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Course Overview and Foundations

Course Introduction: Objectives, Outcomes, and Assessment Plan

Wave Picking Fundamentals and Terminology

Designing Effective Wave Strategies

Wave Design for Shipping: Carrier- and Destination-Based Grouping

Wave Design for Manufacturing: Work Center–Aligned Replenishment

Release Timing, Batch Sizing, and Sequencing Policies

Data-Driven Wave Policy Architecture

Operational Integration and Execution

Integrating Wave Picking With Fulfillment and Production Workflows

Picking Modalities, Slotting, and Resource Planning in Waves

Staging, Loading, and Dock/Line Coordination

Performance Management, Optimization, and Governance

Quantitative Evaluation: KPIs, Analytics, and Simulation

Change Management and Cross-Functional Alignment

Assessment: Quizzes

Quiz 1: Core Concepts of Wave Picking

Quiz 2: Shipping Wave Design by Carrier and Destination

Quiz 3: Manufacturing Wave Design for Work Centers

Quiz 4: Release Timing and Batch Sizing Policies

Quiz 5: Sequencing and Prioritization Rules

Quiz 6: Operational Integration and Modalities

Quiz 7: Staging and Loading Coordination

Quiz 8: Analytics, KPIs, and Simulation

Quiz 9: Comparing Wave Paradigms and Business Case

Quiz 10: Change Management and Governance

Master the science and execution of wave picking to compress waiting time, raise throughput, and protect service levels across shipping and manufacturing. Advanced Wave Picking Design and Optimization for Integrated Fulfillment equips Supply Chain, Operations, and Industrial Engineering professionals to architect carrier- and destination-based shipping waves and work center–aligned replenishment waves for production. You’ll learn how to translate transportation schedules, dock capacity, takt time, and consumption patterns into data-driven wave templates, release cadences, and sequencing rules. The course blends foundational concepts with practical techniques: order segmentation, batch sizing trade-offs, pick-path optimization, zone-within-wave strategies, staging/loading design, and governance. You’ll build a policy architecture inside WMS/ERP/MES environments, apply analytics and queueing theory to right-size waves, and run A/B pilots and simulations to quantify ROI. By the end, you will be able to integrate waves end-to-end—from order release through picking, packing, staging, loading, and confirmation—while coordinating with kitting, line-side delivery, and yard/dock scheduling. If you manage fulfillment centers, factories, or hybrid operations seeking to cut dwell and line starvation without overstaffing, this course provides the blueprint, tools, and playbooks to implement resilient, high-performance wave operations.

Advanced Wave Picking Design and Optimization for Integrated Fulfillment

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            <p>Advanced Wave Picking Design and Optimization for Integrated Fulfillment equips Supply Chain and Operations managers to architect, execute, and continuously improve wave strategies that minimize waiting time across shipping and manufacturing flows. Grounded in practice and supported by quantitative methods, the course clarifies when wave picking outperforms discrete, batch, zone, and waveless approaches, and where it does not. Participants will learn the full vocabulary of wave management—templates, release timing, batch sizing, sequencing, dwell time, staging windows, and cutoff times—so they can design policy frameworks that balance throughput, labor utilization, service levels, and inventory exposure.</p>

<p>The curriculum progresses from foundations to design, integration, and governance. In shipping contexts, you will develop carrier- and destination-based grouping rules, synchronize waves with transportation schedules and dock capacity, and optimize pick paths, cluster picking, and staging alignment to hit carrier cutoffs. In manufacturing environments, you will map work centers and takt time to replenishment waves, coordinate with kitting and changeovers, and reduce starvation and blocking through line-side staging and Kanban-compatible releases. Release timing, batch sizing, and sequencing policies are treated rigorously, including time- versus event-based strategies, wave interleaving, and exception handling for shorts, substitutions, partials, and re-waves.</p>

<p>Operational integration is addressed end-to-end: receiving, putaway, slotting, picking modalities, packing, staging, loading, and confirmation—plus line-side delivery routes, supermarkets, and milk runs. You will evaluate slotting strategies in a wave context, plan labor and shifts to match carrier and work center cadence, and align enabling technologies such as RF, voice, pick-to-light, conveyors, and automation. The course embeds data-driven policy design using WMS/ERP/MES rule engines, with order segmentation, resource constraints, and KPI targets including waiting time, order cycle time, on-time-to-cutoff, and line starvation rate.</p>

<p>Performance management and governance are reinforced through analytics, simulation, and disciplined change management. You will apply Little’s Law and queueing concepts for wave sizing, build digital twin experiments for shipping and manufacturing scenarios, and run A/B pilots to compare wave versus alternative paradigms and quantify ROI. A control-tower approach—with daily wave boards, SOPs, exception playbooks, and escalation paths—prepares you to sustain results through peak season volatility, system outages, carrier changes, and product mix shifts. Assessment is delivered via targeted quizzes and applied exercises to validate mastery and ensure transfer to live operations.</p>
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