1. Processing Warehouse Orders for Pinnacle Auto Parts

2. Welcome Why is this important? Universal changed how it pulls orders for Pinnacle Auto Parts. We’re using different part numbers, different warehouse space, different paperwork, and different packaging. It seemed a good time for a different way to train our employees. This lesson should clarify what you have to do to complete an order for Pinnacle. To get through this program, you just need the arrow keys shown here. They’re at the bottom right corner of your keyboard. Left goes back. Right goes forward. Try pushing the right arrow now to go to the next page. Introduction

3. What You’ll Learn This lesson covers the entire order fill process from start to finish. You’ll Learn: What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order Introduction

4. What You’ll Learn This lesson covers the entire order fill process from start to finish. You’ll Learn: What Makes a Good Pallet Building the Order How to Package the Shipment How to Ship the Order Introduction

5. Lesson Goals At the end of the lesson, you will process an actual order. You’ll demonstrate what you’ve learned to:  Pick a good pallet  Pull the correct parts with correct labels  Pack the order on a skid  Complete the paperwork  Inform the Shipping Manager You’re Finished What Makes a Good Pallet Building the Order How to Package the Shipment How to Ship the Order Introduction

6. Work from the Bottom Up You will “build” an order from the bottom up. Think of a shipment like a house: it’s as strong as its foundation. Build on a strong foundation by choosing a good pallet. So what makes a good pallet? What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order What Makes a Good Pallet

7. Pallet Structure Recall the parts of a pallet Pallet Truck Openings Forklift Openings Stringer What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order What Makes a Good Pallet

8. Pallet Structure Recall the parts of a pallet Top Board Bottom Center Boards What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order What Makes a Good Pallet

9. A Good Pallet A good pallet must have all of the following features:  4-Way Entry  Solid Stringers  Made from Hardwood  About 48” x 40” on top  7 Boards on Top  3 Center Boards on Bottom What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order What Makes a Good Pallet

10. A Good Pallet in Detail  4-Way Entry  Solid Stringers  Made from Hardwood  Openings on all four sides so the pallet can be lifted by a pallet truck or forklift  No splits along the length of the stringer or chunks missing  No pallets built from plywood or non-wood materials What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order What Makes a Good Pallet

11. A Good Pallet in Detail (cont.)  About 48” x 40” on top  7 Top Boards  3 Center Bottom Boards  The most common pallet size in the plant  7 planks running between stringers on the upper side of the palette  3 planks running between the middle of the stringers on the under side of the palette What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order What Makes a Good Pallet

12. The Perfect Pallet Do you see all the required elements?  4-Way Entry  Solid Stringer  Made from Hardwood  About 48” x 40” on top  7 Boards on Top  3 Center Bottom Boards 48” 40” What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order What Makes a Good Pallet

13. A Bad Pallet What is right and wrong with this pallet? Right:  4-Way Entry  Probably the right size Wrong:  Made of Plywood  No Center Boards  No Bottom Center Boards  Doesn’t have Stringers What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order What Makes a Good Pallet

14. Pallet Exercises Refer to your exercise manual. Answer problems 1-6. Do not click to the next slide until you have completed the exercises. Did you finish problems 1-6? If so, click to the next slide to check your answers. What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order What Makes a Good Pallet

15. Pallet Exercise 1 Answer Is this a good pallet? If it is not a good pallet, why? Not a good pallet.  It does not have 4-way entry. What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order What Makes a Good Pallet

16. Pallet Exercise 2 Answer Not a good pallet.  Does not have 4-way entry.  It does not have three center boards on the bottom. Is this a good pallet? If it is not a good pallet, why? What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order What Makes a Good Pallet

17. Pallet Exercise 3 Answer Not a good pallet. It has 4-way entry and is hardwood but  Only 6 of 7 top boards  1 instead of 3 center bottom boards. Is this a good pallet? If it is not a good pallet, why? What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order What Makes a Good Pallet

18. Pallet Exercise 4 Answer Not good pallets. Has 4-way entry but:  Made of cardboard, not hardwood Are these good pallets? If they are not good pallets, why? What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order What Makes a Good Pallet

19. Pallet Exercise 5 Answer Not a good pallet. It has 4-way entry, solid stringers, and is made of hardwood but  Does not have 7 top board  Does not have 3 center bottom boards. Is this a good pallet? If it is not a good pallet, why? What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order What Makes a Good Pallet

20. Pallet Exercise 6 Answer What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order Not a good pallet. It has 4-way entry and is made of hardwood but  It only has 6 of 7 required top boards  It has no bottom boards Is this a good pallet? If it is not a good pallet, why? What Makes a Good Pallet

21. Add up the number of exercises you got right. Did your reasons match the answers? Did you get all six right? If not, take a few moments to review this section and make sure you understand why the pictures were examples of good or bad pallets. If you got all six right, you’re ready to move on to pulling the order. What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order How Did You Do?

