Pack & Ship Service Integration

Overview

Attribute	Value
Context	Pack & Ship Service
Pattern	Open Host Service
Direction	Outbound (Process Path → Pack & Ship)
Protocol	Apache Kafka + REST API
Topics	`process-path.routing.`, `pack-ship.packing.`

Integration Summary

Process Path exposes a standardized interface for Pack & Ship Service. Process Path signals when shipments are ready for packing and provides SLA priority information. Pack & Ship consumes these signals and reports completion status.

flowchart LR
    subgraph PP["PROCESS PATH"]
        PRS[Pack Ready Signals]
        SLA[SLA Priority]
        CA[Chute Assignments]
        SC[SLAM Coordination]
    end

    subgraph PS["PACK & SHIP"]
        PSM[Pack Station Mgmt]
        CS[Carrier Selection]
        LG[Label Generation]
        WV[Weight Verification]
    end

    PRS -->|PackReadyEvent| PSM
    SLA -->|SLAPriorityEvent| PSM
    CA -->|ChuteAssignment| PSM
    WV -->|PackingCompleted| SC
    LG -->|SLAMCompleted| SC

Pack-to-SLAM Sequence

sequenceDiagram
    participant PP as Process Path
    participant PACK as Pack Station
    participant SLAM as SLAM Station
    participant SHIP as Transportation

    PP->>PACK: PackReadyEvent
    Note right of PP: Tote arrived<br/>SLA: GREEN

    PACK->>PACK: Assign to station
    PACK->>PACK: Packer retrieves item
    PACK->>PACK: Pack into box

    PACK->>PP: PackingCompletedEvent
    Note left of PACK: Box A1 used<br/>Duration: 1m30s

    PACK->>SLAM: Send to SLAM
    SLAM->>SLAM: Weigh package
    SLAM->>SLAM: Print & apply label
    SLAM->>SLAM: Record manifest

    SLAM->>PP: SLAMCompletedEvent
    Note left of SLAM: Tracking: 1Z999AA1...<br/>Carrier: UPS

    PP->>SHIP: Shipment ready

Events Published by Process Path

PackReadyEvent

Purpose: Signal that shipment is ready for packing

Topic: process-path.routing.events

Pack & Ship Action: Queue for pack station assignment

{
  "specversion": "1.0",
  "type": "com.paklog.processpath.pack.ready.v1",
  "source": "/process-path-service",
  "id": "evt-pack-123456",
  "time": "2025-01-20T10:15:00.000Z",
  "subject": "SHP-123456",
  "data": {
    "shipmentId": "SHP-123456",
    "orderId": "ORD-789012",
    "pathType": "SINGLES",
    "sourceLocation": {
      "type": "TOTE",
      "toteId": "TOTE-789",
      "conveyorZone": "PACK-ZONE-A"
    },
    "itemCount": 1,
    "slaPriority": "GREEN",
    "carrierCutoffTime": "2025-01-20T16:00:00Z",
    "packingInstructions": {
      "recommendedBoxSize": "A1",
      "requiresPadding": true,
      "giftWrap": false,
      "specialInstructions": null
    },
    "readyAt": "2025-01-20T10:15:00Z"
  }
}

AFEConsolidationCompleteEvent

Purpose: Signal that AFE order is fully consolidated

Topic: process-path.routing.events

Pack & Ship Action: Pack from rebin wall chute

{
  "type": "com.paklog.processpath.afe.consolidation.complete.v1",
  "data": {
    "shipmentId": "SHP-123456",
    "orderId": "ORD-789012",
    "wallId": "WALL-AFE-01",
    "chuteId": "CHUTE-A-45",
    "itemCount": 3,
    "slaPriority": "YELLOW",
    "chuteLight": "YELLOW",
    "packingInstructions": {
      "recommendedBoxSize": "B2",
      "requiresPadding": true,
      "giftWrap": false
    },
    "consolidatedAt": "2025-01-20T10:20:00Z"
  }
}

SLAPriorityEscalatedEvent

Purpose: Update pack queue priority

Topic: process-path.sla.events

Pack & Ship Action: Reprioritize in pack queue, update chute light

{
  "type": "com.paklog.processpath.sla.escalated.v1",
  "data": {
    "shipmentId": "SHP-123456",
    "previousPriority": "GREEN",
    "newPriority": "RED",
    "timeToSLACutoff": "PT25M",
    "expeditedRouting": true,
    "packStationOverride": "PACK-EXPRESS-01"
  }
}

Events Consumed from Pack & Ship

PackingCompletedEvent

Purpose: Track shipment completion, update cycle time metrics

Topic: pack-ship.packing.completed

{
  "type": "com.paklog.packship.packing.completed.v1",
  "data": {
    "shipmentId": "SHP-123456",
    "orderId": "ORD-789012",
    "packStationId": "PACK-STATION-05",
    "packerId": "WORKER-123",
    "boxUsed": "A1",
    "actualWeight": 1.52,
    "packDuration": "PT1M30S",
    "packedAt": "2025-01-20T10:17:00Z"
  }
}

