Opex Perfect Pick Cortex Operator's Manual

All rights reserved. This document is provided by OPEX for use by their customers, partners and dealers. No portion of these materials may be reproduced, published, or stored in a database or retrieval system, other than for its intended use without the express, written consent of OPEX Corporation. August 2020 Perfect Pick® Cortex™ Operator Manual WARNING Read this manual thoroughly before attempting to operate or service this equipment. Keep a current copy for your reference. 9146910OM-EN Revision 20-01 Original Instructions Cortex™

OPEX Corporation Contacting OPEX For technical support: OPEX Technical Support 835 Lancer Drive Moorestown, NJ 08057 USA Americas: 1 800.673.9288 -OR- 856.727.1950 EMEA: +1 800.673.9288 Australia: +1 800.945247 [email protected] https://www.opex.com/support-service For other inquiries: OPEX® Corporation 305 Commerce Dr. Moorestown, NJ 08057-4234 USA Tel: +1 856.727.1100 Fax: +1 856.727.1955 https://www.opex.com/ If you find errors, inaccuracies, or any other issues or concerns with this document, please contact the OPEX Technical Writers via email at: [email protected] For help with opexservice website-related issues, please contact the OPEX Web Developers via email at: [email protected]

OPEX Corporation Document History Translation History Language codes: Doc Rev Date Changes (click blue text to go to that page) 20-01 Aug. 25, 2020 Initial release. Table 1: Revision history for translated manuals Source (English version) Date Translation Revision Details (click blue text to go to that page) DE German ES Spanish IT Italian PL Polish EN English FR French JA Japanese

Perfect Pick Cortex™ Operator Manual OPEX Corporation Table of Contents Chapter 1 Introduction 1.1. About This Manual .................................................................................. 8 1.1.1. Manual navigation ........................................................................... 8 1.1.2. Safety message conventions .......................................................... 9 Chapter 2 Safety 2.1. Safety Guidelines .................................................................................. 12 2.1.1. Arc flash and electrical safety ........................................................ 13 2.1.2. Electrostatic discharge precautions ............................................... 14 2.2. Personal Protective Equipment (PPE) .................................................. 15 2.3. Safety Labels ........................................................................................ 16 2.3.1. Workstation Labels ........................................................................ 17 2.3.2. Perfect Pick Operator Station Labels ............................................ 23 2.4. Emergency Stops (E-stops) .................................................................. 27 2.5. Light Tower ........................................................................................... 29 2.6. Lock-out Tag-out (LOTO) Procedures .................................................. 30 2.6.1. What is Lockout Tag-out? ............................................................. 30 2.6.2. Lock-out/Tag-out devices required ................................................ 31 2.6.3. LOTO - Machine Maintenance and Repair .................................... 32 2.6.4. Fully de-energizing AC power ....................................................... 36 2.6.5. Restoring the machine to normal operation .................................. 37 2.7. Ergonomics ........................................................................................... 39 Chapter 3 Overview 3.1. Overview ............................................................................................... 42 3.2. Cortex Workflow .................................................................................... 43

5 Perfect Pick® Cortex™ Operator Manual OPEX Corporation 3.2.1. Cortex workflow ............................................................................. 44 3.3. The OPEX Integrated Workstation ........................................................ 47 3.4. Perfect Pick ........................................................................................... 48 3.4.1. Cortex Computer ........................................................................... 49 3.4.2. WRTC Computer ........................................................................... 49 3.4.3. Bin Locator Light ........................................................................... 49 3.5. Cortex Software .................................................................................... 50 3.5.1. Workstation User Interface (WUI) ................................................. 50 3.5.2. Warehouse Real Time Controller (WRTC) .................................... 50 3.5.3. Aisle Controller (AC) ...................................................................... 51 3.6. Understanding Zones ............................................................................ 52 3.6.1. Zone sensors ................................................................................. 53 Chapter 4 Operation 4.1. Starting up the system .......................................................................... 58 4.1.1. Launching the Perfect Pick host software ..................................... 58 4.2. Starting the Cortex system .................................................................... 62 4.3. Operating the Cortex system ................................................................ 64 4.3.1. Pick mode ...................................................................................... 73 4.3.2. Put-away mode ............................................................................. 76 4.4. Workstation User Interface tabs ............................................................ 83 4.4.1. Order Info tab ................................................................................ 83 4.4.2. Details tab ..................................................................................... 84 4.4.3. Selected tab .................................................................................. 84 4.4.4. Work Queue tab ............................................................................ 85 4.4.5. Options tab .................................................................................... 86 4.4.6. System Status tab ......................................................................... 87 4.5. Hot Actions ............................................................................................ 88 4.5.1. Cycle Count ................................................................................... 89 4.5.2. Audit ............................................................................................ 100 4.5.3. Consolidate ................................................................................. 101 4.5.4. Cubing ......................................................................................... 102

Perfect Pick Cortex™ Operator Manual OPEX Corporation 4.5.5. Reprint ......................................................................................... 107 4.5.6. Reconfigure Tote ......................................................................... 107 4.5.7. Sequence .................................................................................... 108 4.6. Preventive Maintenance ..................................................................... 109 4.6.1. Mirrors ......................................................................................... 109 4.6.2. Sensors ....................................................................................... 109 Chapter 5 Troubleshooting 5.1. Overview ............................................................................................. 112 5.2. Workstation interruptions .................................................................... 114 5.2.1. Interrupted zone - stage sensor blocked ..................................... 114 5.2.2. Missed window ............................................................................ 115 5.2.3. Interrupted zones with missed windows ...................................... 117 5.2.4. Missed barcode read ................................................................... 118 5.2.5. Unknown containers .................................................................... 120 5.2.6. Duplicate Scan ............................................................................ 121 5.2.7. Last Zone Interruption ................................................................. 123 5.2.8. Container Collision ...................................................................... 124 5.2.9. All interrupted zones .................................................................... 125 Chapter G Glossary G.1. List of Acronyms ................................................................................. 128 G.2. List of Terms ...................................................................................... 129

Operator Manual 1. Introduction 1.1. About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.1.1. Manual navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.1.2. Safety message conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

OPEX Corporation 1.1. About This Manual This manual contains information about the OPEX Cortex™ system and its operational procedures and safety-related components, including: • safety information, safety hazards and precautions • component identification and function • system specifications • operation and use This information is required to ensure proper and safe operation of the machine. This manual will be updated to reflect equipment design changes, part number changes, or to correct errors (a table detailing the document revision history can be viewed on page 4). Be sure to retain the latest electronic release of the manual for your reference. The latest release can be downloaded in PDF format at www.opexservice.com (authorized, registered users only). 1.1.1. Manual navigation This manual is designed primarily for use on a tablet device. To improve navigation, the manual contains blue underlined links you can click on or tap to go directly to a particular page or web address. In addition, all items in the “Table of Contents” as well as the bookmarks in the side bar of the PDF file can be clicked or tapped to navigate directly to a particular page. Make sure to use the latest version of Adobe® Acrobat Reader®* for optimal performance. *Adobe and Acrobat Reader are registered trademarks of Adobe Systems Incorporated.

