Claim kits, create a pick run, and walk the route

A pick run is one walk of the floor that fills several kits at once. Instead of picking each kit separately and revisiting the same bin each time, ION groups the demand into stops (one stop per bin) and orders them into a route. Use it when several released kits need parts from overlapping locations. For a single kit, the Kitting page is still the shorter path.

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Claim a kit from the queue

The Kit request queue on the Kitting page lists the kits waiting to be filled.

1. Filter the queue with Open, My kits, or All.
2. Search by kit number, run, or part number with Search kit #, run, or part #.
3. Click Claim on a kit to take it. It moves into your My kits filter, so the rest of the team can see it is being handled.

The sort menu offers Recommended, Longest waiting, Newest first, Most fillable, and Least fillable. Use recommended puts the queue back on the recommended order. A kit that is already on a live pick run carries an On pick run #<n> pill.

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What the fillability badge means

The badge reads Fillable when every line can be picked from available stock, or <n>% · Short when it cannot. The percentage is the share of the kit’s remaining need that free inventory can cover. Two things it deliberately does not tell you:

• It is scored for that kit alone. Kits picked together in one run share the same inventory, so a batch can fill less than the individual badges suggest.
• It is advisory. The score is recalculated when its inputs change, so another transaction can consume stock the score still counts. The pick list at allocation time is the authority.

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Create a pick run

1. Select the kits you want to pick together using their checkboxes.
2. Optional: check Consolidated pull. See Per kit or consolidated.
3. In the bar at the foot of the queue, click Pick run for <n> kits.

ION plans the route immediately and opens the run. Planning happens before anything is written, so a run that would pick nothing is refused rather than created empty. A kit can be on only one live run at a time. If your selection includes a kit that is already on one, planning is refused, and the bar names the run that holds it with Resume run #<n> and Cancel so you can finish or release it first.

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Per kit or consolidated

A run is planned in one of two modes, and the mode belongs to the run: you choose it when you plan, and it can’t be changed afterwards.

• Per kit (the default). Each row on a stop is split per kit, so you can see how many units of that lot belong to which kit before anything leaves the shelf.
• Consolidated pull. As the checkbox’s own hint puts it, you “pull each part once per bin for the whole batch and sort to kits at the bench, instead of walking a separate pick for every kit.” Each row shows one quantity for the whole batch.

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Walk the run

On the pick run page, each stop is one bin, and its rows are the inventory to pull there. The bar at the top counts units and stops picked.

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How the route is ordered

Stops follow the pick order set on your locations, which runs across the whole site. Stops without a pick order come after every ordered stop, in bin-name order, and stock with no location comes last. To set the order, see Manage locations. A kit line filled from more than one bin walks at the earliest of them. One kit line can span several lots, so it can appear at one stop while its remainder sits at another.

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Confirm a stop

1. Tick each row as you pull it, or tick the stop itself to tick all of its rows. Confirm pick needs every row ticked.
2. Adjust a quantity inline if you pulled less than planned. The kits keep the shortfall as remaining need.
3. Click Confirm pick. This is the moment the stock moves: that bin’s inventory is issued into the kits, and the run moves on to the next stop.

A scan of the label on a stop’s last unticked row confirms the stop straight away, the same as ticking it and clicking Confirm pick.

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Scan to confirm

Scanning an inventory label ticks the row it belongs to, without a tap. Both a wedge (HID) barcode gun and the phone camera work. An ION barcode label identifies the one inventory record it was printed for, so the scan matches that record. A label read through a custom barcode pattern, such as a supplier label that encodes a part number and lot number, is looked up by those fields instead. Kitting splits a lot into several records that keep the same lot number, so either kind of scan can land on a piece that’s already in a kit rather than on the stock on the shelf, and open the mismatch prompt below. Scan the label on the stock you’re actually pulling.

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When you scan something the stop doesn’t plan

ION doesn’t accept it silently. It opens That is not the planned item, shows what you scanned, and asks Which planned item does it replace? Choose the row and click Use scanned instead. Using it records the scanned lot against the stop and why the pick diverged. Nothing moves yet: the stock moves when the stop is confirmed, or immediately if it was the last row you had left. The plan itself is left alone.

