second, a label of 2, the third, a label of 3, and so on.
04:19
This label not only identifies the order number but is also used to apply a color to the order,
04:25
which makes it easier to identify it throughout the simulation.
04:30
In the ProcessFlow, the next several steps in this activity block pertain to the put wall.
04:37
Prior to creating picks, it is important to include the put wall slot reservation steps here,
04:43
so that you can appropriately assign each order along with its picks to a put wall slot.
04:48
This will be reviewed in more detail later in the course.
04:53
Next, create the pick tokens for the order using a Create Tokens activity, here, called Create Pick Tokens.
05:02
Remember, in Order Size, you created a label called Picks with a uniform distribution between 1 and 12
05:09
to randomly assign a number of items to the order token.
05:13
In Create Pick Tokens, in the Quantity field, you reference this number with “token.Picks”
05:20
so that the number of pick tokens created matches the number of items in the order.
05:25
Set Create As to “Child Tokens” to associate each pick with its parent token, the order.
05:33
Under Parent Label Access, select Read to allow parent tokens to read child labels.
05:40
Ensure Label Access on Parent Only is disabled.
05:45
This allows you to apply labels to Child Tokens.
05:49
Add a new label.
05:52
For the Name, input “PickNum”, and then set the Value to creationRank.
06:02
This creates a label on each pick token with a number based on its creation so that you can easily identify each pick token within an order.
06:11
Next, navigate to the Picks logic of the process flow.
06:16
Once your pick tokens are created, they need to undergo additional steps.
06:22
For example, a Delay activity is used to represent a Time to Pick, and then pick tokens are assigned a Pick Area,
06:30
which determines where the corresponding item arrives within the 3D model.
06:35
Reset and then Right-click in the model.
06:39
Select Object Groups > Select Picking Areas.
06:45
The picking areas are Queues and are highlighted in the model by the red boxes.
06:51
In Toolbox > Groups > Picking Areas, the six pick areas are listed in the Group Properties dialog.
07:02
In the ProcessFlow, open the Assign Labels activity, called Pick Area.
07:09
The PickArea label is set to a uniform distribution between 1 and 6
07:13
so that one of the pick areas will be randomly assigned to each pick token.
07:19
Next, a Create Object activity, here called Create Pick, is used to create the corresponding pick item in the model.
07:27
Select Object > FlowItems > Pick to define the object that will be created.
07:36
Note that Pick is not a default flowitem option, this is a custom flowitem created for this model.
07:43
Then, set up where the object will be created, in this case, the picking area.
07:51
Additionally, add a Label to the picks called “StationNum”, with a Value of “token.StationNum”.
07:59
Remember that each rack was assigned a Station Number when it was set up in the 3D model;
08:05
this label will identify which rack the item travels to.
08:09
Next, define the logic for the picks to join with their order.
08:14
Here, a Pull from List activity is used for the order token to wait for its picks, called “Wait for all Picks to arrive in PutWall”.
08:24
The pick tokens arrive at a Push to List activity, called “Notify Order of Arrival”, and are pushed to the Arrived Picks list.
08:34
Once all tokens arrive at the list for an order, the Order token will remove the picks from the list, advancing them in the process.
08:43
For the Pull from List activity, the Request and Require Number are set to “token.Picks”.
08:51
This references the total number of picks assigned to the order,
08:55
ensuring that all items are required to arrive before the order token can pull the picks from the list.
09:01
The Partition ID is set to “token” to ensure the order token pulls only those pick tokens whose Partition ID matches the Order,
09:10
or parent, token.
09:12
Similarly, for the Push to List activity, the Partition ID is set to “token.parent” to partition the picks by their parent token.
09:22
Setting up the List activities in this way and appropriately partitioning the tokens
09:27
allows you to ensure that all picks will be matched with their parent order.
09:32
The initial logic to create, and then consolidate, your order tokens and pick tokens is now set up,
09:39
and you are ready to create the logic for the put wall reservation slots.
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