The Application of Barcode Technology in Electronic Factory Material Management - A Deep Dive into Chapter 7: Put-Away and Location Assignment |
Executive Summary (Chapter 7 Preview) |
The receiving dock is where materials enter the factory, but the put-away process is where they find their home. After a shipment is received and verified, every reel, tray, and tube must be assigned to a specific storage location within the warehouse. This process, known as put-away, is the critical link between inbound receiving and production kitting. A well-executed put-away ensures that materials are stored safely, can be retrieved quickly, and are tracked with absolute precision. This chapter explores how barcode technology transforms put-away from a manual, error-prone task into a systematic, verified operation. We will examine the concept of dynamic location assignment, where the system recommends the optimal storage spot based on part characteristics, availability, and workflow. We will explore how American and Chinese companies implement put-away using barcode scanning to confirm placement and update inventory maps in real time. Real-world examples from Oracle's warehouse management systems, Infor's Factory Track solutions, and Shenzhen Weiming Photoelectric's intelligent storage towers will illustrate how barcode-based put-away enables accurate inventory management and rapid material retrieval. |
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Chapter 7: Put-Away and Location Assignment |
7.1 The Journey from Dock to Bin |
Imagine a pallet of component reels arriving at the receiving dock of a large electronics factory. The pallet has been scanned, verified against the purchase order, and accepted into the system. Now the real work begins. Each reel must be moved from the receiving area to its designated storage location within the warehouse. This journey - the put-away process - is where the physical material meets its digital home. |
In a factory without barcode-based put-away, this process is fraught with risk. A worker might carry a reel to a random shelf, write the location on a piece of paper, and hand the paper to a data entry clerk. Days later, when production needs that reel, no one can find it. The material is 'lost' in the system, even though it is physically present. This leads to expediting, production delays, and wasted labor. |
In a barcode-enabled factory, the put-away process is systematic, verified, and instantaneous. The worker scans the material barcode, scans the location barcode where they place it, and the system updates the inventory map in real time. The material is now 'found' - its precise location is known to the system, and it can be retrieved with a single scan when production calls for it. |
This chapter explores how this transformation is achieved, from the underlying principles of location management to the real-world systems deployed by leading companies. |
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7.2 The Concept of Dynamic Location Assignment |
One of the most important innovations in modern warehouse management is dynamic location assignment. In the old model, every part had a fixed bin. A specific capacitor always went to bin A-12, regardless of how many were in stock or what else was stored nearby. This worked for small inventories, but it is hopelessly inefficient for the complexity of a modern electronics factory. |
Dynamic location assignment means that the system decides where to store each incoming shipment based on a set of rules and real-time conditions. The system considers factors such as: |
Part characteristics: Is the part moisture-sensitiveIf so, it should go to a climate-controlled area. Is it heavyIt should go on a lower shelf. Is it largeIt needs a larger bin. |
Turnover velocity: Fast-moving parts that are frequently issued to production should be stored close to the production line, minimizing travel time. Slow-moving parts can be stored in deeper, more distant racks. |
Space utilization: The system optimizes storage density, filling empty slots efficiently to maximize warehouse capacity. |
Lot management: Different lots of the same part may need to be stored separately to maintain traceability. The system ensures that new lots do not mix with older lots unless they are identical. |
Expiration management: Materials with approaching expiration dates can be stored in more accessible locations to ensure they are used first (FIFO - First In, First Out). |
The system recommends a location for each incoming material. The worker scans the material, scans the recommended location, and confirms placement. The system records the transaction, updating the inventory map in real time. If the worker places the material in a different location, they scan that location instead, and the system updates accordingly. |
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7.3 The Put-Away Workflow: Scan, Place, Confirm |
The put-away workflow in a barcode-enabled factory follows a consistent pattern, whether implemented in an American plant or a Chinese factory. Let us walk through the steps as they would appear in a typical warehouse management system. |
7.3.1 Receiving the Put-Away Assignment |
After receiving is complete, the system generates a put-away task. The task specifies the material to be put away, the quantity, and the recommended storage location. This task is sent to the worker's handheld scanner or mobile device. |
In Infor Factory Track, a warehouse management system used by many American manufacturers, the put-away transaction is initiated from the main menu. The worker taps 'Putaway,' and the system displays a screen where they can specify the origin of the items - purchase order, transfer, return, RMA, or job completion. This origin information helps the system track the material's source for traceability purposes. |
