FD Warehouse Operations Workflow

1. Objective

Standardize warehouse execution into clear receiving, picking, packing, shipping, inventory control, and facility support workflows that reduce touches and rework while increasing throughput accuracy.

2. Scope

In Scope

  • All receiving
  • Put-away
  • Picking (standard, kit, fabrication, large orders)
  • Packing & shipping (ground, LTL, international, will call)
  • Inventory control
  • Adjustments
  • Maintenance of storage areas
  • Material handling
  • Truck loading

Out of Scope

  • Procurement decisions
  • Sales order entry
  • Production planning logic

PROCESS 1: Receiving & Put-Away

Combines: Receiving Standard PO, Overseas Vendor Receiving, Returned Material Receiving, Receiving Put-Away, Receiving Transfers

Objective: Receive and put away product accurately in one flow without staging backlogs.

Inputs

  • PO
  • Packing list
  • Transfer document
  • RMA

Outputs

  • Inventory received in ERP
  • Product put away in bin
  • Exception logged (if discrepancy)

Step-by-Step Process

  1. Unload truck.
  2. Match packing list to PO.
  3. Inspect for damage.
  4. Receive into ERP same day.
  5. Label if required.
  6. Move product directly to assigned bin (no bulk staging).
  7. Close PO or flag discrepancy.

Exceptions + Escalation

  • Damage → Document and notify Procurement.
  • Qty variance >2% → Inventory Control review.

PROCESS 2: Order Release & Printing

Combines: Standard Order Printing/Sorting, Kit/Fab Order Printing/Sorting

Objective: Release orders to the floor in one consolidated batch process to reduce interruptions.

Inputs

  • Pick-ready orders

Outputs

  • Sorted pick tickets (or RF queue)
  • Prioritized wave

Step-by-Step Process

  1. SO Expedite screen is refreshed continuously.
  2. Sorted by freight/ground & customer class.
  3. Release wave to pickers.
  4. Stage large or special orders separately.

Exceptions + Escalation

  • Approved expedites are printed immediately.

PROCESS 3: Picking & Staging

Combines: Standard Order Picking, Kit Order Picking, Fabrication Order Picking, Large Order Picking & Staging, Item Fabrication Workorders, Will Call Order Processing, Picking Office Supply Orders

Objective: Pick all order types using one controlled workflow to minimize travel and mis-picks.

Inputs

  • Released pick wave

Outputs

  • Picked & staged order
  • Variance report (if issue)

Step-by-Step Process

  1. Accept assigned pick wave.
  2. Follow optimized pick path.
  3. Scan each item.
  4. Stage by shipping method.
  5. Flag shortages immediately.
  6. Move completed orders to packing zone.

Exceptions + Escalation

  • Stockout → Notify Inventory Control immediately.
  • Repeated location miss → Pick Path review.

PROCESS 4: Packing & Shipping

Combines: Ground Order Packing, Freight Order Packing, Ground Shipping, LTL Freight Shipping, International Shipments, Special Attention Customer Shipping, Secondary Packing Review, Loading Trucks

Objective: Pack and ship orders accurately with minimal double handling.

Inputs

  • Staged picked orders

Outputs

  • Shipped order
  • Tracking uploaded
  • Bill of lading (if LTL/Intl)

Step-by-Step Process

  1. Verify items vs pick ticket.
  2. Pack according to shipping method.
  3. Apply shipping label and documentation.
  4. Perform secondary review only for:
    • International
    • LTL
    • Special attention accounts
  5. Move to outbound staging.
  6. Load truck by route.

Exceptions + Escalation

  • Shipping damage risk → Repack before loading.
  • Missing documentation → Hold shipment.

PROCESS 5: Inventory Control & Accuracy

Combines: Physical Count Schedule, Lost Product, Quantity Adjustments, Problem Order Review

Objective: Maintain >98% inventory accuracy with structured controls.

Inputs

  • Cycle count schedule
  • Adjustment requests
  • Problem order flags

Outputs

  • Counted inventory
  • Approved adjustments
  • Root cause actions

Step-by-Step Process

  1. Follow weekly cycle count schedule.
  2. Count assigned bins.
  3. Recount variances immediately.
  4. Approve adjustments (threshold-based).
  5. Log root cause if repeat issue.
  6. Review problem orders weekly.

Exceptions + Escalation

  • Variance >5% → Warehouse Manager review.
  • Repeated shrinkage area → Investigate process failure.

PROCESS 6: Facility & Equipment Support

Combines: Pick Path Maintenance, Mezzanine Maintenance, Sit Down Forklift Operation, Material Handling

Objective: Maintain safe, efficient warehouse flow and equipment readiness.

Inputs

  • Maintenance schedule
  • Safety checklist

Outputs

  • Updated pick path map
  • Maintained equipment
  • Safe facility

Step-by-Step Process

  1. Adjust for velocity changes.
  2. Conduct daily forklift safety check.
  3. Perform monthly mezzanine inspection.
  4. Log maintenance issues.