mcp-wms-wiki/wiki/concepts/consolidation.md

---
title: "Consolidation"
type: concept
sources:
  - areas/consolidation/index.md
  - areas/consolidation/consolidation_admin/consolidation_process_creation.md
  - areas/consolidation/consolidation_automatic/index.md
  - areas/consolidation/consolidation_automatic/2loc_PK_consolidation.md
  - areas/consolidation/consolidation_automatic/ManualMP_PK_consolidation.md
  - areas/consolidation/consolidation_automatic/Buffer_consolidation.md
related:
  - concepts/container.md
  - concepts/location.md
  - concepts/stock.md
  - concepts/task.md
  - concepts/shipping.md
last_compiled: "2026-04-10"
---

# Consolidation

## Overview

**Consolidation** in EasyWMS is the process of moving stock from multiple partially-full containers into a single destination container, eliminating peaks and optimizing space usage in the warehouse. It is designed to run during **periods of inactivity**, interfering minimally with active warehouse operations.

Two types of consolidation exist:
1. **Stock consolidation (warehouse)** - covered here. Compacts incomplete containers in storage to reduce the number of occupied locations.
2. **Shipping consolidation** - reorganizes prepared stock for outbound orders (see [shipping](../concepts/shipping.md)). Not covered here.

Stock consolidation applies to both **manual** and **automatic** warehouses.

---

## Supported Use Cases

| Use case | Warehouse type | Container type |
|---|---|---|
| Single-reference container (one item), manual warehouse | Manual | Container with "full quantity" configured per item/container type |
| Single-reference container (one item), automatic warehouse | Automatic | Container with "full quantity" configured per item/container type |
| Multi-reference container with business areas, automatic warehouse | Automatic | "Full quantity" configured per business area type/container type |

> Stock of different item presentations is **never mixed** in a single consolidation order.

---

## Architecture: Process → Orders → Tasks

```
Consolidation Process (criteria, priority, destination station)
    │
    ▼ [Release]
Consolidation Orders (N orders = N destination containers)
    │
    ├── Destination consolidation task (1 per destination container)
    └── Source consolidation tasks (1 per source container)
```

**Consolidation process:** A filter definition created by a user specifying which containers are candidates and where consolidation should happen.

**Consolidation order:** Groups source containers (to be emptied) → destination container (to receive all stock). One order = one destination.

**Consolidation order lines:** Each line represents one source container.

---

## Process Configuration

When creating a consolidation process, the user specifies:

### Process Definition
| Field | Description |
|---|---|
| Code | Unique process identifier |
| Priority | Determines task priority for this process's orders |
| Maximum duration | When exceeded, no new consolidation orders are generated |
| Maximum number of orders | Stops generating new orders when this total is reached |
| Maximum simultaneous orders | Controls how many active orders exist at once; new ones created as old ones finish |

### Filtering Criteria
| Filter | Description |
|---|---|
| Item | Restrict to a specific item |
| Item type | Restrict by item type |
| Hazard | Filter by hazard classification |
| ABC classification | Filter by ABC rotation class |
| Owner | Filter by stock owner |
| Supplier | Filter by supplier |
| Max occupation % | Skip containers whose fill % exceeds this threshold |

> Regardless of item filter, each consolidation order is always for the same item **and** conversion (UoM). Different item presentations are never consolidated together.

### Allow Mixing
Logistic attributes that can be mixed within the same item (e.g., different lots in the same container).

### Destination Station
The picking conveyor or buffer where consolidation will physically occur.

---

## Process Lifecycle

```
Standby (created)
    │
    ▼ [Release]
Released  ← EasyWMS evaluates and generates orders
    │
    │ [Pause]
    ▼
  Paused  ← can be re-released
    │
    ▼ [Cancel]
  Canceled  ← all associated orders, lines, and tasks canceled
```

A process can only be released from **Standby** or **Paused** status.

---

## Consolidation in Automatic Warehouses

For automatic warehouses, consolidation is a guided, task-driven process. Containers must be extracted to a picking station.

### Consolidation at Picking Conveyor (2 Locations)

Containers arrive sequenced at the PK:
1. **Destination container** arrives first and occupies one PK location
2. **Source containers** arrive one by one at the second PK location
3. Operator confirms source → destination transfer at the workstation

**Issues the operator can report:**
| Issue | Result |
|---|---|
| Incorrect quantity in origin | Stock adjustment on source container; if less than expected, consolidation line also adjusted |
| Item not found in origin | Consolidation order line canceled |
| Item not found at destination | Entire consolidation order canceled |
| Capacity exceeded at destination | Line adjusted; source remains non-empty |

**Transactions:**
- `CON.MOVE` - container location changes (warehouse → PK → warehouse)
- `STK.MOVE` - stock moved from source to destination container
- `CON.SEND.L&F` - if empty source container is sent to Lost & Found

### Consolidation at Picking Conveyor with Manual Preparation Zones (MP)

1. All source containers arrive first at the PK and stock is extracted to MP tables
2. Destination container arrives last; all MP stock dumped onto it
3. Mixing of different items within the same MP table is **not allowed**

### Consolidation at Buffer

1. All source containers arrive at the buffer station first
2. Destination container arrives last
3. Stock movement between containers is **not guided** (no task confirmation) once containers are out of the warehouse

Hardware: PC + RFT (buffer consolidation supports both)

---

## Configuration Requirements

For consolidation to work correctly:
1. **Full quantity must be configured** per container type, item, and unit of measure
2. If the warehouse uses divisions: full quantity per **business area type**, container type, item, and UoM
3. If consolidating at a picking station with preparation zones: allocation mode must be set to **Automatic**
4. Picking station working mode must be **All Modes** or **Consolidation Only**

---

## Interface

| Path | Equipment |
|---|---|
| `Consolidation > Consolidation processes` | PC |
| `Consolidation > Consolidation orders` | PC |
| `Consolidation > Consolidation order lines` | PC |
| `Warehouse > Tasks` (task monitoring) | PC |
| `Workstations > Picking` (execution at PK) | PC |

---

## Common Errors

| Symptom | Cause | Solution |
|---|---|---|
| No consolidation orders generated after release | Full quantity not configured for item/container type | Configure "full quantity" in item/container type master |
| Consolidation orders generated but no tasks | PK station not in "All Modes" or "Consolidation Only" | Update picking station working mode config |
| Process stuck at maximum simultaneous orders | All slots occupied; waiting for existing orders to finish | Wait for current orders to complete or cancel stale ones |
| Source container not empty after consolidation | Stock in another division or incident reported | Create return-to-warehouse task manually if needed |

---

## Related

- [[container]] - Consolidation moves stock between containers; source containers are emptied, destination receives all stock
- [[location]] - Consolidation frees up locations by eliminating partial containers
- [[stock]] - STK.MOVE transactions update stock records during consolidation
- [[task]] - Consolidation generates source/destination task pairs; priority set by process priority
- [[shipping]] - Shipping consolidation (distinct concept) reorganizes prepared stock for outbound orders