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Pick from another location

When the planned bin is empty or the stock there is unusable, click the location icon on a row. The Pick from another location dialog lists the part’s other stock in the order ION recommends it. Choose the lot you actually took and click Use this lot. ION records it against the stop when you confirm.

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A lot another stop is using

Picking a lot another stop of the same run also wants is allowed, and ION tells you what it costs:

• A lot another stop is owed. The row reads Already owed to stop <n> · <bin>. When you choose it, ION warns that it “spends the claim held by” that stop and that the stops below will be re-planned. Confirming releases the other stop’s claim and rebuilds the rest of the walk around it, so a later stop may move to a different bin or lot. ION refuses the pick only when the re-plan can’t cover what it released, and says why on the row.
• A lot staged on another stop. A lot you’ve already chosen as a substitute on another open stop on this page reads Already staged by stop <n> · <bin> and can’t be chosen again until that stop is confirmed or changed. Staging reserves nothing: it’s a choice on this screen that ION only records when the stop is confirmed. If another device takes the same lot first, ION refuses whichever confirm comes second.
• A lot another pick run holds. ION refuses it. Claims held by a different run aren’t released.

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Skip a stop

Click Skip stop when a bin cannot be picked. ION asks for a reason: Nothing is issued from a skipped bin. The kits keep their remaining need, and the reason is recorded so the plan can be improved.

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Re-plan a run

Click Re-plan when the plan no longer matches the floor. Stops you have already picked or skipped are kept exactly as they are. Only the pending stops are rebuilt against current stock, and they’re re-sequenced so the walk still runs forward from where you are.

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Sort the cart

Once every stop is done, the run page shows Sort the cart: one section per kit, listing the lines and quantities that were picked for it, and the bin and lot each came from. Tick a line, or tick a kit to tick all of its lines, as you move parts from the cart into each kit’s container. Ticking only keeps your place. The stock moved into its kit when you confirmed the stop, so nothing you tick here changes what ION holds.

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Print from a run

The Print menu groups what it prints:

• Paper
  • Pick sheet: the stops in walk order, for a picker working from paper.
  • Kit audit sheets: a sheet per kit with hand-tick Picked and Confirmed columns.
• Labels
  • Kit labels: one label per kit the run plans to fill, in walk order, so you can tag empty totes before the first stop.
  • Kit + assembly labels: the kit labels, plus one label for each assembly the kits’ runs are building. Several kits feeding one run share a single assembly label.
  • All labels: appears once the run is complete, and adds the labels for everything the run kitted.

Confirming a stop also offers to print labels for what that stop just issued. When a stop splits one lot across several kits, print those labels at the stop rather than leaving them for later. For how labels are ordered and printed, see Print a label.

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Mark kits delivered

When the run is complete, click Mark <n> kits delivered. Only kits attached to a run can be delivered this way. When none of the run’s kits are, the bar says No kits ready to deliver and See why lists the reason for each. The count is the kits the delivery will actually move. Delivered moves each kit to its delivery location, and its kitted inventory with it. The pick run itself is unchanged.

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Cancel a run

Click Cancel run to abandon a walk. The remaining walk is abandoned and the stock it was holding is released, so its kits can be planned onto a new run. Stops you’ve already picked are kept, and their stock stays in the kits. Cancelling can’t be undone, and a cancelled run becomes read-only.

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Find a run on the Kit Pick Runs page

Kit Pick Runs in the sidebar lists pick runs with their status, planner, location scope, batch mode, progress, expiry, and when they closed. Click a run number to open it. A live run has a Resume action. The page opens on live runs only: pending and in-progress. That narrowing is an ordinary filter, so the filter button shows it and Clear filters removes it. When it hides everything, the page says a status filter is narrowing the view and offers Show all statuses. Your filter choice is kept for the next visit.

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When a run expires

A pick run expires 24 hours after its last confirmed or skipped stop, or after it was planned if no stop has closed yet. Your organization can set a different window to match its shift pattern. Ticking rows or scanning doesn’t reset the clock; only closing a stop does. An expired run becomes read-only, and its claims on inventory are released, so the stock is free for other kitters immediately rather than being held by an abandoned walk. To pick its kits, plan a new run.