OPEX Corporation 1.1.2. Safety message conventions This manual uses the following conventions to alert you about safety hazards associated with certain procedures and situations. Please be aware of these conventions when reading the manual and operating the equipment: See important safety information in Chapter 2: “Safety”. DANGER Indicates a hazardous situation that, if not avoided, will result in death or severe injury. The use of this signal word is limited to the most extreme situations. WARNING Indicates a hazardous situation that, if not avoided, could result in death or serious injury. CAUTION Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury. NOTICE Indicates information considered important, but not hazard related (e.g. messages relating to property damage).

OPEX Corporation (This page is intentionally blank)

Operator Manual 2. Safety 2.1. Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 2.1.1. Arc flash and electrical safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 2.1.2. Electrostatic discharge precautions. . . . . . . . . . . . . . . . . . . . . . . 14 2.2. Personal Protective Equipment (PPE) . . . . . . . . . . . . . . . . . . . . . 15 2.3. Safety Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2.3.1. Workstation Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2.3.2. Perfect Pick Operator Station Labels . . . . . . . . . . . . . . . . . . . . . 23 2.4. Emergency Stops (E-stops). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 2.5. Light Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 2.6. Lock-out Tag-out (LOTO) Procedures . . . . . . . . . . . . . . . . . . . . . 30 2.6.1. What is Lockout Tag-out? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 2.6.2. Lock-out/Tag-out devices required . . . . . . . . . . . . . . . . . . . . . . . 31 2.6.3. LOTO - Machine Maintenance and Repair . . . . . . . . . . . . . . . . . 32 2.6.4. Fully de-energizing AC power . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 2.6.5. Restoring the machine to normal operation. . . . . . . . . . . . . . . . . 37 2.7. Ergonomics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

OPEX Corporation 2.1. Safety Guidelines This section provides safety guidelines to be observed when working with this equipment. The Perfect Pick HD® and OPEX Workstation adhere to the NFPA 79 electrical standard for industrial machinery, which provides safeguards to protect operators, equipment, facilities, and work-in-progress from fire and electrical hazards. Familiarize yourself with the location of the Emergency Stop (E-stop) switch and pull-cord. The E-Stop switches and E-stop pull-cord enable a quick stop of all motors in the machine, in the event of an emergency involving potential personnel injury. Pressing an E-Stop switch or pulling the E-stop pull-cord stops movement of the conveyor. Electrical Safety - Always assume electrical wiring is hot any time the machine is plugged in. Failure to use caution may result in severe bodily injury or death from electric shock. Use caution to avoid contact with exposed, non-insulated areas of any electrical devices or wiring. Never handle or place a tool on the exposed terminals of any electrical device, such as a circuit breaker, transformer, switch, relay, terminal block, fuse block, for example, without first shutting off all power to that device. Ensure that all electrical outlets and extension cords are equipped with a third earth grounding conductor-to-chassis ground. Keep loose objects away from any exposed, moving parts of the machine - The moving parts of the Perfect Pick Integrated Work Station can become jammed and/or damaged by foreign objects. Keep hands, hair, loose clothing and jewelry away from the moving parts. CAUTION Follow these safety guidelines whenever installing, operating, servicing, or maintaining the equipment described in this manual.

OPEX Corporation Proper Tool Usage - Keep loose tools and other objects away from any electrical and mechanical components of the machine. Use and maintain tools properly, according to manufacturer’s instructions. Do not attempt to clean the machine while it is running - A cloth (or similar material) should never be used to clean moving parts such as belts or rollers. The use of such material on moving mechanisms can result in damage to the machine or severe personal injury. If a belt, roller, gate or similar part needs to be cleaned, hand-crank the part during cleaning or clean it while stationary. Do not use flammable, high pressure, “canned air” to clean dust and debris from the machine. Keep away from children - This equipment is not suitable for use in locations where children are likely to be present. Personal Protective Equipment (PPE) - Wear personal protective equipment that is appropriate to the job being performed. Requirements for personal protective equipment such as face masks, vests, safety glasses, and gloves may vary with the build site, depending on local code and end-user customer safety policies. 2.1.1. Arc flash and electrical safety The owner of this equipment is responsible for developing and maintaining safe work policies and practices to minimize employee exposure to arc flash and electrical shock hazards. These practices should be in accordance with applicable workplace safety codes and should include: a) evaluation of the equipment for arc flash and electrical shock hazards; and b) proper labeling of the equipment to alert employees to the hazards, arc-flash boundaries, and PPE requirements. For more information, refer to applicable electrical safety publications of the country or region where the equipment is operating. USA customers: refer to publication NFPA 70E, Standard for Electrical Safety in the Workplace Canada customers: refer to CSA Z462-15, Workplace Electrical Safety EU customers: refer to British Standards BS EN 50110-1:2013 Operation of electrical installations- General requirements

OPEX Corporation 2.1.2. Electrostatic discharge precautions The printed circuit boards used in the Perfect Pick Integrated Work Station are particularly susceptible to damage from electrostatic discharge (ESD). For this reason, basic precautionary measures must be taken while handling these devices: • Always wear an anti-static wrist strap when handling circuit boards. • Always handle circuit boards by their edges, never putting your fingers on edge connectors or components. • After removing a circuit board, place it either on an ESD-grounded mat or into an electrostatic shielding bag. • Always store and ship circuit boards in electrostatic shielding bags. • Never place anything else in the electrostatic shielding bag with the board.

OPEX Corporation 2.2. Personal Protective Equipment (PPE) Personal protective equipment (PPE) refers to wearable safety items such as gloves, safety glasses, hard hats, and high-visibility vests. The Perfect Pick/Cortex system falls within Arc Flash PPE Category 1 for Alternating Current (AC) systems, per NFPA 70E standards. The following PPE items are advised for Arc Flash Category 1, per NFPA 70E, and are recommended during the period beginning with machine installation and commissioning, prior to completion of the machine owner’s (customer’s) arc flash and electrical hazard assessment and labeling. • Arc-Rated Clothing, Minimum Arc Rating of 4 cal/cm2 (16.75 J/ cm2) - Arc-rated long-sleeve shirt and pants or arc-rated coverall - Arc-rated face shield or arc flash suit hood - Arc-rated jacket, parka, rain wear, or hard hat liner (AN) • Protective Equipment - Hard hat - Safety glasses or safety goggles (SR) - Hearing protection (ear canal inserts) - Heavy-duty leather gloves - Leather footwear (AN) Check with local law and the specific job site to find out what additional PPE is required before starting.