SLAMCompletedEvent

Purpose: Track SLAM completion, trigger shipping handoff

Topic: pack-ship.slam.completed

{
  "type": "com.paklog.packship.slam.completed.v1",
  "data": {
    "shipmentId": "SHP-123456",
    "orderId": "ORD-789012",
    "trackingNumber": "1Z999AA10123456784",
    "carrier": "UPS",
    "serviceLevel": "GROUND",
    "labelApplied": true,
    "manifestRecorded": true,
    "actualWeight": 1.52,
    "slamStationId": "SLAM-01",
    "slammedAt": "2025-01-20T10:18:00Z"
  }
}

WeightVerificationFailedEvent

Purpose: Handle weight discrepancies

Topic: pack-ship.slam.weight-failed

{
  "type": "com.paklog.packship.weight.failed.v1",
  "data": {
    "shipmentId": "SHP-123456",
    "expectedWeight": 1.50,
    "actualWeight": 2.10,
    "variance": 0.60,
    "variancePercent": 40,
    "action": "DIVERT_TO_PROBLEM_SOLVE",
    "failedAt": "2025-01-20T10:18:00Z"
  }
}

Pack Station Coordination

Singles Path Flow

sequenceDiagram
    participant TOTE as Tote
    participant PP as Process Path
    participant PACK as Pack Station
    participant PACKER as Packer
    participant SLAM as SLAM

    TOTE->>PACK: Arrives at station
    PP->>PACK: PackReadyEvent
    PACK->>PACKER: Assign to station
    PACKER->>TOTE: Scan & retrieve item
    PACK->>PACKER: Display instructions
    PACKER->>PACKER: Select box & pack
    PACKER->>SLAM: Send package
    PACK->>PP: PackingCompletedEvent

AFE Path Flow

sequenceDiagram
    participant CHUTE as Rebin Chute
    participant PP as Process Path
    participant PACK as Pack Station
    participant PACKER as Packer
    participant SLAM as SLAM

    Note over CHUTE: All items arrived
    PP->>PACK: AFEConsolidationCompleteEvent
    PP->>CHUTE: Set light (priority color)

    PACKER->>CHUTE: Retrieve all items
    PACK->>PACKER: Display multi-item instructions
    PACKER->>PACKER: Consolidate & pack

    PACKER->>SLAM: Send package
    PACK->>PP: PackingCompletedEvent
    PP->>CHUTE: Release for reuse

Chute Light Protocol

Process Path controls chute lights based on SLA priority:

Priority	Light Color	Meaning
GREEN	Green	Normal priority, standard processing
YELLOW	Yellow/Magenta	Elevated priority, pack soon
RED	Red	Critical, pack immediately

{
  "type": "com.paklog.processpath.chute.light.update.v1",
  "data": {
    "wallId": "WALL-AFE-01",
    "chuteId": "CHUTE-A-45",
    "lightColor": "RED",
    "reason": "SLA_CRITICAL",
    "shipmentId": "SHP-123456"
  }
}

SLAM Integration

Weight Verification Rules

Process Path provides expected weight for SLAM verification:

{
  "shipmentId": "SHP-123456",
  "expectedWeight": {
    "itemWeight": 1.2,
    "packagingWeight": 0.3,
    "total": 1.5,
    "varianceThreshold": {
      "absolute": 0.5,
      "percent": 10
    }
  }
}

SLAM Outcomes

Outcome	Process Path Action
PASS	Mark shipment complete, update metrics
FAIL_WEIGHT	Route to problem solve, track exception
FAIL_LABEL	Retry label, escalate if persistent

Pack Station Capacity

Pack & Ship reports station capacity to Process Path:

{
  "type": "com.paklog.packship.capacity.report.v1",
  "data": {
    "stationType": "SINGLES",
    "stations": [
      {
        "stationId": "PACK-STATION-01",
        "status": "ACTIVE",
        "queueDepth": 8,
        "throughputPerHour": 180,
        "workerId": "WORKER-101"
      }
    ],
    "totalActive": 12,
    "totalCapacity": 15,
    "utilizationPercent": 80
  }
}

Process Path uses this for:

Path capacity scoring
Load balancing decisions
Bottleneck detection

Error Handling

Packing Errors

Error	Pack & Ship Action	Process Path Action
Item damaged	Divert to problem solve	Update shipment status
Wrong item	Divert to problem solve	Investigate routing
Box unavailable	Select alternate size	Update packing instructions

SLAM Errors

Error	Pack & Ship Action	Process Path Action
Weight variance	Divert to reweigh	Flag for investigation
Label print fail	Retry, manual if needed	Track exception rate
Manifesting fail	Queue for retry	Alert if persistent

Performance Metrics

Metric	Target	Impact
Pack cycle time (singles)	< 2 min	Path cycle time estimate
Pack cycle time (multi)	< 4 min	AFE cycle time estimate
SLAM pass rate	> 98%	Exception handling load
Station utilization	70-85%	Capacity scoring

Monitoring

Key Metrics

pack_ship_packing_completed_total
pack_ship_slam_completed_total
pack_ship_weight_failures_total
pack_ship_station_utilization
process_path_pack_ready_events_total

Alerts

Pack queue depth > 20 per station
SLAM failure rate > 5%
Station utilization > 95%
Pack cycle time > 5 min average