Warehouse TroubleStation
Resolve warehouse exceptions in real time—not after the fact. JASCI Trouble Station diagnoses issues, takes corrective action, and immediately re-releases trouble work back into picking without breaking inventory, labor, or ERP alignment.
What Is Trouble Station?
Trouble Station is JASCI's centralized workbench for resolving exceptions when an order, pick, or LPN cannot be completed as planned. These exceptions—called trouble work—include shortages, damages, mis-picks, lot or serial mismatches, and inventory that is physically unavailable even though the system indicates it should be.
In JASCI, Trouble Station is not a manual cleanup step or supervisor-only function. It is a system-driven execution workflow that allows warehouse teams to diagnose issues, take corrective action, and immediately re-release trouble work back into picking, packing, or reallocation without breaking inventory, labor, or ERP alignment.
Key Distinction
Instead of pausing operations and relying on spreadsheets, emails, or ad-hoc decisions, JASCI embeds exception handling directly into day-to-day execution. When exceptions happen, JASCI adapts and continues—fixing the issue, re-releasing the work, and keeping fulfillment moving.
The result: exceptions are resolved immediately, corrected orders flow back into picking without delay, inventory accuracy is preserved even during manual intervention, labor is fully tracked and auditable, and operations scale without adding exception-handling headcount.
Why Trouble Station Matters
Exceptions are not edge cases. In most warehouses, 5–15% of orders encounter some form of disruption during picking, packing, or staging. Without a structured process, these issues compound into operational chaos.
Stalled Orders
Orders get stuck in exception queues, forgotten until customers complain.
Inventory Drift
Manual picks and workarounds corrupt inventory accuracy over time.
ERP Chaos
Backorders and cancellations are handled inconsistently across systems.
Excess Rework
Audits, escalations, and customer complaints multiply without resolution.
Many WMS platforms identify the problem but stop there. JASCI goes further— Trouble Work resolves the issue and immediately puts the order back into motion.
The Core Problems Trouble Station Solves
JASCI addresses all of these through a single, guided workflow that keeps execution moving
Inventory appears available but cannot be physically located
Backorder and reallocate from verified locations
Items are damaged or short-picked mid-process
Split quantities and re-release remaining lines immediately
Orders must ship partially while remaining lines are corrected
Create new work control numbers for split shipments
Manual workarounds bypass the system and corrupt inventory
Validated re-picks enforce lot, serial, and location rules
Re-picked work is fixed but never released back to execution
Automatic release puts corrected work back in queue instantly
How JASCI Trouble Station Works
A complete exception resolution engine built into warehouse execution
System-Driven Resolution
Trouble Work is not a manual cleanup step. It is a guided execution workflow that walks operators through diagnosing and resolving exceptions systematically.
Automatic Release to Picking
Once corrected, JASCI automatically reallocates inventory, applies highest priority, and releases work immediately—no supervisor approval or batch job required.
Line-Level Visibility
See exactly what was required, what was picked, what is missing, what is backordered, and what needs re-picking for each line on the order.
Flexible Corrective Actions
Backorder partial or full quantities, manually re-pick from valid locations, split to a new work control number, or restart the order for fresh allocation.
Inventory Rule Enforcement
Every manual re-pick validates against live inventory, lot, serial, and location-type rules before adjusting inventory—preventing downstream reconciliation issues.
SmartTask Integration
Automatically trigger SmartTask workflows when trouble processing is completed, enabling custom escalation, notification, or follow-up actions.
Back Order All with Rollback
Cancel orders completely and generate putaway work to return picked inventory to storage locations. Creates new LPNs and prints putaway labels automatically.
KTO Order Support
Special handling for Kit-To-Order scenarios with base quantity validation, quantity alerts, and intelligent restart logic for component lines.
Skip Location Selection
Configurable option to allow manual picks without requiring location selection when TROUBLE_CONTROLS.CONTROL_11 is enabled.
View Trouble Orders
The View Trouble Orders screen (Outbound → Trouble → View Trouble Order) provides a filterable list of all orders in trouble status with powerful search and action capabilities.
Filter Options
Search by selecting a column and operator (Equal, Not Equal, Starts With, Contains):
Available Actions
Release All Button
When filtering by product, use "Release All" to flag all WCNs in trouble with that product. Orders are released by the trouble release scheduler on its next run.
Trouble Station Workflow
From exception detection to automatic release—step by step
Assign Trouble Work Bench
Operator scans and locks into a validated Trouble Work bench. Labor tracking begins automatically.
Scan and Validate LPN
JASCI loads full order context including work type, work control number, prior activity, picked quantities, and remaining demand.
Analyze the Exception
Line-level visibility shows what was required, what was picked, what is missing, what is backordered, and what needs re-picking.
Take Controlled Action
Backorder partial/full quantities, manually re-pick from valid locations, split into new work control number, or restart order for fresh allocation.
Automatic Release
JASCI automatically reallocates inventory, assigns pick locations, applies highest priority, and releases work to picking or Trouble Putwall.
Stage and Complete
Re-picked work is staged into a Trouble Putwall or returned to normal execution flows based on configuration.
Automatic Release and Reallocation
This is a key differentiator. Trouble Work does not just fix problems—it releases work back into execution automatically.
