Quick answer: A put wall system should be sized and configured from actual order profiles, item characteristics, wave rules and operator workflow. Map how orders become put instructions, how slots are assigned, what happens when an item or order is missing and how completed orders are confirmed. Then test representative work before using a headline slot count as a capacity promise.
1. Start with the order profile
Collect representative order data rather than describing the operation with an average order size alone. Include order lines, unit quantities, item dimensions where available, multi-line frequency, item mix, peak periods and how often one SKU appears in several orders. Identify whether orders are discrete, batched or released in waves and who decides the grouping logic. Remove customer information that is not needed for analysis. A useful profile shows the ordinary workload and the exceptions the system must handle. Without this information, a proposed wall may be based on a slot count that does not reflect how orders arrive or how operators work.
2. Define the item and tote characteristics
Describe the range of items placed into the wall, their packaging, dimensions, handling constraints and barcode or identifier. Note whether products can be stacked, must remain upright or require special handling, and have the operator confirm those rules. Identify the container, tote or order receptacle used at each stage and its dimensions. Explain when one order might exceed the assigned space. Ask the integrator to show how the concept handles unusual or bulky items rather than assuming every product fits a standard cubby. This information helps the team assess whether the proposed slot geometry supports the assortment and whether a separate route is needed for exceptions.
3. Map order assignment and slot lifecycle
Document when an order receives a slot, how that slot is identified, what signal tells the operator to place an item and how the system confirms completion. Describe whether a slot is reused after an order is closed and how the wall shows that it is ready for the next order. Clarify the relationship among order ID, tote or receptacle ID, item scan and completion event. If a slot is reserved, released or reassigned under specific conditions, list those rules. The software workflow should be understandable from order release through packing, not only during the physical put step. Ask the supplier to walk through a normal order and a multi-item order using a representative scenario.
4. Design the operator’s movement and visibility
Share a floor plan showing the wall, induction or pick area, packing area, replenishment route and any adjacent workstations. Identify the operator’s walking path, reach zones, screen or light visibility and the location where completed orders are removed. Ask the integrator to model the workflow with representative operators and order containers. The design should make it clear where each item goes and what action is required next. Consider how staff will replenish empty containers and respond to a full slot without crossing the active flow. Do not use a theoretical cycle figure without a defined staffing pattern and order mix. Record layout assumptions so the site team can validate them.
5. Plan for misses, shortages and order exceptions
Write down what happens if an item is missing, damaged, unscannable or placed in the wrong slot. Define how an operator requests help, how the order is held and which status returns to the warehouse system. If a partial order is allowed, state how the remaining lines are tracked and which team decides whether to complete, substitute or cancel. Include orders that need more than one container, split shipments or special packing. The system should make exceptions visible and preserve a traceable relationship between the original order and each action. Ask the supplier to demonstrate the exception flow during a trial instead of discussing only successful placements.
6. Specify integration data and system ownership
List the fields passed between the order management or warehouse system and the put wall control: order reference, item identifier, quantity, slot, confirmation and exception status as applicable. State which system is the source of truth for each field and who owns mapping or interface changes. Define how messages are retried or reconciled if a connection is interrupted. Ask for an interface map and a test plan that uses representative data. Avoid assuming that a device or software package automatically connects to an existing WMS. Integration scope should include configuration, environment, test data, acceptance and post-launch support responsibility.
7. Estimate capacity with a clear measurement boundary
Define the period and work content used to discuss capacity: order release, travel, scanning, placement, order close and removal for packing. State the staffing level and item mix assumed. If the buyer has a peak profile, test it separately from an average period. Ask the supplier to show how slot count, replenishment, exception handling and packing interact in the estimate. A single capacity figure can be misleading when it excludes upstream picking or downstream packing. Agree on the test conditions before a performance claim is used in procurement documents and record what changes would require a new validation.
8. Include ergonomics, safety and maintenance planning
Review working height, reach, lifting, replenishment, aisle access and visibility with site operations and qualified safety personnel. Confirm any facilities, electrical or network requirements and identify space reserved for service access. Ask which components require routine inspection and how faults are reported. The exact layout should be assessed at the buyer’s facility, not copied from a reference installation without review. Include training and handover for supervisors and operators. A design that is easy to operate at normal load should also give staff a clear path to respond when a slot, scanner or workstation needs attention.
9. Run a representative acceptance trial
Choose a sample of orders that reflects normal mix, multi-line cases and expected exceptions. Agree on scan rules, slot assignment, completion evidence, throughput boundary and error recording before the test. Ask the supplier to preserve logs or a report that identifies the tested configuration. Include training and a handover checklist so that site staff can repeat the workflow. For system options and project questions, review TrueLiSort put wall systems and provide anonymized order profiles, layout and integration requirements with the request.
For buyers comparing available product and supplier options, see TrueLiSort put wall systems.
Questions buyers often ask
What data is most useful when sizing a put wall?
Provide representative order-line data, item dimensions, order mix, peaks, staffing assumptions and exception frequency. Use an anonymized sample that reflects real operations.
Does more wall slots automatically mean higher capacity?
No. Capacity also depends on order mix, induction, operator travel, replenishment, exception handling and packing. Define and test the measurement boundary.
Should the put wall own order status?
Define which system is the source of truth and specify the status messages and confirmations exchanged between the wall control and warehouse system.
What should a system acceptance trial include?
Use representative orders, normal and exception flows, scan confirmations, agreed cycle boundaries, error records and operator handover.