22. Pulling the Order Pinnacle will only order 86 possible part numbers for their stock orders. Since Pinnacle requires special labels with their own part numbers, the 86 part numbers are located in a separate part of the warehouse and stocked by Pinnacle number. Each Pinnacle number matches a location number. Your pick list will always sort part numbers from lowest location number to highest. The map on the next screen shows locations. What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order How to Pull the Order

23. Pulling the Order (cont.) This is the map of the warehouse layout. Copies of this map are posted in the warehouse to help you find your way. What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order How to Pull the Order

24. You will be given a pick list to use as a worksheet. The pick list, shown below, has a lot of information that you can ignore. When pulling the order, focus only on the quantity ordered and part number. Qty. Ord.ShippedB/O Part NumberDescription Exchange Each Core Each Core Total Ext. Total 5501-165RMFG CARB 55010-325ARMFG CARB 77010-344RMFG CARB 55010-345RMFG CARB 55014-107RMFG CARB What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order How to Pull the Order Pulling the Order (cont.)

25. You will start with the LAST number on the pick list and pull backwards in order until you reach the first number on the list. This is to keep the part numbers in ascending order on the skid. To find the location of the last part number on your pick list, start at location 86, walk in the direction of the arrows on the map, and look for the Advance number 7-7587. In this case it is location 76. What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order Qty. Ord.ShippedB/O Part NumberDescription Exchange Each Core Each Core Total Ext. Total 1109-222RMFG CARB 3409-224RMFG CARB 3309-226RMFG CARB 5509-75RMFG CARB 7707-7587RMFG CARB How to Pull the Order Pulling the Order (cont.)

26. Once you have found the right location, your pick slip tells you to pull 7 carburetors with that part number. As you pull boxes, you need to verify three things:  Each box has two labels: Universal and Pinnacle.  The Pinnacle number on each box matches the part number ordered  The barcodes on the Universal and Pinnacle labels will scan with a barcode reader. What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order How to Pull the Order Pulling the Order (cont.)

27. Label Check Each carburetor box that you pull should have two labels, as shown below. As you pull, check for:  Both Universal and Pinncle labels  Clear barcodes – not smeared, broken, or rubbed off  Correct part number compared to location sign and pick slip What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order How to Pull the Order

28. Label Check (cont.) Since Pinnacle scans everything they check in to their warehouse, you need to make sure the barcodes on the labels are clearly printed and complete. This is a bad barcode because it is ripped and will not scan. Replace it with a new label. What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order How to Pull the Order

29. Label Check (cont.)  Both Universal and Pinnacle labels  Clear barcodes  The part matches the location sign and the number on the order  If both labels aren’t present  Check for an “x” which means it needs a gasket. Pull one from the gasket area of the warehouse  If there’s no “x”, get a label.  If barcodes aren’t clear, get a new label printed  If it does not match, relocate the part to its correct location using the interchange provided. What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order How to Pull the Order

30. Loading the Pallet You will load boxes into a cardboard gaylord on the pallet. As you load the pallet, stack boxes from back to front and left to right with all labels facing you. This will make it easier to keep track of what you already pulled. What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order This is a top view of the pallet showing the pallet loading order. How to Pull the Order

31. Loading the Pallet (cont.) What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order As you stack boxes, insert a piece of cardboard about the size of the gaylord between the second and third layer to add support. Then continue stacking until you reach five layers high. To ensure stability, no pallets will be loaded higher than five layers. How to Pull the Order

32. Once you have checked the labels, barcodes, and part numbers of all 7 carburetors for part number 7-7587, it is time to take notes on the pick list. It is important that employees used standard notes. These notes communicate information to the office and other employees. Uniform notes reduce confusion and mistakes. What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order Notes on Your Paperwork How to Pull the Order

33. Notes (cont.) Once you’ve checked the labels, you need to take notes on the pick list. Quantity Pulled  If you pulled the entire quantity ordered, put a “-” next to the number in the “Shipped” column.  If you pulled less than the entire quantity ordered, write the quantity you actually pulled and a “-” next to the number in the “Shipped” column. Skid Number  In the “Exchange Each” column, write the number of the skid that the part is packed on. What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order How to Pull the Order