7.3.2 Scanning the Material |
The worker scans the barcode on the material label. The system looks up the item number and verifies that the material is eligible for put-away. If the item is lot-controlled, the worker may need to scan or select a lot number. If it is serial-controlled, the worker scans each serial number. This ensures that every individual unit is tracked, not just the lot as a whole. |
7.3.3 Scanning the Location |
The worker then scans the barcode on the storage location. In a modern warehouse, every bin, rack, and shelf has its own barcode label. These location barcodes are printed and placed on the physical storage spots. When the worker scans the location barcode, the system knows exactly where the material is being placed. |
Location barcodes can be generated and printed directly from the warehouse management system. In Odoo's inventory software, for example, location barcodes are automatically available when the storage locations feature is enabled. Users can select locations from the Locations screen and click Print to download a PDF of barcodes for all selected locations. This makes it easy to label new storage spots. |
7.3.4 Confirming the Quantity |
The worker enters the quantity being put away. If they are putting away only part of a received shipment, they specify the partial quantity. If they are putting away the entire quantity, they confirm the full amount. The system validates that the quantity does not exceed the received quantity. |
7.3.5 System Update and Completion |
When the worker confirms the transaction, the system updates the inventory. The material is now recorded as being in the scanned location. The system also updates the put-away status to 'Stored' or 'Completed.' If labels are configured to be printed, the system may print new labels for the material with the new location information. |
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7.4 System-Directed Put-Away: The Automated Approach |
While manual put-away is a significant improvement over paper-based tracking, system-directed put-away takes automation a step further. In this model, the worker simply follows the system's instructions. The system tells them where to go and what to scan, and the worker executes the task. |
Oracle's Warehouse Management Cloud offers robust system-directed put-away capabilities. The system can calculate a specific put-away type based on the inventory's characteristics and the available storage locations. A put-away method called 'Predetermined Location' allows the system to direct items to a predefined location or work center. |
For example, a factory might configure the system so that all moisture-sensitive components are automatically directed to a climate-controlled area of the warehouse. Or, high-value components might be directed to a secure, restricted-access area. The system applies these rules automatically, removing the need for workers to remember or decide where to place each item. |
Oracle's system also supports direct put-away to work center locations for items procured for immediate use in specific production areas. In this scenario, the purchase order includes the destination location, and the system directs the put-away directly to that work center, bypassing standard storage. This is ideal for components that are needed immediately on the production line and do not require storage. |
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7.5 Real-World Example: Infor Factory Track Put-Away |
To understand how put-away works in practice, let us look at a specific implementation. Infor Factory Track is a warehouse mobility solution used by many American and global manufacturers. The system provides a dedicated put-away transaction that guides workers through the process. |
In the Infor Factory Track put-away screen, the worker specifies the warehouse, the origin type (purchase order, transfer, return, RMA, or job), and the receiving location from which they are retrieving the material. They then scan the item number. If the item is lot-controlled, they select the lot number. The system displays the available quantity to put away. |
The worker then scans or selects the destination location - the 'To Location.' The system may suggest a location by default based on pre-configured rules. The worker enters the quantity to put away and selects 'Process.' If the item is serial-controlled, the system prompts the worker to scan each serial number individually. This level of granularity ensures that every unit is tracked. |
After processing, the system may prompt the worker to print labels. The worker selects a printer, specifies how many labels to print per box, and confirms the print job. The system then prints new labels with the material's updated location information. This ensures that the physical label matches the system's record. |
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7.6 Real-World Example: Shenzhen Weiming's Intelligent Material Tower |
In China, companies like Shenzhen Weiming Photoelectric Co., Ltd. have taken the put-away concept to a fully automated level with intelligent storage towers. The SMD-T Intelligent Material Tower is an automated storage system for SMD reels that integrates put-away with storage and inventory management. |
The SMD-T tower has a standard capacity of approximately 750 reels, expandable to 1,120 reels with height enhancement. It supports fully automatic inbound operations for reels ranging from 7 to 15 inches. A single reel can be processed in just 12 to 15 seconds. |
