Solution ID: 200782365 Date Last Revised: 01/12/2005

Title: Carton Serialization for Pick, Pack and ShipAbstract: The following document describes the changes to the Container information and Advanced Ship Notice (UCC-128) information delivered through the Pick, Pack, & Ship enhancement in PeopleSoft EnterpriseOne 8.9.

Table of Contents

OverviewUCC-128/ASN Processing

Setup UPC/SCC Codes for ItemsSetup ASN Information for CustomersDefine Shipment ConfigurationsWarehouse SetupProcessing Options for Carton Reorganization (P4620)

Carton Label PreferenceExample of the Automatic Creation of Serial Numbers for Cartons

Pick Confirm (P4617)Carton Reorganization (P4620)ASN Information

Overview

Carton Serialization is the process of creating unique numbers that identify a specific carton on a shipment.  These serial numbers would most likely be placed on labels and attached to the cartons they identify.  Ultimately, these numbers represent the carton on the ASN and are arranged in a hierarchy.  The ERP 8.0 functionality, as enhanced through the Pick, Pack & Ship, automatically creates serial numbers for cartons based on the UCC-128 standard.  Although two layers, Tare and Pack, can be created and stored, only one layer of cartons can be created automatically by the system. If any additional layers are created manually, such as putting a case on a pallet, the original Tare or Pack numbers may be overridden and lost. 

The Carton Serialization enhancement for 8.9 has the following improvements from the ERP 8.0 release:

Change the process of creating and storing carton serial numbers, which, currently in ERP 8.0, can overwrite existing serial numbers and cause discrepancies between system data and the actual cartons

Rework functionality to handle the Label Next Number and Standard Pack Cartonization portions of the automotive enhancement. Note: Even though the Carton Reorganization (P4620) has all the necessary processing options, this portion of the enhancement will not be available until 8.10.

Improve the flexibility of automatically creating carton serial numbers.

Simplify the setup needed to take full advantage of the serialization functionality.

Carton Serialization changes now make it possible to store serial numbers for multiple layers of cartons without numbers being overridden and lost.  This enhances the ERP 8.0 cartonization method, by allowing multiple layers of cartons to be automatically created. This feature will improve the flexibility of creating serial numbers, while simplifying the setup.  The setup no longer requires checkboxes in the carton master or item UOM definition.

        Serial Numbers No Longer ‘Lost’ or ‘Wasted’

      Cartons Assigned a Unique Serial Number

Example Previous (ERP 8.0):                                         Tare                                                                     Pack            Pallet 12345 Blank

      Case 12345 04321•         Box 12345 04321

Example Current (ERP 8.9):                                                                                                                 Serial Number      Pallet                                                                                      12345

      Case                                                                          04321•         Box                                                              09876

UCC-128/ASN Processing

The process of using Advanced Ship Notices (ASN) in conjunction with serialized shipping container labels is commonly known in the retail industry as UCC-128 compliance. An ASN is an EDI document sent by the supplier to the customer when goods are shipped. It identifies what was shipped and how it was shipped. This EDI transaction in combination with a bar coded serialized shipping container label (applied by the supplier prior to shipment), automates the receipt process. As the retailer receives the goods, he/she scans the shipping label, which the system then matches to the ASN to generate internal transaction records.

Cartons with a UCC-128 label can be read by the inbound or outbound scanner systems, the data is ‘looked up’ in database, and the carton routed to its destination with no further labeling or labor. The UCC-128 bar code label is currently affixed to a majority of the inbound cartons by suppliers. The eighteen (18) digit bar code on the UCC-128 label identifies each carton uniquely, sort of its own serial number.  The customer’s host system generally receives Advance Shipping Notice (ASN) transactions from their suppliers which references the unique Carton Serial Number field in the UCC-128 bar code.

Setup UPC/SCC Codes for Items

To identify items for ASN purposes based on UPC/SCC codes. A UPC (Universal Product Code) identifies the lowest saleable unit of a specific product (usually the primary unit of measure).  The UPC code is the same as an EAN (European Article Number), the two codes are interchangeable.  An SCC (Shipping Container Code) identifies an “intermediate pack” of a specific product.  These codes are fixed and are either pre-printed on the product or applied as a label.  Besides generating the UCC 128/ASN information for the Item level (UPC code) and intermediate pack the system will also create the SSCC (Pack and Tare) information to manage placement of individual cartons in other types of operations.  Through the Carton Reorganization (P4620) the System generates Carton ID numbers to track nested, serialized containers (cartons, etc.) of either mixed or homogeneous product within larger unit loads. The Carton ID becomes the header number for a record which contains the carton’s inventory data.  Included in the record are content information, gross weight and the net weight of the contents of each carton.

The UCC-128 standard consists of both a Code symbol with a special start pattern and a data structure. The data is structured according to the Application Identifier (AI) format. An AI is a two, three, or four-digit number that defines the meaning of the data that follows.