OPEX Corporation 2.3. Safety Labels Safety labels are used in specific locations throughout the Cortex system to alert you to certain safety hazards. These labels may appear in various languages or styles depending on the region or country where the machine is operating: • Bilingual English/Spanish labels for US machines • Bilingual English/French labels for Canadian machines • Graphics-only labels for EU and various international machines (no text). Although they appear different, the locations of these labels are identical. Note: Only those labels found within the Cortex system will be described here. Please refer to the Perfect Pick Operator Manual for all Perfect Pick labels and their locations. WARNING Follow the safety precautions on all labels when operating and maintaining the Cortex system. Failure to follow these precautions may result in severe bodily injury or death as well as damage to the machine.

OPEX Corporation 2.3.1. Workstation Labels 2.3.1.1. Arc Flash and Shock Hazard Warning label Location: Front of Workstation Control Panel (Table 2-1). Purpose: Advises owner of machine to follow all arc flash and electrical safety requirements per applicable standards.This is a temporary label to be removed by the employer only, after completion of arc flash and electrical hazard assessment and labeling (see “Arc flash and electrical safety” on page 13). Table 2-1: Arc Flash and Shock Hazard warning label Label location Description US (8165700) CA (8165710) AU, EU, JP (8165730) Front of Workstation Control Panel

OPEX Corporation 2.3.1.2. Ratings / Serial Number label Location: Underneath power switch on Workstation Control Panel (Table 2-2). Purpose: Identifies product electrical ratings, machine serial number for U.S. & Canada; EU; Japan. Table 2-2: Ratings/Serial Number label Label locations Description All (6088000) Front of workstation control panel VOLTAGE: 480VAC CORPORATION MOORESTOWN, NJ (USA) R MANUFACTURER: CURRENT: 6A SCCR: 200kA DRAWING NUMBER: 6055400 SERIAL NUMBER: ##### FREQUENCY: 60Hz PHASES: 3P+E BUILD DATE: 08/2020

OPEX Corporation 2.3.1.3. Fuse Chart label Location: Inside hinged cover of Workstation Control Panel (Table 2-3). Purpose: Identifies the correct fuses needed within the control panel. Table 2-3: Fuse Chart label Label location Description All (6088100)

OPEX Corporation 2.3.1.4. Agency Approval label Location: Front of Workstation Control Panel (Table 2-4). Purpose: Identifies that the system has met agency approval qualifications. The ETL label is not an OPEX label; it is provided by Intertek after field inspection is completed. Table 2-4: Agency Approval label Label location Description All (N/A)

OPEX Corporation 2.3.1.5. Zone labels Location: Front edge of: Scan Tunnel, staging conveyor, Workstation; one at the end of the input conveyor, one at the beginning of the output conveyor (Table 2-5). Purpose: Used to identify each of the zone locations for containers/boxes. Table 2-5: Zone label Label location Description All (N/A)

OPEX Corporation 2.3.1.6. Sensor Cover labels Location: Front edge of Scan Tunnel (Table 2-5). Purpose: Identifies the sensor cover tool, and the location where it is used. Placing the cover in this location blocks a sensor and prevents containers from entering the OPEX Scan Tunnel. Table 2-6: Sensor Cover labels Label location Description All (N/A)

OPEX Corporation 2.3.2. Perfect Pick Operator Station Labels Note: Only the Perfect Pick labels seen by the operator when in the pick station area are described here. Descriptions of all other Perfect Pick safety labels can be found in the Perfect Pick Operator Manual. 2.3.2.1. Machine Entry label Location: Both sides of the Pick Station (Table 2-7). Purpose: Informs that only approved OPEX technicians and qualified personnel can enter the machine. Table 2-7: Machine Entry label Label location Description US (7681300) CA (7681310) AU, EU, JP (7681330)

OPEX Corporation 2.3.2.2. Keep Hands Away label Location: Both both sides of each pick station, on the metal plate above the diagonal track (Table 2-8). Purpose: Informs the operator to keep hands, hair and loose objects away from any exposed, moving parts of the machine. The moving parts of the Perfect Pick can become jammed and/or damaged by foreign objects. Table 2-8: Keep Hands Away label Label location Description US (7686000) CA (7686010) AU, EU, JP (7686030) Pick station Pick station left side right side

OPEX Corporation 2.3.2.3. Safe Use Notice Location: Front of the pick station on the computer access door (Table 2-9). Purpose: Advises personnel to read Instruction Manual for safe use. Table 2-9: Safe use notice label Label location Description US (8074300) CA (8074310) AU, EU, JP (8074330) Front of pick station

OPEX Corporation 2.3.2.4. UPS Voltage Present Warning label Location: Front panel door where the UPS is located (Table 2-10). Purpose: Warns about residual electrical hazard inside, and to disconnect UPS power before servicing. Table 2-10: UPS voltage warning label Label locations Description US (2850900) AU, CA, EU, JP (2850910)

OPEX Corporation 2.4. Emergency Stops (E-stops) For operator safety, the Cortex system incorporates Emergency-Stop (E-stop) switches, as well as a pull cord to stop the machine in the event of an emergency. There is an E-Stop located on the OPEX Scan Tunnel, and one on the Perfect Pick at the Operator Station. Details regarding the Perfect Pick E- stop can be found in the Perfect Pick Operator Manual. If you hit the Scan Tunnel red e-stop button, the conveyor system will stop. You must disengage the e-stop for the Cortex system to be able to continue running. Once you have disengaged the e-stop, you must hit the reset button and then the Start button on the main enclosure for the conveyor to start. Note that the machine will still remember container positions during an E-stop. There is also a pull cord attached to the emergency stop which runs from the e- stop button to zone one. Pulling this long, tensioned cable is the same as pressing the e-stop button. Pushing any E-stop button or pulling the E-stop cable cuts power to the conveyors. The exact placement of the body of this device depends on the site. Usually, it is mounted to the OPEX scan tunnel. The pull-cord runs the length of the work station, just below the side of the conveyor area.

