Capacity consumption staging area

[oskar_alarcon]

Hello everybody, I know that is a little extensive this post but I don't see any other way to explain it in detail. We are having an issue with the capacity consumption of the staging area, this area has a pallet flow rack with capacity for 15 pallets, the client wants only one consolidation group (TU/Destination) by bin. The storage type has this setup: Storage type role=D (staging area group), putaway rules =3 (consolidation group) and capacity check= 2 (check packaging material). Two things to considerate: First: with the storage type role D, is not possible put a quantity classification. Second: The source storage types have the behavior 2 (bulk storage), for that reason is not possible determinate the exact HU during the WT creation, and for that reason not possible get the capacity consumption by the HU, to solve this on the product master we create on the storage type data a view for the staging area ST, an on this view put a putaway quantity classification, this let the system determinate a packing specification when we create the WT, and on the pack specification we have the capacity consumption (1). This works ok if the WT is for full pallet, but if the WT is for less than a pallet (forward pick area) the WT "send" the boxes to the staging area and each WT consume 1 of the capacity of the bin, but on the creation of the order we send the less than a full pallet to a WC to consolidate them (we create WO for 2m3 that correspond to a full pallet size), but the WT already consumed capacity on the bin. To try to give better understand of the issue look this sample: we created 21 WTs, 11 of them are for only one box and the rest are for full pallet each one, on this moment the system “sends” 11 WTs for less than a pallet to the first bin, 4 full pallets to the first bin on the staging area (the capacity of 15 is full), and the other 6 to another bin. After that on the WO creation, the WTs for one box, are sent to a WC, and when consolidate them, only create one pallet, and when is closed, is sent it to the first bin on the staging area. The final result is 5 pallets on the first bin and 6 on other storage bin. Any clue how solving this? Thanks.