34. Notes (cont.) What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order Lets see what the notes look like on the sample pick list below. Qty. Ord.ShippedB/O Part NumberDescription Exchange Each Core Each Core Total Ext. Total 1109-222RMFG CARB 3409-224RMFG CARB 3309-226RMFG CARB 5509-75RMFG CARB 7707-7587RMFG CARB Let’s say you were able to pull all 7 of the 7-7587. Then you would mark the paperwork as shown below. On the next number, you were only able to pull 3 of the 9-75. Then you would mark the paperwork as shown below. 1 1 3- - Now let’s say there are no 9-226. You would not write anything in the “shipped” or “exchange each” columns. How to Pull the Order

35. Notes Exercises Refer to your exercise manual. Answer problem 7-9. Do not click to the next slide until you have completed the exercises. Did you finish problems 7-9? If so, click to the next slide to check your answers. What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order How to Pull the Order

36. Notes Exercise Answer What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order 7. How many total parts were pulled from this order? 8. Are there any mistakes in the notes? If so, where? Qty. Ord.ShippedB/O Part NumberDescription Exchange Each Core Each Core Total Ext. Total 1109-222RMFG CARB 3409-224RMFG CARB 3309-226RMFG CARB 5509-75RMFG CARB 7707-7587RMFG CARB 1 1- 4- - 1 2 21- 14 There should only be a “-” next to the 1 in the first row. The 2 in the “core each” column should be in the “exchange each” column. There should not be a skid number for the third row listed since no parts were pulled. How to Pull the Order

37. Notes Exercise Answer What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order 9.Which part number would you expect to find on the bottom of the first skid? Qty. Ord.ShippedB/O Part NumberDescription Exchange Each Core Each Core Total Ext. Total 1109-222RMFG CARB 3409-224RMFG CARB 3309-226RMFG CARB 5509-75RMFG CARB 7707-7587RMFG CARB 1 1- 4- - 1 2 21- 7-7587 How to Pull the Order

38. From Pick List to Packing Slip What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order Once you have the entire order pulled and your notes on the pick slip are complete, take the paperwork to the office. They will convert the pick list into a packing slip. While the office is making the packing slip, you can move on to finalizing packaging for shipment. How to Pull the Order

39. Packaging the Shipment What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order EACH pallet shipped should be:  Tightly shrink-wrapped around gaylord to avoid shifting  Labeled with a “Mixed” sign and skid number The LAST pallet in each shipment should:  Labeled with the white copy of the packing slip (the office keeps pink and yellow) How to Package the Shipment

40. Packaging Details What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order Using the shrink-wrap roll, tie the end to the pallet. Walk around the pallet clockwise several times, working from the bottom up. Pull tightly as you go. When you reach the top, tape the mixed and skid number signs to the pallet and shrink wrap over them. When all boxes are secured, cut the wrap and tuck in the loose end. How to Package the Shipment

41. Packaging Details (cont.) What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order Now that the order is pulled and packaged, it is time to notify the shipping manager that the order is ready to ship. It is important to notify the manager immediately so that Pinnacle will receive the product as soon as possible. The Shipping Manager will arrange shipping with a freight truck company and create the freight paperwork (known as a Bill of Lading). Attach the bill of lading to the packing slip. How to Package the Shipment

42. Your role in final shipment is to make sure that the last pallet loaded on the truck is the one with the packing slip. That way, Pinnacle will have the paperwork as soon as they start unloading the truck. Shipping the Order What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order Mixed 1 of 3 Mixed 2of 3 Mixed 3 of 3 Pack Slip How to Ship the Order

43. Order Complete What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order Once the parts are on the truck, your done with the shipment. Following the methods discussed here, you have done your part to ship carburetors correctly, quickly, and in good condition. When Pinnacle receives the right parts in a timely manner and in good condition, it helps them sell our parts faster. The faster Pinnacle sells our products, the quicker they will reorder from us. So you see that doing your job right every time really does make a difference. Keep in mind what you’ve learned as you work and let your manager know if you’d like to refresh your memory with this program in the future.

44. Ready To Try It Yourself? What Makes a Good Pallet How to Pull the Order How to Package the Shipment How to Ship the Order You’ve come to the end of the lesson. Take a moment to assess how well you could process an Pinnacle order. If you need to, go back and review. When you think you’re ready, inform the manager that you would like to pull a “test” order.