OPEX Corporation The pull-cord E-stop (Figure 2-1) has two versions available, supporting maximum lengths of 38 meters and 75 meters. Aside from the maximum length, the only difference is that the 75-meter version requires higher tension. This means the 75-meter version can be used in place of a 38-meter version if you account for the tension setting. Figure 2-1: Pull-cord E-stop

OPEX Corporation 2.5. Light Tower A light tower is mounted on the workstation at the back corner furthest from the Perfect Pick (Figure 2-2). Note that the color bands for the Workstation light tower are in reverse order from the light tower on the Perfect Pick. Figure 2-2: Workstation Light Tower Note: From Maintenance mode, the machine is restarted, which will bring the solid green light on in addition to the flashing blue light. Once the technician determines that the machine is operating properly, he/she will turn off the flashing blue light by exiting out of Maintenance mode, leaving only the solid green light. • Audible - beeps when starting • Red – Interlock/E-Stop tripped • Yellow – Flashes on start-up • Blue – Jammed/maintenance required (see note) • Green – Running/Normal Operation

OPEX Corporation 2.6. Lock-out Tag-out (LOTO) Procedures 2.6.1. What is Lockout Tag-out? Lockout Tag-out (LOTO) is a safety procedure to ensure that a machine is safely shut off and cannot be powered up or operated while maintenance or repair work is performed. During a LOTO event, Authorized service personnel must install locking devices, including padlocks and warning tags, to the machine’s power controls, electrical plug or remote electrical disconnect switch (see examples in Figure 2-3). The LOTO devices must only be removed by the Authorized service personnel, once they determine that the work is complete and the machine is safe to operate. Figure 2-3: Examples of LOTO devices installed WARNING Only Authorized Employees are permitted to perform the LOTO Procedures. Lockout device(s) MUST be installed to the machine before servicing to prevent power from being applied while working on the machine. Operators and/or other Affected Employees: Do not attempt to remove or defeat the lockout devices or operate the machine while it is locked out.

OPEX Corporation 2.6.2. Lock-out/Tag-out devices required 2.6.2.1. Lockout station The LOTO procedures require the use of the Lock-Out Station (Figure 2-4) or an equivalent kit. Figure 2-4: Lock-Out/Tag-Out Wall Mount Station This kit includes: Wall mountable container 4 keyed-different padlocks 2 Hasps 12 tags 12 Cable Ties

OPEX Corporation 2.6.3. LOTO - Machine Maintenance and Repair Power down the PPIWS and install the lockout device as follows: 1. Notify all personnel that you are about to begin the LOTO procedure. 2. Place the “Caution” sign on the monitor (Figure 2-5). Figure 2-5: Caution Sign DANGER You must shut down and lock out the Perfect Pick Integrated Work Station (PPIWS) to prevent others from inadvertently applying power while you are working on the machine. Be aware that there could be more than one technician working on the machine. In this case, you could see more than one lock on the hasp.

OPEX Corporation 3. Turn off the power switch on the Workstation control panel (see Figure 2-6). Figure 2-6: Main power switch - off 4. Disconnect the ECAT_IN cable (Figure 2-7). Figure 2-7: Remove this cable Main power switch

OPEX Corporation 5. Pull the red tab out on the main power switch and place a hasp on it (Figure 2-8). Figure 2-8: Hasp detail 6. Attach a padlock to one of the holes in the hasp. Each Authorized Employee working on the machine must have their own lock, and that lock must have their name on it or an identifying tag that cannot be easily removed or damaged. The key must be kept in the possession of that Then close the hasp, so that a padlock can be attached through one of the six holes Open the hasp, and attach it to the switch.

OPEX Corporation person. You can also simply attach the lock to the red tab out on the main power switch (Figure 2-9). Figure 2-9: Lockout switch with padlock

OPEX Corporation 2.6.4. Fully de-energizing AC power At most customer sites, the PPIWS is hard-wired to a dedicated AC main disconnect switch located near the machine. To safely de-energize the PPIWS AC Distribution enclosure, the incoming power must be shut off by turning off and locking out the customer’s main disconnect switch. An Authorized Employee or qualified electrician must proceed as follows: 1. Complete all steps under “LOTO - Machine Maintenance and Repair” on page 32. 2. Customer’s site maintenance personnel only: shut off the main AC disconnect switch and install a Lockout-Tagout device (Figure 2-10). Figure 2-10: Example- AC main disconnect with Lockout/Tagout WARNING Contact the customer’s site supervisor before attempting this procedure. Only the customer’s authorized site maintenance personnel are permitted to shut off the site AC power.

OPEX Corporation 2.6.5. Restoring the machine to normal operation After the jam is cleared or the required maintenance or repair is complete, the Authorized Employee shall restore the machine to normal operation as follows: 1. Remove all tools and other materials from the area. 2. Ensure the machine is closed up and operationally intact. 3. Notify operators and affected persons that the machine will be restarting. 4. Make sure everyone is safely away from the machine. 5. Verify all controls are set to the neutral or OFF position. 6. Remove all LOTO devices and “Caution” sign. 7. Turn the power switch to the ON position. 8. Verify that the lights in the control panel are on (Figure 2-11). Figure 2-11: Workstation control panel lights 9. Reconnect the ECAT-IN cable. Note: The ECAT-IN disconnect/reconnect needs to be clean and in one motion; any noise on the line will cause the InTime to crash. Should this occur, contact OPEX Technical Support.

OPEX Corporation 10. Press the Start button on the top of the Workstation/Conveyor (Figure 2- 12). Note that the location for this button may vary. Figure 2-12: Workstation Start button 11. Fix any discrepancies, and then notify the operators and affected persons that LOTO devices have been removed and equipment is now ready for use.

OPEX Corporation 2.7. Ergonomics As in any occupation that requires you to perform the same motion repeatedly during the course of your work, it is important to consider how you perform your task. Listed below are some guidelines to help you minimize the risk of physical discomfort and injury while operating the equipment. When at the pick station: • Maintain an upright body posture. • Occasionally change the angle of your posture for greater comfort. • Avoid operating the machine for longer than a single 10-hour shift. If possible, stretch between breaks. NOTICE Always observe the following guidelines when operating the Cortex system.