When a reel arrives for put-away, the system scans its barcode or QR code. The system then automatically assigns the reel to an available storage slot within the tower. The reel is mechanically loaded into the assigned slot, and the system updates the inventory in real time. This entire process - from code scanning to storage - is completely automated, requiring no human intervention. |
The SMD-T tower also supports batch loading, where multiple reels are scanned and loaded in sequence. The system can integrate with MES, ERP, and WMS systems, automatically backing up data and monitoring reel lifespan and inventory. It also tracks expiration dates and locks expired reels to prevent them from entering the production process. |
This level of automation eliminates the risk of human error in put-away. There is no chance of a worker placing a reel in the wrong bin, because the machine handles the placement. The system's precise location tracking means that any reel can be retrieved within seconds when production calls for it. |
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7.7 Location Barcodes: The Invisible Infrastructure |
Underpinning the entire put-away process is the location barcode. Every storage location in the warehouse - every bin, rack, shelf, and slot - must have a unique barcode label. These location barcodes are the 'addresses' of the warehouse, allowing the system to know exactly where every material is stored. |
Location barcodes are typically generated by the warehouse management system and printed on adhesive labels. In Oracle's Warehouse Management Cloud, location records include a barcode field that can be printed on labels. In Odoo, location barcodes can be printed directly from the Locations screen. In Infor Factory Track, location barcodes are part of the overall label printing process. |
The location barcode encodes a unique identifier for that specific spot. When a worker scans the location barcode during put-away, the system knows exactly where the material is being placed. When they later scan it during picking, the system knows where to find the material. The location barcode is the key that links the physical warehouse to the digital inventory map. |
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7.8 The Importance of Location Assignment in Traceability |
Put-away and location assignment are not just about efficient storage. They are essential for traceability. When a quality issue is discovered, the factory needs to know not just which lot is affected, but where that lot is physically located. If a component from a specific lot needs to be quarantined, the system must be able to identify its exact location so that workers can retrieve it quickly. |
Dynamic location assignment supports this traceability by associating each lot with a specific storage location. The system records not just that a lot exists, but where it is stored. This enables rapid recall and quarantine actions. As described in the Infor Factory Track process, the system tracks the origin of the put-away - whether it came from a purchase order, a transfer, or a return - creating a complete audit trail of the material's journey. |
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7.9 Comparing American and Chinese Approaches to Put-Away Automation |
The put-away process in American and Chinese electronics factories shares the same fundamental goals: accuracy, speed, and traceability. However, the implementation approaches can differ based on labor costs, capital investment, and operational philosophy. |
In many American factories, put-away is a semi-automated process. Workers use handheld scanners to scan materials and locations, and the system guides them through the process. This approach balances the benefits of automation with the flexibility of human decision-making. The Infor Factory Track and Oracle WMS systems exemplify this approach, providing powerful system-directed put-away while still relying on human labor for the physical movement of materials. |
In China, the trend is toward full automation. The SMD-T Intelligent Material Tower represents a future where put-away is entirely machine-driven. Reels are scanned, assigned, and stored without human intervention. This approach is particularly attractive in high-volume, low-mix environments where the capital investment in automation can be quickly recovered through labor savings and reduced errors. |
Both approaches are valid. The choice depends on the factory's specific needs, budget, and production volume. What is universal, however, is the reliance on barcode technology as the foundation of the put-away process. Whether a worker scans a reel with a handheld device or an automated tower scans it with an integrated camera, the material's identity is captured via barcode, and its location is recorded in the system. |
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7.10 Challenges and Best Practices in Put-Away |
While barcode-based put-away is a proven technology, successful implementation requires attention to several challenges. |
7.10.1 Location Label Durability |
Location labels are exposed to the warehouse environment - dust, humidity, and physical handling. They must be durable enough to remain readable for years. Many factories use polyester or polyimide labels with thermal transfer printing, similar to the labels used on components. The location label must also be large enough to scan easily, with a clear quiet zone and good contrast. |
7.10.2 Worker Training |
Workers must be trained to follow the put-away process correctly. They need to understand the importance of scanning the location barcode before confirming the transaction. A worker who skips the location scan and manually enters a location is introducing a potential error. Training programs should emphasize the 'scan, place, confirm' sequence. |
