Warehouse – configure and operate fixed-location and chaotic storage

1. Open warehouse management

Warehouse management belongs to the Fixed-location and chaotic storage add-on library. Load and activate the package; the signed-in role must also have the required permissions. Open warehouse management through Libraries.

1. Save the project under its own name first.
2. For initial setup in design mode, complete the offered database setup.
3. If no valid locations exist, choose Configure warehouse now.

For runtime operation, the database and locations must already exist. Material management and stock transactions become available once valid locations have been created.

2. Fixed-location or chaotic storage: select the type

In the Warehouse configurator, under 1 Warehouse structure and location naming → Storage type, select Fixed-location storage (FIX) or Chaotic storage. The library supports configuring both types.

The selection is saved with the warehouse configuration and generated locations. Booking still requires selecting a location. Selecting a storage type alone does not perform automatic slot selection or create a fixed material-to-location assignment. A destination compartment must be empty or contain the same material; different materials in one compartment are rejected.

1. Enter the warehouse name and PLC symbol prefix.
2. Select the storage type.
3. Enter rows, columns and levels for the physical grid.
4. Set column, row and level identifiers and the separator.
5. Independently of storage type, select the automation profile: Warehouse data only, Sensors, Control word / target number or Stacker crane X/Y/Z.
6. Check generated names and positions in the location plan before applying the configuration.

Grid example: 2 columns × 3 rows × 1 level produce six locations. Choosing FIX or chaotic storage does not change the number of physical locations.

3. Configure the warehouse structure

1. Open Configure a new warehouse. Set identifiers for columns, rows and levels plus their separator, for example X1_Y1_Z1.
2. Select the automation profile. It determines the required fields and PLC signals. Protocol choices follow the drivers enabled in the project.
3. For stacker-crane operation, define the home position and external transport destinations with their own target numbers, positions and tolerances.
4. Check the location plan and PLC preview: identifiers, target numbers, absolute positions, addresses and data types.
5. Check communication table first generates a preview. A second click with an unchanged, valid configuration applies the checked data.
6. Save the project after successful application. The location plan, PLC interface list and text description are written to the project’s Lager folder.

Ctrl+S in the warehouse configuration dialog saves the draft. This does not yet apply PLC symbols. Configuration changes require another preview check.

4. Maintain materials and minimum quantities

1. Open Material & minimum quantity and select a material or choose New.
2. Complete the material fields and minimum quantity. Available fields depend on the configured material schema.
3. The standard warehouse requires an article number; the internal ID does not replace it.
4. Save and check the success message and list entry.

Available = stock − reserved quantity. The minimum-stock status compares available quantity with the minimum quantity. Creating a material record does not create stock.

5. Book receipts, issues and transfers

1. Open Book stock and select a material on the left. Its stock is listed below by location and batch.
2. Select receipt, issue or transfer under Transaction type.
3. Enter a batch and a quantity greater than zero. For issues and transfers, select an existing batch.
4. Check the source and destination appropriate to the transaction. For receipts, add an expiry date and comment where applicable.
5. Choose Execute transaction. Check the success message and updated stock. If rejected, inspect the reported cause.

A receipt increases destination stock, an issue removes source stock and a transfer moves stock between locations. A stock transaction is not a stacker-crane transport order.

6. Correct an expiry date

The stock list shows the expiry date for each batch. Expired dates and dates within the next 30 days are highlighted.

1. Under Book stock, select the affected stock record.
2. Enter the correct expiry date and an explanatory comment.
3. Choose Correct expiry date of selected stock and verify the result.

This function requires a separate permission. The date must reflect the actual batch; do not change it merely to remove a warning.

7. Operate stacker-crane orders

A stacker-crane order reserves the specified quantity and passes source and destination to the PLC. Travel sequencing, interlocks and safety functions remain in the PLC.

1. At runtime, open Stacker-crane order and select available stock on the left.
2. Select a configured external transport destination and a positive quantity not exceeding available stock.
3. Check source, destination and comment, then choose Send stacker-crane order.
4. Monitor Active stacker-crane order and PLC feedback. Another order cannot be sent while an order remains open.

Cancellation: “Cancel active transport order” requests controlled cancellation after entering a reason and confirming. The order is not simply deleted: the PLC must confirm cancellation and material position. Use Incident / clarify material position to investigate an unresolved position.

Missing drivers, PLC target numbers, signals or role permissions may block order operation. See communication setup.

8. Database, saving and history

Stock, material records and transactions are stored in the warehouse database. With local SQLite it resides in the project’s Lager subfolder; a configured server database is accessed through its connection. Successful material saves and transactions write to this database.

Also use Save project for configuration and PLC assignments. Closing a dialog or reloading the project does not undo an executed stock transaction. A complete backup must include the project and its associated warehouse database.

Transaction history opens recorded events if the role permits it. If the database is unreachable, contact the responsible administrator; creating an empty warehouse does not restore existing data.

9. Troubleshoot common problems

• Material or transaction controls unavailable: check valid locations, database connection and role permissions.
• Material cannot be saved: check required fields, article number and numeric minimum quantity.
• Transaction rejected: read the message and check material, batch, quantity and locations.
• Transport order unavailable: check runtime mode, available stock, destination, target numbers and an existing open order.

For support, include help ID LIB-WAREHOUSE, application version, exact message and affected location, material and order. Prepare a support request.