Root Cause: Confusion on axis orientation.

Answer: Length is the Picker Facing dimension. Refer to the "Length Width Height" tab in the configuration reference for a visual guide.

Root Cause: Some or all products may be missing dimensions.

Answer: When products do not have dimensions, there are two key risks to communicate to the client: 1. Under-utilization of totes and picking carts — instead of fitting as many items as possible, the system will fall back to hard limits configured for the client and warehouse. 2. If items are physically large, the system may create jobs where items do not fit into the assigned tote or picking cart.

Answer: Volume information is not mandatory.

Answer: The system calculates volume from the entered dimensions and compares it against the manually entered volume value. It then selects whichever value is smaller.

Root Cause: Batch picking and cluster picking require LP types in the system.

Answer: You need one LP type for batch picking and one LP type for cluster picking job types. The batch picking LP type must be larger than the cluster pick LP type so the system can correctly distinguish between them for each job type.

Answer: Yes. You need at least one LP type for cluster picking. The LP type must have the "Use for AI Jobs" toggle turned on and dimensions entered, since LPs created from this type are used during cluster pick. The dimensions of this LP type should be equal to or less than the cell dimensions of the mobile cart.

Answer: Yes. Create one LP type that is larger than all other LP types — this is used for batch picking. The "Use for AI Jobs" toggle must be on and dimensions entered correctly. When entering height, you may add a top-off margin (e.g., if physical height is 50 cm, you may enter 60 cm or more depending on overflow allowance).

Answer: Yes. Create at least several license plates from any LP type that has the "Use for AI Jobs" toggle turned on.

Answer: No. The customer does not need to relabel totes with the AI LP type. The LP type is a required configuration so AI can capture tote dimensions — it does not need to be physically used in the warehouse during picking. There is no need to relabel any LPNs or totes that are physically in use.

Answer: Yes. Having a batch pick cart as a location is a common practice, but the LP type is still required. Similar to the tote LP type, this LP type does not need to be used during picking — it is only for AI to capture batch picking cart dimensions.

Answer: The system selects the largest LP type with the "Use for AI Jobs" toggle turned on as the single batch picking cart reference. Job size will be based on this one LP type only.

Answer: Using the 2D map is not mandatory but is highly recommended. It is a beneficial additional setup for job optimization, but not required.

Also applies to: "How is the task sequence created?" "How is the picking path decided?"

Answer: When there is no 2D Map in the system, the optimization algorithm relies entirely on the Location Metadata provided in your IO data setup. To create a pick path, the system sequences tasks based on a specific hierarchy:

How to Improve Optimization: From a "bird's-eye view" perspective, the Zone, Aisle, and Column data must be unique enough for the system to distinguish between different physical positions.

Root Cause: Order-based jobs are generally the result of either order size being too large to fit into totes, or an LP type and mobile cart setting mismatch.

Also applies to: "Why are all orders in AI-OrderBasedPickPack?", "Why are these orders in Order Based Pick and Pack job type?"

Answer:

Check 1 — Mobile Cart Type & Mobile Cart Dimensions

First, verify that the client has Mobile Cart Types created and that cell dimensions are entered correctly. If cell dimensions are set to 0, the system will not create multi-item cluster picking jobs.

Check 2 — LP Types (Container Check)

If the client has mobile carts, they must also have LP Types configured for use with AI. Verify the following:

Additionally, a second, larger LP Type must also exist for Batch Picking job types. This LP Type must:

Check 3 — Product & Order Volume Check

Once mobile carts and LP Types are confirmed to be configured correctly, check whether the actual order volumes fit within the LP Type and mobile cart cell. In most cases, order-based pick and pack results from item volumes exceeding the available cell or tote capacity.

Follow these steps for the jobs reported as incorrect:

If the total order volume exceeds the mobile cart cell capacity, the system will assign those orders to the Order Based Pick and Pack job type. This is expected behavior — the fix is to either adjust LP Type dimensions, increase cell dimensions (see Critical Hack #1), or review order sizes with the client.

Answer: Even when only one job type is enabled, Order-based Pick and Pack remains the default job type active alongside any enabled type. For example: if a client enables Identical Order Batch Pick only, the system will create identical order batch picking jobs when minimum limits are met — but all other order types (single item, non-identical) in the wave will fall into the Order-based Pick and Pack job type.

Answer: No. If there are identical items with different lot or batch numbers, they will still be grouped into the same job. This may disrupt operations in lot-tracked warehouses and should be communicated to the client as a known limitation.

Answer: There is a configuration setting to separate identical orders from sort wall jobs. If this setting is set to True, the system will create an identical order batch pick job when there are enough qualifying identical orders.

Answer: The reason for this is the minimum item settings for identical item batch pick job type or minimum single item item count for single item batch pick job type. As an example if the minimum identical item item count limit is set to 5 AI will try to find orders that match the criteria. If it cannot find orders enough for this job type these orders become order based pick and pack initially. But AI tries to fit them into multi item cluster pick cart to at least gain some efficiency.

In some cases, wave might have more than 5 identical item orders. Let's say 18 orders. AI was able to fit 14 of these orders into 1 or 2 identical item jobs. There are 4 identical item orders left and since it is less than 5 AI will not create an identical item batch picking job. Same logic applies to single item batch picking as well.

Answer: Yes. Activation is done at the account/warehouse level, but clients can create a wave rule that allocates only specific clients' orders to be optimized by AI.

Answer: The system has been successfully tested with waves of approximately 50,000 order lines.

Answer: A maximum of 5 waves from one account can be triggered simultaneously. Leave at least 5 to 10 minutes between different AI wave schedules to avoid conflicts.

Answer: Optimization time depends on wave size. It may take between 5 minutes and 60 minutes for a typical wave.

Answer: Yes. The current time limit for job optimization is 2 hours. If a wave optimization is not finalized within 2 hours, rule-based jobs will be released to users to allow warehouse operations to continue.

Answer: The rule-based jobs are automatically released to allow operations to continue in the warehouse without delay.