How To Configure 'Each' Units In A WMS And Pick/Pack Processes

Each is the lowest commonly sold or handled individual unit in a product packaging hierarchy. Properly configuring each-level handling in a warehouse management system (WMS) and aligning physical processes avoids inventory errors, speeds fulfillment, and supports omnichannel sales.

This guide walks through the configuration and operational steps required to manage eaches effectively: defining SKU master data, mapping UOM conversions, labeling, receiving rules, pick/pack flows, and reporting. The goal is repeatable accuracy from dock to ship.

SKU Master Data And Unit Of Measure

Start with clean SKU master data. For every SKU designate the base UOM as the each and record precise dimensions and weights per each. Enter conversion rules for higher packaging levels (eaches per inner pack, per case, per pallet) and assign GTIN/UPC codes to the appropriate level(s).

• SKU Record: Include base UOM = each, alternate UOMs, GTIN for each, and case GTIN if cases are also barcoded.
• Dimensions & Weight: Capture per-each length/width/height and weight for cartonization and freight estimation.
• Conversion Factors: Define exact numeric relationships between each, case, and pallet to support automatic conversions.

Barcode Labeling Strategy

Labeling is critical. Ensure each sellable unit carries a scan-ready barcode tied to the SKU master. Where inner packs or retail-ready packaging exist, decide whether to use a separate barcode or a case GTIN for bulk transactions.

• Each Labels: Attach manufacturer UPC/GTIN or a warehouse-applied label if the product is repackaged.
• Case/Pallet Labels: Use SSCC pallet labels and case labels that include GTIN and quantity-to-each data to expedite receiving and putaway.

Receiving And Putaway Rules

Configure the WMS to accept receiving lines in each, case, or pallet UOMs and to apply conversion factors dynamically. Require scanning of case and each barcodes at receipt when mixed packaging is common. Putaway rules should consider whether eaches will be stored in bulk each locations, forward pick slots, or remain in case storage until broken for picks.

Picking, Break-Pack, And Packing Workflows

Design pick flows that minimize touches. For pure-each orders, enable piece-picking with zone or batch picks and use light-directed or voice pick to speed throughput. For mixed orders, establish break-pack stations where pickers convert cases into eaches; configure the WMS to record the conversion transaction and update inventory accordingly.

• Batch/Zone Picks: Combine each picks into waves to reduce travel time for high-volume SKUs.
• Break-Pack Control: Require scanning of both the case and the resulting eaches to prevent mismatches.
• Pack Validation: Use weight or barcode validation at pack stations to confirm correct each counts before shipment.

Returns And Reverse Logistics

Returns complicate each-level inventory. Create a disposition workflow that inspects returned eaches, assigns condition codes, and routes items back to sellable each locations or quarantine. Track returns by each to reconcile with original sales transactions and to adjust cost of goods sold properly.

Reporting, KPIs, And Replenishment

KPIs should reflect each-level realities: pick accuracy per each, order lines shipped complete per each, and each-level inventory days of supply. Replenishment algorithms must operate on the each where ecommerce demand is prominent; set reorder points and safety stock in each units to avoid stockouts on single-item orders.

Implementation Checklist

• Define UOM: Set base UOM = each in SKU master and document conversion factors.
• GTIN & Barcodes: Confirm GTINs for each and case levels; standardize label formats.
• Configure WMS: Enable multi-UOM transactions, break-pack transactions, and pack validation rules.
• Train Staff: SOPs for receiving, break-packing, picking, and returns with scan enforcement.
• Monitor KPIs: Track each-level accuracy, returns rate, and order lead times post-implementation.

In short, the Each must be explicitly defined in systems and processes to ensure inventory integrity and efficient pick/pack operations. With the right data model, barcode strategy, and operational controls, managing each-level inventory becomes predictable and scalable for omnichannel fulfillment.