OPEX Corporation (This page is intentionally blank)

Operator Manual 3. Overview 3.1. Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 3.2. Cortex Workflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 3.2.1. Cortex workflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 3.3. The OPEX Integrated Workstation . . . . . . . . . . . . . . . . . . . . . . . . 47 3.4. Perfect Pick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 3.4.1. Cortex Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 3.4.2. WRTC Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 3.4.3. Bin Locator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 3.5. Cortex Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 3.5.1. Workstation User Interface (WUI) . . . . . . . . . . . . . . . . . . . . . . . . 50 3.5.2. Warehouse Real Time Controller (WRTC) . . . . . . . . . . . . . . . . . 50 3.5.3. Aisle Controller (AC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 3.6. Understanding Zones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 3.6.1. Zone sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

OPEX Corporation 3.1. Overview Cortex™ is an OPEX software system that interfaces with the customers main Warehouse Management System (WMS), providing “work flow” control at one or more OPEX Perfect Pick machines, with or without a workstation. The Cortex equipment control system keeps track of local tote/cell inventory, and utilizes color-coordinated pick-to-light order progress indicators making integration with warehouse management systems (WMS) quick and easy. At a minimum level, Cortex consists of a Database server with backup functionality, and an Aisle Controller (AC) with a Workstation User Interface (WUI). This document will cover the basic functions and operations of the Cortex system. The actual setup could vary from site to site, since the Cortex system is designed to function and interact with a variety of third-party components and specific site requirements. As a result, images used in this manual may vary from your actual setup.

OPEX Corporation 3.2. Cortex Workflow The Cortex system will operate in either a left or right side configuration (refer to Figures 3-1 and 3-2). Figure 3-1: Workflow - left side configuration Figure 3-2: Workflow - right side configuration Note: The workflows shown are for an automatic conveyor system, as opposed to a manual table mode. Perfect Pick Workstation OPEX Scan Tunnel Staging Incoming Conveyor Outgoing conveyor Operator Station Perfect Pick Workstation OPEX Scan Tunnel Staging Incoming Conveyor Outgoing conveyor Operator Station

OPEX Corporation 3.2.1. Cortex workflow 1. Incoming conveyor - where containers enter the Cortex system. There is a sensor located before the incoming conveyor used to detect that items are properly coming from the customer’s conveyor system (see Figure 3-3). Figure 3-3: Incoming/outgoing conveyors

OPEX Corporation 2. OPEX Scan Tunnel - an array of cameras meant to read barcodes off of boxes or containers as they enter the workstation from the incoming conveyor (Figure 3-4). Figure 3-4: Scan Tunnel 3. Staging - short conveyor located between the scan tunnel and workstation. Once scanned, the containers are positioned in “zones” where the system can better track their location. 4. Workstation - this is where the containers are presented to the operator. Containers rest in zones, where they are monitored by the Cortex system See “The OPEX Integrated Workstation” on page 47 for more information.

OPEX Corporation 5. Perfect Pick/Cortex software - provides totes to the operator. The Cortex monitor informs the operator what action to take. Typically it is one of three actions: remove product from the Perfect Pick and place them into the designated container (PICK mode), remove product from the Workstation container(s) to restock the Perfect Pick (PUT mode), or count the product contained within the Perfect Pick totes (COUNT mode). See “Perfect Pick” on page 48 for more information. 6. Outgoing conveyor - once orders are filled, or the Perfect Pick has been replenished, the containers automatically move to the back of the workstation and advance to the outgoing conveyor. This conveyor has one “integration” zone with a sensor used to detect that items are properly exiting the Cortex system to the customer’s conveyor system (Figure 3-3 on page 44).

OPEX Corporation 3.3. The OPEX Integrated Workstation As individual items are picked from the Perfect Pick®, they are placed directly into shipping containers or boxes on the OPEX® Workstation. Each container moves quietly along the conveyors and across the zero-height transfers to and from its pick-to-light (PTL) location. Once the operator completes an order, the container is transferred back to the client conveyor for any final processing, and another order indexes forward on the workstation’s conveyor. The OPEX Workstation is closely integrated with the Cortex system, reducing latencies and optimizing overall system performance. Figure 3-5: The OPEX Workstation

OPEX Corporation 3.4. Perfect Pick Figure 3-6: Perfect Pick - Operator Station Host monitor Host computer located behind door Pick Station controls Clear To Pick light Start button E-Stop switch Put Away Complete light Cortex monitor Cortex computer located behind door Workstation (partially shown) Break-Away panel Light Tower Optional Bin Locator light iBOT with tote

OPEX Corporation The Perfect Pick is a matrix for storing content. iBOTs deliver the content in totes to the operator. 3.4.1. Cortex Computer The Cortex Computer is located behind the door on the right side of the Perfect Pick (shown in Figure 3-6). The Cortex monitor, used primarily by the operator, is the main interface for the Cortex system. For more information on using the Cortex software, see “Operation” on page 57. 3.4.2. WRTC Computer This is the computer which runs all of the conveyor systems. If anything happens with this computer and/or there is any type of maintenance needed, please contact OPEX Tech Support to troubleshoot and resolve the issue. 3.4.3. Bin Locator Light This optional feature is used to identify the specific area within the tote where the operator is to pick the item. It shines a light in the section, or cell, of the tote (Figure 3-7). Figure 3-7: Bin Locator Light

OPEX Corporation 3.5. Cortex Software 3.5.1. Workstation User Interface (WUI) A software application containing features and information to match the picking and inducting design of the workstation area. The WUI has a configurable amount physical/virtual work zones (Figure 3-8). Figure 3-8: Workstation User Interface 3.5.2. Warehouse Real Time Controller (WRTC) The WRTC communicates to the Workstations or conveyors telling them when to move, and tracks the movement through the Workstations/Conveyors relaying it back to the AC so the WUI and PTLs are informed of the container location.

OPEX Corporation 3.5.3. Aisle Controller (AC) The Aisle Controller (AC) is more than just the “black command box,” it is the heart of the system, and communicates to the Perfect Pick, PTL, WUI, WRTC, & DB. The AC must always be open, though it is usually minimized and behind the Workstation User Interface (Figure 3-9). Figure 3-9: Aisle Controller window • The Aisle Controller gathers and sends information (barcode and location) of a container either holding product (Put-away orders) or ready for product (Pick orders). The AC also sends information to the Perfect Pick as a task to present a tote holding or receiving product. • Data is requested to gather information referencing the barcode or label, and the information is presented graphically in a user-friendly format. • When a container enters the work area, the WUI will highlight the order on screen when it is ready to perform operations, and it will project the same highlighted light into the cell of the Perfect Pick tote. The AC will also send information to the Pick to Lights (PTLs) on the Workstation to illuminate the correct zone with the same colored light as the WUI.