Correction + Release in One Step
Trouble Work does not just fix problems. It releases work back into execution automatically using the same allocation engine as standard order release.
No Supervisor Approval Required
From an operations perspective, Trouble Work is both correction and release—not investigation followed by manual follow-up or batch processing.
Prevents "Fixed But Stuck" Orders
Corrected work is visible to pickers immediately. No waiting for planners, system syncs, or end-of-day batch jobs to release resolved exceptions.
What Happens When an Exception is Resolved
Common Trouble Reasons
Trouble Station handles all types of fulfillment exceptions
Inventory Shortage
Expected inventory not available at pick location. May require replenishment, substitution, or partial shipment.
Address Invalid
Shipping address failed validation. Needs correction or customer contact before shipping.
Item Damaged
Product found damaged during pick. Requires replacement inventory or order modification.
Hold Applied
Order or customer hold preventing fulfillment. Needs authorization to release.
System Error
Technical issue during processing. May need retry, manual intervention, or IT support.
Missing Information
Required order details missing (special instructions, customs docs, etc.).
Inventory, Lot & Serial Control
Trouble Work fully enforces advanced inventory rules. Every manual re-pick is validated against live inventory, lot, and serial rules before inventory is adjusted.
- Lot-controlled and serial-controlled products
- Case, pallet, and handling-unit inventory
- Location-type enforcement (prime, case, pallet)
- Allocatable-only inventory visibility
ERP & Workflow Integration
Trouble Work maintains clean system boundaries, ensuring exception handling never becomes an ERP cleanup project.
- Creates new work control numbers for splits and backorders
- Keeps ERP-facing order states accurate and synchronized
- Writes full work history, shipment, and audit records
- Can trigger SmartTask workflows on completion
Operational Impact
With JASCI Trouble Station, exceptions become part of the workflow—not a disruption to it
Final Takeaway
Trouble Station is JASCI's exception execution and recovery engine. It does not pause warehouse operations when something goes wrong. It fixes the issue, re-releases the trouble work, and keeps fulfillment moving.
Version History
Recent enhancements to Trouble Station
Frequently Asked Questions
Common questions about Trouble Station
QHow do I know if an order is a trouble order?
Trouble orders are flagged in the system and visible in the work details of the order. You'll see a trouble indicator and reason code. The order will also appear in the Trouble Station queue where all current exceptions are listed.
QWhat causes an order to become a trouble order?
Orders become trouble orders when issues prevent normal fulfillment: inventory shortages, invalid addresses, item damage, applied holds, system errors, or missing required information. The system automatically flags orders when these conditions are detected.
QCan I resolve trouble orders without supervisor access?
Many resolutions can be performed by standard operators, such as retrying operations or selecting partial shipment options. However, some actions like releasing holds, canceling orders, or overriding system blocks may require supervisor authority.
QWhat happens after I resolve a trouble order?
Once you apply a resolution, JASCI automatically reallocates inventory and releases the order back into the normal fulfillment workflow with highest priority. It will continue from where it left off—returning to the pick queue, packing station, or shipping.
QHow do I prioritize which trouble orders to resolve first?
Trouble Station displays priority indicators based on order value, customer tier, SLA deadlines, and age. High-priority orders (rush, VIP customers, near SLA breach) are highlighted. You can also sort and filter the queue by these criteria.
QCan I handle inventory shortages automatically?
You can configure rules for automatic handling of shortages: allow partial shipments, substitute items, or hold for replenishment. Trouble Station lets you apply these options manually or set them as defaults for certain order types.
QIs there reporting on trouble order trends?
Yes, JASCI provides analytics on trouble order patterns including common reason codes, resolution times, and repeat issues. This helps identify systemic problems—like a supplier with frequent quality issues or inventory accuracy problems in certain zones.
QWhat is the difference between View Trouble Orders and the Trouble Station Workbench?
View Trouble Orders (Outbound → Trouble → View Trouble Order) is the administrative interface for filtering, releasing, canceling, and managing trouble orders. The Trouble Station Workbench is where operators physically re-pick trouble work. View Trouble Orders handles order-level actions; Trouble Station Workbench handles the physical picking and automatic release.
QWhat does Back Order All with Rollback do? (V4.7)
Back Order All now functions as a complete rollback: it cancels the order and creates PUTAWAY work for each picked line to return inventory to storage locations. The system runs slotting to find optimal putaway locations, generates new LPNs, prints putaway labels, and updates serial statuses for handling units.
QHow does Trouble Station handle KTO (Kit-To-Order) orders? (V4.8)
KTO orders have special handling: quantities must be divisible by the base quantity (set size), an alert displays when quantities don't meet finished good requirements, and the Restart button preserves work group zone, work zone, area, and location for component lines (FUT_C1_03 = B, L, or G) while clearing them for regular lines.
QCan I manually re-pick without selecting a location? (V4.5)
Yes, when TROUBLE_CONTROLS.CONTROL_11 is set to "Y", operators can perform manual picks without being required to select a specific inventory location. The system writes the inventory transaction with area="PAK" and location blank, and updates the work type line quantity.
Ready to Stop Fighting Exceptions?
See how JASCI Trouble Station can resolve exceptions in real time, keep orders moving, and preserve inventory accuracy even when things go wrong.