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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 /kitting 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.
Each card shows the kit number, its run, its destination (or No destination set), how much of it is already kitted, and a fillability badge.

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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.
Sorting the queue by Priority sorts on a custom attribute, not a built-in field, so it only appears once your organization defines a Priority attribute on kits. Use recommended returns the rail to its default order.

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Create a pick run

  1. Select the kits you want to pick together using their checkboxes.
  2. In the action bar, 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. If every selected kit needs stock another live run already holds, ION tells you so instead of opening a run you cannot walk.

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Walk the run

On the Pick run page, each stop is one bin. Its rows are the inventory to pull there, and each row is split per kit, so you can see how many units of that lot belong to which kit before anything leaves the shelf.

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How the route is ordered

Stops follow pickSequence on each location: a numeric walk order that matches your floor’s aisle layout. When a location has no pick sequence set, it comes after every sequenced location, ordered by a natural sort of the bin name, so Bin-2 precedes Bin-10 rather than following it. Stock with no location sorts last. Pick sequences are what make the route match the physical floor. Until they are set, the order is a reasonable guess from bin names, not your aisle layout.
There is no screen for editing pick sequences today. pickSequence is set through the API, on the location record. Ask your ION contact if you want your bins sequenced.

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Confirm a stop

  1. Tick each row as you pull it. The Confirm pick button’s tooltip reads Tick every row to confirm this stop.
  2. Adjust a split’s quantity inline if you pulled less than planned. The kits keep the shortfall as remaining need.
  3. Click Confirm pick to issue that bin’s stock into the kits and move to the next stop.

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Scan to confirm

Scanning a part’s inventory label ticks its row without a tap. Both a wedge (HID) barcode gun and the phone camera work. If you scan stock that is not on the open stop, ION opens a mismatch prompt rather than accepting it silently: it shows what you scanned alongside the stop’s rows, and you choose which row it should count against. The divergence is recorded, so the difference between what was planned and what the floor actually did is reportable later.

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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. When a stop splits one lot across several kits, each split needs a label at the moment of the split. Do not leave labels for a printer station to apply later.
  • Confirming a stop offers to print labels for what that stop just issued.
  • Print all labels on a completed run prints labels for everything the whole run kitted.
If a completed run kitted nothing, the button reports No labels to print rather than opening an empty print dialog.

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When a run expires

A pick run expires after 24 hours without picks. Your organization can set a different window to match its shift pattern. The clock is re-armed by activity, so the rule is no picks for 24 hours, not 24 hours old. An expired run becomes read-only and shows:
This run expired and is read-only. Its stock claims were released, so re-plan it before picking.
Its claims on inventory are released when it expires, so the stock is free for other kitters immediately rather than being held by an abandoned walk.