SSCC in an UCC/EAN-128 Symbol

 

The AI (00) identifies the data in an UCC/EAN-128 Bar Code Symbol as an SSCC.  The AI (00) always prefixes the 18-digit SSCC when it is encoded in a UCC/EAN-128 Bar Code Symbol.  Based on Processing Options and Advance Preferences, UCC-128 SSCC Standard will generate two types of SSCC numbers.

      Tare – 1 0614141 000000011 8

•         Outermost Container or Pallet on Shipment

      Pack – 0 0614141 000000011 1

•         Second Level Case or Carton on Shipment

TARE: The tare level is used to identify pallets. These pallets are being shipped to a single final destination.  If there are no identifiable pallets, this level may be omitted.  Pallets are assigned a UCC-128 Tare SSCC

PACK: The pack level is used to identify the cartons, racks, bags, etc., in which the item is shipped, e.g. label serial numbers. In most cases there will be some sort of packs.  Cartons or Cases are assigned a UCC-128 Pack SSCC

To Set up UPCs/SCCs information for the item, select the specific Item Master Information (P4101) and take the Storage/Shipping row exit. UPC information is held in Item Master Tag (F4101T) file, data item UPCN.

Each item can have only one UPC and up to 8 SCCs, which are optional (PI=1 through PI=8).

UPCs are formatted such that the first 7 digits represent the company that produces the product, the next 5 digits represent the product ID, and the last digit is a system assigned check digit. For example, the UPC for PPS is 1111111254899

Before entering a UPC for an item, the product company must be set up in 41/UC UDC table.

An item can have up to 8 SCCs, each of which represents a different unit of measure (UOM), or packaging indicator (PI).  When entering a UOM, the system automatically assigns the SCC. Note: In the screen print above that the SCC is the same as the UPC, only the SCC has an extra digit on the front, and the last digit is different. The first digit represents the packaging indicator (PI) for the item. The first digit for SCC (PI = 1) will always be 1, for SCC (PI = 2) will always be 2, and so on. The system edits the check digit at the end of the SCC.

UPC information for specific items is held in Item Master Tag (F4101T) file.

Set Up ASN Information for Customers

Before transmitting ASNs to customers, applicable information for each customer needs to be set up.  Set up a default shipment configuration and shipping requirements for each customer in Customer Ship Notice tab of the Customer Billing Instructions (P03013).

Set up a default hierarchical configuration to indicate how shipments are configured to the customer. The default can be a “Pick and Pack” configuration, which allows for any combination of products to be present in a carton, or a “Standard Carton” configuration, which requires that only a single item be present.

Indicate required shipping information for each customer and for each line of business (if applicable).

Define Shipment Configurations

All hierarchical configurations must be defined in Hierarchical Configuration Definition (P47HL) off menu G47215.  The hierarchical configuration is defaulted from the Ship To Address, if one is not found for the Ship To then it will default from the Sold To.

 

A very common example of a hierarchical configuration is:

Name Code Description

SHIPMENT SData that applies to the whole shipment, such as Bill of Lading Number, Lading Quantity, Supplier Code, etc.

ORDER OData related to the receiver’s Purchase Order.

TARE T

Data related to a Shipping Container, such as a pallet. If there is no pallet identification, this level should not be used.

PACK PData related to the package, carton, etc. in which the item is shipped.

ITEM I Data related to the product being shipped, normally used to identify the

consumer unit.

To define a configuration, indicate which file field corresponds to each level in the configuration. For example, if the configuration is S O T P I (Shipment, Order, Tare, Pack, Item), SDCDCD is the field in the Sales Order Detail (F4211) table that contains the shipment number for an order line. SDDOCO is the field in the Sales Order Detail (F4211) table that contains the order number. XDPLT is the field in the SO Pack Confirm Detail (F4216) table that contains the Tare number for a shipment, and so on. Define configurations by Address Number, or enter zero (0) in the Address Book field to indicate that a particular configuration definition is applicable to all Address Numbers.

Warehouse Setup

The ERP8.0 setup required to create carton serial numbers has been simplified.  The field ‘Create UCC-128’ for which UCC-128 creation in ERP8.0 is no longer needed in the U/M Definition by Item (P46011) program.

The field ‘Create UCC-128’ was also removed from the Container and Carton Codes (P46091) program. These options are replaced by the Carton Label Preference.

Processing Options for Carton Reorganization (P4620)

The user will be able to choose when to create serial numbers in their process.  Options are:

Task/Trip R46471

Pick Confirm P4617

Carton Reorganization

P4620

Standard Pack Recommendations

P4615 (8.10 Automotive Enhancement)

Inbound Label Scanning

(External Process - 8.10 Automotive Enhancement) 

Any of these processes, through a version of the Carton Reorganization (P4620), can populate the appropriate UCC-128 information in the SO Pack Confirm Detail (F4216), Carton Detail Information (F4620) and Shipment Pieces (F4943) and can be seeing

online through Carton Reorganization (P4620), Carton Details (P4621), and Work with Shipments (P4915).