OPEX Corporation 3.6. Understanding Zones The workstation, and incoming/outgoing conveyors are divided into sections called “zones.” Sensors are used to determine these areas (Figure 3-10). Figure 3-10: Zone numbering Workstation zones - Zones 1-12 are found within the OPEX Workstation*. Zone 1 is always closest to the operator, and zone 2 is behind zone 1. Odd numbers continue across the front, and even numbers are across the back. Containers or boxes will only stop at zones 1, 3, 5, 7, 9, and 11 for either picking or replenishment. * Depending on your system setup, the amount of zones may vary. You may have as little as two zones, or greater than 12 zones in this area. Perfect Pick Operator Station Zone 4 Zone 2 Zone 3 Zone 1 Zone 14 Zone 12 Zone 10 Zone 8 Zone 6 Zone 15 Zone 13 Zone 11 Zone 9 Zone 7 Zone 5 Zone 25 Zone 23 Zone 21 Zone 19 Zone 17 Zone Numbering - Right Side Outgoing Incoming Zone 3 Zone 1 Zone 15 Zone 13 Zone 11 Zone 9 Zone 7 Zone 5 Zone 25 Zone 23 Zone 21 Zone 19 Zone 17 Zone 4 Zone 2 Zone 14 Zone 12 Zone 10 Zone 8 Zone 6 Zone Numbering - Left Side Outgoing Incoming

OPEX Corporation Incoming and outgoing conveyor zones - In the example shown in Figure 3-10, these sections of the conveyor contain zones 13, 14, 15, 17, 19, 21, 23, 25. Zone 25 is the entry to our system from the warehouse conveyor system. Zone 14 is the exit from our system back out to the warehouse conveyor system. This may vary depending on your system setup. There may be more outgoing zones and/or less workstation area zones, which then shifts conveyor zones, etc. The numbering principle still applies in general, but Zone 25, for example, may not always be the “induction” zone. 3.6.1. Zone sensors These are sensors which are mounted on the walls of the conveyor system and are in the middle of each zone. These sensors are used to communicate when a specific container is at the necessary zone. These sensors only know they should either be blocked or unblocked - they do not carry the information of the barcode for container identification. Figure 3-11: Zone sensors

OPEX Corporation 3.6.1.1. A note about the Induction zone This zone is the entrance to the Cortex system from the warehouse conveyor system. This zone also triggers the cameras in the OPEX Scan tunnel to start scanning for barcode identification for each container entering the system. A jam at this zone is different than a jam at any other zone in the system. Typically, you can pick up a container to reset a stoppage. Not at the induction zone. There is a sensor in this zone right next to our zone sensor, for the warehouse conveyor system, which indicates if the zone is clear for another container to enter (Figure 3-12). Figure 3-12: Induction Zone sensor If an operator was to pick up the container in the induction zone without blocking the warehouse conveyor system sensor, the warehouse conveyor system sees the space as empty and will attempt to induct another container into the OPEX conveyor system, if a container is available. You must block the sensor closest to the OPEX aisle before lifting the container to clear the stoppage. This way, the warehouse conveyor system still believes the zone has a container and will not try and induct a new container. The sensor is highlighted in Figure 3-12.

OPEX Corporation In terms of the hand-off, which occurs at the OPEX induction zone as well as the integrator’s first outbound zone, there are two methods: • Method 1 - an extra sensor in the Induction zone (fed back to Integrator) + sensor in first Integrator outbound zone (Zone 14 on the majority of installs, OPEX controls that sensor). This is the method described above, and if clearing a jam in the Induction zone, one sensor has to be covered. • Method 2 - A hand-off relay is used to signal the status of the OPEX induction zone, controlled via software. This is effectively a “ready-to- receive” signal. When the Induction zone is not interrupted and no container is present, this output is high, which switches a small relay in a stand-alone enclosure (#6095600). Integrator is free to run their control signal through the relay contact (this can be DC or AC). An addition to this relay box is a safety relay, which can be used for safety integration. When it is required to shut down the OPEX Workstation and conveyor with the Inte- grator’s section of conveyor, there are also provisions for a signal from the Integrator, done in a similar manner for communication in both directions. When issues are seen with the Induction zone, if this method is used, the relay should be checked (it has a green LED which should be “ON” when the induction zone sensor is unblocked). For the Outbound integration, it may still include an extra sensor or may act in a similar manner with the Integrator, providing a relay contact with a “ready-to-receive” signal. 3.6.1.2. Transition sensors These sensors are between the zones and are used to shut off the motors once a container has made it into the required zone. These sensors are in the walls of the conveyor and also under the conveyor at the work station.

OPEX Corporation (This page is intentionally blank)

Operator Manual 4. Operation 4.1. Starting up the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 4.1.1. Launching the Perfect Pick host software . . . . . . . . . . . . . . . . . . 58 4.2. Starting the Cortex system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 4.3. Operating the Cortex system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 4.3.1. Pick mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 4.3.2. Put-away mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 4.4. Workstation User Interface tabs . . . . . . . . . . . . . . . . . . . . . . . . . . 83 4.4.1. Order Info tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 4.4.2. Details tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 4.4.3. Selected tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 4.4.4. Work Queue tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 4.4.5. Options tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 4.4.6. System Status tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 4.5. Hot Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 4.5.1. Cycle Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 4.5.2. Audit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 4.5.3. Consolidate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 4.5.4. Cubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 4.5.5. Reprint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 4.5.6. Reconfigure Tote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 4.5.7. Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 4.6. Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 4.6.1. Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 4.6.2. Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

OPEX Corporation 4.1. Starting up the system This chapter describes how to operation the Cortex™ system. Note: The Perfect Pick® host software must be running in order to access the Cortex software. 4.1.1. Launching the Perfect Pick host software The Perfect Pick® Host software interface is described in detail in the Perfect Pick Operator Manual. This software provides the main interface with the system’s controls. Used primarily by the OPEX technician (or qualified personnel), the Host software is used to select and run jobs, remove/insert iBOTs, run diagnostic tests, and view statistical reports on the machine. The Perfect Pick Host computer will launch the Host software as part of the system’s start-up routine. If you mistakenly close the Host software, or if the Host software does not start with the machine, you can start it manually. 1. If the Host software is not already running, double-click on the Perfect Pick icon (Figure 4-1) on the desktop, OR click Start > Programs > OPEX > PerfectPick to open it. Figure 4-1: Perfect Pick HD desktop icon

OPEX Corporation 2. The Login screen will appear (Figure 4-2). Select a Username from the drop-down list. Figure 4-2: Login screen 3. If required, enter the password for the selected user. 4. Click Login.

OPEX Corporation The Host software then displays the Main window (Figure 4-3). Figure 4-3: Main window 5. Click the Run button found in the Menu bar. The Run screen opens. The run screen offers several tabs for viewing different elements of the machine and its operational process. One of the most common views is found by clicking the iBOTs tab (see Figure 4-4). Figure 4-4: Run Screen - iBOTs tab

OPEX Corporation 6. On this screen, buttons are available for conserving iBOT power, and parking the iBOTs. 7. On the top of the screen, click START (Figure 4-5). Figure 4-5: Start button location Alternatively, you can start the Perfect Pick with the hardware Start buttons located at the Pick Stations. The Perfect Pick system will enter a Running state.