7.10.3 System Response Time |
The put-away transaction must be fast. A worker who waits for the system to respond before moving to the next task is wasting time. The system should confirm the put-away in milliseconds, as described in Chapter 5. Infor Factory Track and Oracle WMS are designed for this speed, but the underlying network and database must also be optimized. |
7.10.4 Integration with Other Systems |
The put-away system must integrate with receiving, inventory, and production planning. When a material is put away, the inventory is updated. This triggers reorder alerts if the stock falls below a threshold. It also makes the material available for production kitting. The integration must be seamless and real-time. |
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7.11 The Future of Put-Away: AI and Robotics |
The future of put-away in electronics factories is heading toward greater intelligence and automation. AI will play a growing role in optimizing location assignment. Instead of static rules, AI models will analyze historical data to predict which locations are optimal for each material. The system might learn that certain parts are frequently issued together and store them near each other. It might learn that certain lots are more likely to be recalled and store them in easily accessible locations. |
Autonomous robots, such as automated guided vehicles (AGVs) and autonomous mobile robots (AMRs), will increasingly handle the physical movement of materials. In this scenario, the system not only recommends the location but also dispatches a robot to carry the reel to that location. The robot scans the location barcode to confirm placement, and the system updates the inventory. The entire put-away process becomes zero-touch from the operator's perspective. |
The SMD-T tower is an early step in this direction, integrating put-away with storage and automated retrieval. As these systems become more sophisticated and affordable, they will become the standard in high-volume electronics factories worldwide. |
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Detailed Summary of Chapter 7 |
This chapter has provided a comprehensive examination of the put-away process - the critical step where received materials are assigned to specific storage locations and recorded in the factory's inventory map. We began by establishing put-away as the link between inbound receiving and production kitting, and the critical importance of accurate location assignment for inventory accuracy and production efficiency. |
We explored the concept of dynamic location assignment, where the system decides where to store each incoming shipment based on part characteristics, turnover velocity, space utilization, lot management, and expiration management. This contrasts with the old model of fixed-bin storage, which is inefficient for the complexity of modern electronics manufacturing. |
We walked through the put-away workflow: receiving the assignment, scanning the material, scanning the location, confirming the quantity, and system update. We described how this workflow is implemented in real-world systems such as Infor Factory Track, where workers use handheld scanners to execute put-away tasks with system guidance and verification. |
We then examined system-directed put-away, where the system automatically determines the optimal location and guides the worker. Oracle's Warehouse Management Cloud provides powerful system-directed put-away capabilities, including the ability to direct materials to predetermined work center locations for immediate production use. |
A major focus of the chapter was the real-world example of Shenzhen Weiming Photoelectric's SMD-T Intelligent Material Tower. This fully automated storage system for SMD reels performs put-away with minimal human intervention. The tower scans barcodes or QR codes on incoming reels, automatically assigns them to storage slots, and updates the inventory in real time. With a capacity of up to 1,120 reels and a cycle time of just 15 seconds per reel, it represents the cutting edge of put-away automation. |
We discussed the critical role of location barcodes as the physical addresses of the warehouse. We described how location barcodes are generated, printed, and used in put-away and picking. We also compared American and Chinese approaches to put-away, noting that American factories often favor semi-automated, worker-guided systems, while Chinese factories are increasingly adopting fully automated storage towers. |
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Finally, we addressed the challenges of put-away implementation - location label durability, worker training, system response time, and integration with other systems - and looked to the future of AI-driven and robotics-enabled put-away. |
The bottom line is that barcode-based put-away, whether guided by a handheld scanner or executed by an automated tower, is essential for maintaining accurate inventory records and enabling rapid material retrieval. When every put-away transaction is verified by scanning both the material and the location, the inventory map becomes a reliable representation of the physical warehouse. This reliability, in turn, enables just-in-time production, reduces expediting, and supports robust traceability and recall capabilities. The next chapter will explore the next step in the material's journey: kitting for production, where the put-away records are used to issue materials to the production line. |
cs@easiersoft.com