In order to create UCC-128 information the Carton Reorganization (P4620) has the following Processing Options:

      

The processing option #1 on the Serial Number tab of Carton Reorganization (P4620) has now 3 options:

Blank: do not create serial numbers 1: create UCC-128 style numbers

2: create label next numbers (this Functionality will not be available until 8.10)

Processing option #7 indicates whether to use the Carton Label Preference (Advanced Preference #39) or not.  This Preference determines what cartons get a serial number assigned and whether a SSCC Tare style or a Pack style is created.

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Carton Label Preference

The Carton Label Preference off menu G40311 is used any time the system automatically creates carton serial numbers (Task/Trip, Pick Confirm, Standard Pack Recommendations, or Scanning (8.10)) and the Carton Reorganization (P4620) Processing Option to use the Carton Label Preference is turned on.  If UCC-128 serial numbers are created and the Carton Label Preference is not being used, labels will be created for all cartons and will automatically default as pack style numbers.

In order to set up the Carton Label Preference an Advanced Preference Schedule is defined in the system constants. See the Advanced Preferences white paper (ODS-04-0016) for more information.

 

An Advanced Preference Name is attached to an Advanced Preference of type 39. Any of the relevant fields are filled in. It is recommended to use a preference hierarchy that moves from Sold To, Ship To, All Customers and All Items.  Items and Item Groups cannot be used as part of this preference.

Through Advanced Detail Preference Revisions the details associated with this Preference are added.

In combination with the Preference Hierarchy (P40073) and the Preference Detail (P4072) the user chooses which cartons get serial numbers based on any combination of the following:

Sold To Ship To

Branch/Plant

Carton Type

The Create Tare field asks whether a Pack style UCC-128 number or a Tare Style UCC-128 number is created, valid values are:

Blank:  Pack Style - The system will create a pack style number when the Carton Reorganization (P4620) processing option "Use Carton Preference" is '1', the UCC-128 option is being used on the Tare/Pack tab, and the Carton preference is set to create a pack number.

1 (One):  Tare Style - The system will create a tare style number when the Carton Reorganization (P4620) processing option "Use Carton Preference" is '1', the UCC-128 option is being used on the Tare/Pack tab, and the Carton preference is set to create a tare number.

The Carton Label Field drives whether or not a serial number is generated for this particular Carton Code valid values are:

Blank:  The system will not generate a serial number for this Carton Code.

1 (One):  The system will generate a serial number for this Carton Code.

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Example of the Automatic Creation of Serial Numbers for Cartons

Task and Trip Creation (R46471) Warehouse Task/Trip will use the defined version of Carton Reorganization (P4620) to determine whether or not to create serial numbers and recommend cartons for the suggestion processed.  Matching SO Pack Confirm Detail (F4216) records can also be created.  The Move Slips (R46472) shows the Carton being recommended

Pick Confirm (P4617)

The carton details can also be created from the Pick Confirmation program. In this example the Carton Detail Information (F4620) is already populated with carton details and carton serial numbers. The Pick Confirm (P4617) can create serial numbers for the confirmed suggestions along with SO Pack Confirm Detail (F4216) records only if they do not previously exist. In this case, since serial numbers already exist, they can not be overwritten.

Carton Reorganization (P4620)

The user can add, update, and delete multiple layers of a carton hierarchy and maintain the serial number for each and every carton without overwriting lower level serial numbers through Carton Reorganization. 

Carton Reorganization allows:

Serial numbers created automatically for entire shipment after Carton Reorganization pack confirm.

Manual serial numbers created for cartons by typing in the numbers.

System serial numbers created for cartons through the radio button.

Change existing serial numbers by typing in new numbers.

Edit existing serial numbers through the radio button.

For this test the Carton Detail Information (F4620) already shows all the Carton details and Carton Serial Numbers.  

Manual Assignment: If UCC-128 was not generated through Task and Trip Creation (R46471) or Pick Confirm (P4617), the same information can also be added manually to cartons/containers added from the Carton Reorganization (P4620) screen.

On this example the Carton Reorganization (P4620) is used to maintain the carton structure. The two cases are rolled up into a tare serial number (Pallet) added manually. Pallet/Carton is displayed in Carton Reorganization tree structure. 

The carton has a UCC-128 tare serial number assigned with the two child boxes. The items are displayed under the Pallet carton code with the UCC-128 pack serial numbers created by Task/Trip assignment.

ASN Information

The ASN Extraction functionality processes shipments that have matching records in Sales Order Detail (F4211) and SO Pack Confirm Detail (F4216) file. For each line of information in the Carton Detail Information (F4620), the system stores a record in the SO Pack Confirm Detail (F4216) file. 

The Carton Detail Information (F4620) shows the carton serial numbers, the pallet number is placed in the tare field while each case keeps its own pack number.  SCC number is blank because the order was created only for EA. The SO Pack Confirm Detail (F4216) table holds the Tare and Pack Serial Numbers for the top two carton levels, the outermost carton layer goes to the Tare and the second layer goes to the pack.

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