OPEX Corporation 4.2. Starting the Cortex system To start the Cortex AC/WUI, double-click the Aisle-Restart command on the Desktop, This will start the AC, and the WUI (Figure 4-6). Figure 4-6: Aisle Restart Command On systems with multiple stations (front/back) the WUI-Restart command is used to restart the WUI only, as the AC only runs on one of the Cortex computers (Figure 4-7). Figure 4-7: WUI-Restart command To stop the AC, you can use the Aisle-Stop command, this is only used for troubleshooting purposes (Figure 4-8). Figure 4-8: Aisle-Stop Command To stop the WUI, click the Exit button on the WUI window.

OPEX Corporation Note: The Aisle-Restart and Stop commands should only be initiated if the system is not processing any work at the time the commands are initiated (Figure 4-9). Figure 4-9: Aisle Controller Desktop

OPEX Corporation 4.3. Operating the Cortex system With the Cortex system, iBOTs pull totes from storage locations in the Perfect Pick, and delivers the totes to the operator at the pick station. The Workstation User Interface (WUI) displays which item in the tote is needed to fulfill an order. The operator then picks the specific item(s) from within the tote and places it/ them in order-requested containers located on the Workstation or a similar conveyor. The operator could also be presented with a “Put-Away” screen, which is used for restocking inventory. In this situation, an empty (or near empty) tote is presented to the operator to be refilled. Items to replenish are delivered to the operator on the workstation/conveyor, and the monitor shows the location within the iBOT-delivered tote to restock the item(s). Note: Because the Cortex is customizable to a client’s needs, screen shots shown in this chapter may vary in appearance from those in your system. However, functionality should be identical.

OPEX Corporation 1. Start up the Perfect Pick and Cortex, as described in “Starting up the system” on page 58. When you start up the Cortex system, it displays the Welcome screen shown in Figure 4-10. Figure 4-10: Cortex Welcome Screen 2. Enter your password, then click Enter on the keyboard, or the Login button to access the software.

OPEX Corporation 3. Press the green Start button at the Pick Station (Figure 4-11). Figure 4-11: Start button 4. The iBOTs will move in preparation for the job, and the monitor displays the WUI (see example in Figure 4-12). Figure 4-12: Cortex WUI example Start button Container detail Order detail

OPEX Corporation 5. (Referring to Figure 4-13) This WUI example shows: a description of the item to be picked (Item detail), the location of the item within the tote (Tote Location), how many of the items need to picked (Quantity), and a photo of the item (Item image). An iBOT could present one large tote, or a compart- mentalized tote. Figure 4-13 shows a tote broken up into six parts (Tote location), and the operator is directed to pick from the front right quadrant. Figure 4-13: Cortex WUI screen - detail 6. The OPEX Workstation is located on either the left or right side of the Perfect Pick (for more details on the OPEX Workstation, see “The OPEX Integrated Workstation” on page 47). As the containers advance toward the Perfect Pick, they pass through the OPEX scan tunnel (page 45) or an individual scanner (shown in Figure 4-14), which reads the barcode on Item detail Tote location Quantity Item image

OPEX Corporation each container. The scanned information is used to determine in which container to place the picked parts. Figure 4-14: Container scanner 7. The WUI identifies the location of the container on the workstation conveyor where the user needs to place the picked part. In Figure 4-15, there are four available locations which are identified by the PTL bar. The light bar uses color-coded buttons to assist in identifying the correct container. In the example in Figure 4-15, the second container has a magenta light, and the third container has a blue light. If the first container was completed, it would be transferred to the back conveyor and move on for further processing, such as the addition of items from another area, QC monitoring, or to have Scanner

OPEX Corporation the items packaged for shipping. The other containers would advance, and the color-coding would also advance to follow the containers. Figure 4-15: PTL Bar Labeler PTL

OPEX Corporation 8. Pick the quantity identified in the interface, and place it into the appropriate container on the Workstation. In the example in Figure 4-16, 10 items should be placed into the first container on the Workstation. Figure 4-16: Place the item in the container Depending on your operation, you might also have to bag the items and place a label on the bag (a labeler is shown in Figure 4-15 on page 69). 9. Figure 4-17 shows an example where 32 items are needed for the first container, and one is needed for the second container. These quantities are Place item(s) into identified location Quantity

OPEX Corporation identified both on the monitor and the PTL bar. Put the selected quantity in the correct container(s). Figure 4-17: Displaying the quantity needed 10. Press the color-coded PTL bar button. This tells the system that you’ve picked the part, and the iBOT will exit the picking station, returning the tote to the storage section. Note: In cases like the example in Figure 4-17, where the same item is needed in more than one container, add the item(s) to the container identified in the WUI first. When all items have been added to that container, press its colored button on the light bar. In this example, it is the blue button. The monitor then points to the next container that needs the Quantities shown in PTL bar Quantities identified in Workstation UI

OPEX Corporation item. Once that is filled, push that container’s colored button on the PTL bar. 11. If more items are needed, an iBOT will bring the next tote to the pick station so that the operator can repeat the process. 12. When an order has been completed (all parts picked for one container), press the color-coded PTL bar button to send the container to the back conveyor on the workstation, and advance for further processing, such as the addition of items from another area, QC monitoring, or to have the items boxed for shipping. Note: The client can determine what happens when an order container is completed. For example, as shown in Figure 4-18, the PTL displays a series of dashes, as the packing list prints. Depending on your operation, your system may not require a printer. Figure 4-18: Order completed example Identifies container by scanned barcode Dashes indicate completed order

OPEX Corporation The OPEX Cortex Inventory Control System will provide information as to when the job is finished. 4.3.1. Pick mode 4.3.1.1. Pick Steps The operator scans the order to be picked. The Workstation User Interface (WUI) will present the following screen: Figure 4-19: Pick Screen At this point, the Perfect Pick Aisle (PPA) will present the operator with a tote containing the items to be picked. The cell where the items are located will be shown on the screen as well as illuminated in the PPA.

