Before you start
You'll need the following in place before using assembly management in the app:
Assembly management must be enabled in Assembly Settings.
Warehouse locations must be configured in Access Evo.
Assemblies must be finalised in Unleashed, including all component lines and quantities, before their status is changed to your configured sync status (for example, 'Placed'). Avoid making changes after this point, as the app picks up assemblies at the next 10-minute sync interval.
How assembly picking differs from standard picking
If your team already uses standard sales order or shipment picking, there are a few important behavioural differences to be aware of before going live.
| Standard picking | Assembly picking |
Stock on hand (SOH) | Reduces at dispatch. | Reduces when the assembly is completed, either via the Complete Assembly button in the app or manually in Unleashed. |
Order type | Sales order or sales shipment. | Assembly order. |
Packing and dispatching | Optional but recommended. | Not available. |
Order status after picking | Moves to Packing. | Remains in Picked until the assembly is completed. |
Configure assembly settings
To configure how the app imports and completes assemblies, open Assembly Settings.
Click the profile icon in the top right of the screen.
Select Settings from the dropdown.
Select Assembly Settings.
The following settings are available:
Import assemblies: Enable or disable assembly imports from Unleashed. Disabled by default.
Assembly status to import: The assembly status that triggers an import into the app, including any custom statuses set up in Unleashed. Set to Parked by default.
Auto-complete assembly: When enabled, a Complete Assembly button appears after picking is finished. Selecting it automatically marks the assembly as complete in Unleashed. Disabled by default.
📌 Note: The Assembly Status to Import field is free text with no validation. A spelling error will prevent assemblies from importing. Double-check the value against your Unleashed configuration before saving.
Important: If your operation records wastage, turn off Auto-complete assembly. When enabled, the assembly completes the moment the operator taps Complete Assembly, leaving no opportunity to record wastage in Unleashed first. Complete the assembly manually in Unleashed after entering wastage instead.
Pick components for an assembly
Picking components for an assembly follows the same steps as standard picking in the Access Warehouse Management app. The key difference is that the source document is an assembly order rather than a sales order or shipment.
For step-by-step picking instructions, refer to: Picking with Warehouse Management.
📌 Note: Component stock on hand only reduces when the assembly is completed, not at the point of picking. This is different from standard sales order picking, where stock on hand is reduced at dispatch.
Complete the assembly
Once all components have been picked, the order moves to Picked status. The operator can then complete the assembly.
Auto-complete assembly is enabled
A Complete Assembly button appears on the summary screen.
Click Complete Assembly.
Confirm the prompt.
The app sends the completion to Unleashed automatically. Component stock on hand decreases, and finished product stock on hand increases at this point.
Auto-complete assembly is disabled or unavailable
When the finished product of an assembly is batch-tracked, or when the Auto-complete assembly setting is disabled, the Complete Assembly button does not appear. The operator must open Unleashed and complete the assembly there manually.
Once completed in Unleashed, the app reflects the updated status at the next sync (every 10 minutes).
For batch-tracked finished products, the batch number must be entered manually in Unleashed to complete the assembly. The app displays the Assembly ID after picking as a reminder.
Assembly not completed immediately
If the operator closes the summary screen without completing the assembly, the order stays in Picked status. It is accessible from the Picked > Pending tab and can be completed at any time.
Once completed, whether via the app or Unleashed, the order moves to the Picked > Completed tab.
Put away the assembled product
After the assembly is completed, the operator can put away the finished product into a bin location immediately or defer it for later. Refer to: Put away with the Warehouse Management app.
Manage batch-tracked components
For warehouses using batch-tracked components, only hard allocation is supported.
The picker is shown the pre-assigned batch number from Unleashed and can only pick from that batch. The picked batch is recorded and sent back to Unleashed.
If a component is batch tracked but no batch has been pre-assigned in Unleashed, a banner appears on the order detail page and picking cannot proceed.
To resolve this:
Assign the batch to the component in Unleashed.
Wait for the next sync interval (every 10 minutes).
Return to the order in the app and resume picking.
Alternatively, the operator can defer the affected item or pause the pick.
🤓 Tip: Pre-allocate batches to all batch-tracked components in Unleashed before the assembly reaches your configured sync status. The app cannot prompt for batch allocation at the time of picking.
Manage multi-level assemblies
For products that require sub-assemblies, the app controls the order in which pick orders appear.
Parent assembly pick orders are hidden until all required sub-assembly finished products are available in stock (status: Completed).
Once a sub-assembly is completed and its finished product is in stock, the parent assembly pick order becomes visible and ready to pick.
This prevents pickers from being assigned orders they cannot yet fulfil.
If a parent assembly pick order is not visible, one or more sub-assembly finished products are not yet in stock. Check the status of any linked sub-assemblies in Unleashed and confirm they have been completed. Parent orders become visible automatically once all dependencies are met.
Sync with Unleashed
The Warehouse Management app syncs with Unleashed every 10 minutes throughout the assembly lifecycle.
Updates: If an assembly is modified in Unleashed, for example, components or quantities change, the corresponding pick order updates automatically at the next sync.
Known limitations
Review the following limitations before going live. They may affect your operation depending on how your assemblies are configured.
Batch-tracked finished products
The app cannot send batch information for the finished product to Unleashed at completion. Auto complete assembly is not available for these orders. The operator must enter the batch number in Unleashed and complete the assembly manually. The app provides the Assembly ID as a reminder.
Serial-tracked products are not supported
Assemblies that include serial-tracked components or a serial-tracked finished product are not supported. Contact your Access representative if this affects your operation.
First in, first out (FIFO) picking is not supported for non-batch components
For non-batch-tracked components stored across multiple bin locations, the app directs pickers to a bin but does not sequence suggestions by receipt date. Customers on first in, first out (FIFO) costing should be aware that physical picking may not align with costing assumptions.
FIFO batch picking is not supported for assembly components
Batches must be pre-allocated to the assembly in Unleashed before the assembly reaches your configured sync status. If no batch is pre-allocated, picking will be blocked.
Wastage cannot be recorded in the app
Wastage quantity must be entered manually in Unleashed before the assembly is completed. If Auto complete assembly is enabled, the assembly completes automatically as soon as the operator clicks Complete Assembly, leaving no opportunity to record wastage. Turn off Auto complete assembly if your operation requires wastage tracking.
Deleted assemblies are not automatically removed from the app
Deletion handling is not yet fully automated. When an assembly is deleted in Unleashed, the associated pick order is not automatically removed from the Warehouse Management app. If an operator opens a deleted assembly's pick order, a banner notification is displayed requiring their acknowledgement. Full auto-deletion support will be introduced in a future release.