The Reverse Logistics
(a.k.a. Returns Processing)
Method

This method facilitates the physical processing of returned products by processing a cart of products that have been inspected, reconciled against an RMA and labeled using a customer Legacy System (LS).  Based upon data sent to FastFetch by the LS that identifies the product(s) in each cart location, FastFetch directs the picker to the correct bay locations where the product(s) must be offloaded.  Depending on the capabilities of the company's WMS/ERP, this method of operation may be used to replenish picking bays from bulk storage.

FastFetch hardware and support software can be used by the LS to assist in a  "rough cut sort" of the returned products as part of the inspection, reconciliation and labeling process.  With the execution of a non-disclosure agreement, FastFetch Corp will share the protocols and other information necessary for a client to integrate the FastFetch hardware into its LS.

Example Application

The first part of the reverse logistics process is performed  by the company's Legacy System (LS). 

A truck delivers and unloads boxes of products that have been authorized for return using Return Materials Authorization (RMA) documents that specify the expected contents of each box. As each box is opened, each item is manually compared with a list of authorized items (usually by reading information on a computer display) and when matched, an entry is made into the company's  LS to print a bar coded label that is attached to the returned item.  At the same time the LS determines which one of "N" putaway bays the product must be directed to, and using FastFetch light modules (using information provided by FastFetch Corporation), the customer's LS flashes a light module LED  adjacent to one of "N" totes (each corresponding to a putaway bay) to identify the  tote into which the item should be placed. This process continues until a tote becomes full or all boxes have been opened and audited.

When a tote becomes full (or is otherwise determined to require put-away) the tote is scanned and placed on a conveyor for transport to a cart   A new tote is then assigned to the empty location by scanning the tote  bar code and touching a flashing, red, light module LED adjacent to the empty location (to confirm placment) and the process continues.  Data concerning the filled tote bar code and information concerning each item in the tote are written to the SQL database server for subsequent access by the FastFetch Optimizer PC.

The next part is performed by the FastFetch system. 

When the full tote reaches the end of the coveyor, a picker will carry it to a cart, scan the tote's bar code label and place it at a cart location adjacent to a red light module LED that was flashed as a result of the scan.  As usual, the flashing LED wil be touched to confirm correct placement on the cart.  After all locations on the cart are filled (or earlier if directed by the picker) the picker will press a button requesting the PDA or Tabet PC to start a process similar to Phase 2  of the 2-Phase Pick/Put method.  Using voice commands, the PDA or Tabet PC will direct the picker to travel to the first bay where a tote is to be offloaded.  When the bay is reached, the PDA or Tabet PC will tell the picker to "STOP", flash a light on a cart location of a tote requring offloading and speak a command directing the picker to scan the bar code on an item in the tote.  After scanning, the PDA or Tabet PC will flash a red LED on a bay light module where the product must be placed.  After placing the item at the location, the next item will be scanned, another red, light module LED will be flashed and the process continued.  As usual, voice commands and location bar code scanning may be used for bay locations that don't have attached light modules. 

This process will continue until all items in the tote adjacent to the flashing cart LED have been scanned and offloaded to the bay.  The picker will then be directed, with a voice command and with a different flashing, red, light module LED, to either begin unloading another tote at this bay or to travel to the next bay where the process continues by offloading all the items in another tote.   Type 1 errors (items expected in the tote were not there) are addressed by sending a message to the LS in the same way as a short pick during other picking methods.  Type 2 errors (Items found in the tote were not expected to be there) will be marked and left in the tote for later resolution by a person responsible for the LS.

This picking method can be used in multiple cart/bay configurations.  Click here to learn more.

Also see:  1-Phase Order Picking    2-Phase Picking w/ Dynamic Slotting    2-Phase Pick/Put