OPEX Corporation Once the operator has removed the product from the PPA and placed it in the box/container, they can either press the Box on the screen or press the corresponding PTL button to bring forward the next box/container. This process repeats until all items for an order are presented and confirmed picked. 4.3.1.2. Pick Exceptions If the product is missing, then the operator indicates how much product is missing from the tote that is presented. They may be asked upon dismissing the tote to re-count the remaining items in the tote if a discrepancy is noted from the amount of inventory Cortex is showing in that tote, to the amount of inventory removed for both the order and any missing product (Figure 4-20). Figure 4-20: Product missing

OPEX Corporation If the product is damaged, the operator will be presented with a screen as shown in Figure 4-21, and will indicate how many damaged items are being removed from the order. Figure 4-21: Product Damaged

OPEX Corporation If the product will not fit in the carton presented for this order, then the operator needs to indicate how many items will fit in the given carton (Figure 4-22). Figure 4-22: Product will not fit 4.3.2. Put-away mode This mode is used for restocking inventory. 4.3.2.1. Put-away Steps 1. The Workstation User Interface (WUI) will present a screen similar to the one in Figure 4-23. The monitor shows “PUTAWAY.” along with the number

OPEX Corporation of items to be replenished (Figure 4-23). In this example, there are 90 items to put away. The operator scans the container to be put away. Figure 4-23: Putaway screen

OPEX Corporation In some cases, this screen will also show the location in the tote where to place the items (Figure 4-24). In this example, 162 items need to be added to the top left quadrant of the tote. Figure 4-24: Run Screen - populated 2. At this point, the PPA will present the operator with a tote for putting the product into. Fill the amount requested into the tote in the pick station. 3. When complete, the operator presses the corresponding PTL button or the container icon in the WUI (Figure 4-25) and the tote is taken away for storage in the PPA. NOTICE You should never restock a tote with items piled higher than the top of the tote. Overfilling the tote will likely cause over-height jams in the machine.

OPEX Corporation Figure 4-25: Press the Container button

OPEX Corporation 4.3.2.2. Put-away Exceptions If the product is missing, then the operator indicates how much product is put into the tote that is presented (Figure 4-26). Figure 4-26: Product Missing

OPEX Corporation If the product is damaged, the operator will be presented with a screen as above, and will indicate how many damaged items are being removed from the order (Figure 4-27). Figure 4-27: Product Damaged

OPEX Corporation If the product will not fit in the tote, either due to bulging or an over-height error, then the operator indicates how many items will fit in the given tote (Figure 4- 28). Figure 4-28: Product will not fit

OPEX Corporation 4.4. Workstation User Interface tabs 4.4.1. Order Info tab This shows the line-by-line detail of the order that is currently selected. This includes item numbers, quantity to be worked in that order, current status of that line, the line ID that corresponds to that line of work, the Container ID that the work is being performed to or from, and the time that the work for that line was completed (Figure 4-29). Figure 4-29: Order Info

OPEX Corporation 4.4.2. Details tab The Details tab is not currently implemented. 4.4.3. Selected tab This tab allows you to dismiss a selected container. This will suspend any work that is planned for this container for later consideration (Figure 4-30). Figure 4-30: Selected tab

OPEX Corporation 4.4.4. Work Queue tab This tab will highlight when there are cycle counts awaiting completion, as shown in Figure 4-31. The operator can then select how many virtual locations any waiting work can be assigned to. The operator can also access the Hot Actions screen from this tab (for more information, see “Hot Actions” on page 88). Figure 4-31: Work Queue

OPEX Corporation 4.4.5. Options tab Allows setting language, and access to logs (Figure 4-32). Figure 4-32: Options tab

OPEX Corporation 4.4.6. System Status tab Shows the current status of all connected systems including, Perfect Pick, Workstation Conveyor, Host Database, and PTL Module (Figure 4-33). Figure 4-33: System Status

OPEX Corporation 4.5. Hot Actions Click the Hot Actions button under the Work Queue tab (Figure 4-34). Figure 4-34: Hot Actions button The Cortex Console will display additional options as described in this section. • Cycle Count - used to confirm the total items in a tote. You can also perform a cycle count for a specific item - which will deliver all totes that contain that item. • Audit - will bring only the totes that an order affected. • Consolidate - allows you to move identical items from one cell of a tote to another, with the intent of freeing cells for new or more product. • Cubing - allows you to tell the system how many items can fit into a cell. • Reprint - This is only used for sites with labelers. It allows for the reprinting of a label at the pick station. • Reconfigure tote - allows you rearrange items in a tote to different cells better used for more than two cell configurations. • Sequence - allows you to select the site to which the product is attached.

OPEX Corporation 4.5.1. Cycle Count Cycle Counts are created either by a Cycle Count order or manually. 4.5.1.1. Count Steps When the work queue tab is red, there is work waiting (Figure 4-35). Most often, this is a cycle count. Figure 4-35: Awaiting cycle count

OPEX Corporation When Start is pressed, additional virtual locations are added to allow the cycle counts and audits a space to process (Figure 4-36). Figure 4-36: Cycle count - work queue

OPEX Corporation Figure 4-37 shows the count screen. The operator will be presented with a tote, and need to validate the count in the tote. Figure 4-37: Count screen

OPEX Corporation 4.5.1.2. Count Exceptions Re-count and confirm will display if the counts do not match (Figure 4-38). Figure 4-38: Re-count and confirm

OPEX Corporation This is the screen displayed if product is removed from the container. The Operator needs to select how many items are being removed (Figure 4-39). Figure 4-39: Remove Product

OPEX Corporation The screen shown in Figure 4-40 is displayed if product is recalled, and has to be removed from the container. The Operator needs to select how many items are being removed. Figure 4-40: Recalled items

OPEX Corporation To create a cycle count manually: 1. Select SKU for the item to check, or Tote for a specific tote to check (Figure 4-41). Figure 4-41: Cycle Count When you enter the item number, it will populate with all the Units of Measure (UOM), the smallest unit is “EACH” - in other words, one single

OPEX Corporation item. This is usually the UOM needed to select when creating a cycle count (Figure 4-42). Figure 4-42: Item number entered 2. Click the Create Cycle Count button.

OPEX Corporation A window will populate asking to confirm the cycle count (Figure 4-43). Figure 4-43: Confirm Cycle Count Window 3. Click Create. 4. Click Close in the top right corner.

OPEX Corporation 5. Click on the Work Queue tab, so you can start your virtual conveyor. Notice in Figure 4-44 that the Work Queue tab text is red, indicating work present on virtual conveyor (if not red, then no work is present). Figure 4-44: Cycle Count - Work Present

OPEX Corporation A circular arrow above the containers indicates Cycle count (Figure 4-45). Figure 4-45: Circular arrows indicate cycle count

OPEX Corporation 4.5.2. Audit Works like a Cycle Count, but unlike a cycle count that will check every tote that has a specific item, the audit will only check the totes that were used in relation to an LPN (License Plate Number), Order number, or a single item order Line (Figure 4-46). Figure 4-46: Audit window This makes correcting orders faster and more accurate than trying to guess what tote was used.