Pack2Light Installation Guide
This document provides an in-depth overview of the Pack2Light process, including requirements, setup instructions, operational procedures, and inventory management tips for implementing Pack2Light in your warehouse.
Overview
Pack2Light enhances warehouse efficiency by utilizing light modules to guide packers directly to the required items for each order. Integrated with the ShipHero packing application, it aims to increase packing speed and accuracy for single-order fulfillment by visually indicating item locations.
Key Points:
- Guided Packing: Uses LED lights to direct packers to item locations.
- Efficiency Focused: Designed to streamline the single-order packing process.
- ShipHero Integration: Works directly with the ShipHero Packing App.
Prerequisites
Before you begin the Pack2Light setup, ensure you have the following components and configurations in place:
Hardware:
- ShipHero Attainable Automation Starter Kit (includes Hub, LED modules, JST connectors).
- A dedicated pack station computer.
- A 2D barcode scanner connected to the pack station computer.
-
USB to UART Driver (CP210x VCP Windows - 3rd in the list): Required only if using a Windows computer. Download from Silicon Labs
Software & Account Settings:
- The most recent version of the ShipHero Packing App installed on the pack station computer. Download from ShipHero Apps. The Hub will only work on v0.7.3 or later
- Feature Activation: The enable_pickless_p2l_mode feature flag must be activated in CASH. Contact support if you need assistance with this step.
Command Barcodes/Buttons:
Either printed command barcodes or an Adaptive Packing Station configured with buttons for essential commands (e.g., Get Next Order, Print Labels).
How to Set Up Pack2Light
Follow these steps to configure your Pack2Light hardware and software:
Establish Pack Station Locations in ShipHero:
- Unique Prefix: Assign a unique prefix to each Pack2Light station (e.g., PS01, PS02). This distinguishes stations from each other.
- Location Naming: Create locations within ShipHero for each bin/spot at the station. The naming convention must be [Prefix]-[Numeric ID] (e.g., PS01-01, PS01-02, PS01-03, etc.). Only use numeric values after the hyphen.
- Location Type: It's recommended to create a specific location type (e.g., "Pack2Light Station") for these locations to aid in reporting and inventory management. Ensure these locations are marked as sellable and pickable.
Wire the Hub and LED Modules:
- Mount Hub: Securely attach the Pack2Light Hub to the packing rack, ensuring it's close enough to the computer for the USB connection.
- Connect Hub: Plug the Hub into a USB port on the pack station computer.
- Connect First Light: Use a provided JST male-to-male connector to link the Hub to the INPUT port of the first LED module. This module should correspond physically to your first location (e.g., PS01-01).
- Connect Subsequent Lights: Daisy-chain the remaining LED modules by connecting the OUTPUT port of one module to the INPUT port of the next using the JST connectors. Maintain the sequence corresponding to your location numbering (01, 02, 03...).
Create Force Allocate QR Code:
- Purpose: This specific QR code ensures the packer only receives orders that can be completely fulfilled by items in that station's prefix.
- Format: The command embedded in the QR code must follow the format: shp2l__[location prefix]
- Examples: For stations PS01 and PS02, the codes would be shp2l__PS01 and shp2l__PS02, respectively.
- Generation: Use this QR code generator, or any standard online tool) to create a QR code for each station's specific command.
Command Barcodes:
- Printed Barcodes: Standard ShipHero command barcodes (e.g., for "Get Next Order", "Print Invoice and Labels"). https://d2s9s6xmfnfu1v.cloudfront.net/desktop/test_prints/command_sheet.pdf
- Adaptive Packing Buttons: Configure buttons on an Adaptive Packing Station screen for these commands.
-
Suggested Commands Barcodes:
- Get Next Order
- Print Invoice and Labels
- Okay/Confirm (if used in your workflow)
- Send to Hospital (if used in your workflow)
Pack2Light Operational Process
Here’s how to use the Pack2Light station for daily packing:
Start Packing Session:
- Open the ShipHero Packing App on the computer.
- Navigate to ‘Shipping’ > ‘Single Orders’.
- Scan the Station's Force Allocate QR Code (e.g., scan the printed shp2l__PS01 code). This locks the app to only process orders fulfillable from locations starting with PS01-.
Process Orders:
- After the QR code is scanned a modal confirming that Location Prefix is assigned
- Scan "Get Next Order" command barcode/button or click Open order
- An order will open on the packing app, and the corresponding LED light at the item's location will be illuminated.
- Pick the item and scan its barcode. The light will turn off.
- Repeat for all items in the order.
- Once all items are scanned and packed, scan the "Print Invoice and Labels" command barcode/button.
- Continue: Scan the "Get Next Order" command barcode/button to proceed to the next available order for that station.
Inventory Management & Monitoring
- Stock Levels: Orders will cease being allocated to the station if any required item is out of stock in its assigned Pack2Light location. Consistent replenishment is crucial.
- Monitoring: Use the Product Locations report in ShipHero to monitor inventory levels. Filter by your specific Pack2Light location type or by SKUs stocked at these stations.
- Replenishment Pro-Tip: When the same SKU is stocked at multiple Pack2Light stations, using the Locations Report combined with mobile inventory transfers is generally recommended over the standard mobile replenishment features for better control.
Troubleshooting
Troubleshooting Guide: ShipHero Attainable Automation Pack to Light