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What you describe is a common mistake. You think the transporter is picking items and therefore he is responsible for the item he is picking. That isn't true. The rack is responsible, which items are going to the next object. And the rack tells the transporter to do the transport job. You have set your racks to release the items instantly (minimum Dwell Time = 0), when an item is entering the rack. Because the transporter is still doing previous transport tasksequence you see a gap between the releasing of the item out of the rack and the time the transporter transfers the item to the next object. If you switch off the option Use Transport you will see how you model really works. My approach is the management of items which the rack is going to release and then I let the transporter do his job. I control the flow of items out of the rack by releasing them in the order and criteria I like. The items must stay in the rack. This is done by the picklist option in the function Send To Port under Flow tab "Do Not Release Item". I release the item out of the rack by the command releaseitem(obj item, num port).

obj item is the item I have identified in the rack which matches may criteria. The Port number is connected to the object which the item has to go. I must explicitly tell the function which Port I use. Otherwise the function Send To Port is called again. And you know therein is the option Do Not Release Item. The item is going to stay. You achieve this misbehavior if the port number is "0" in the parameters of the command.

You can find the item by searching your rack with two for-loops. The second is inside of the first loop. The first for loop searches the Bays of the rack from 1 to the rackgetnrofbays(obj. rack) and the second loop searches the cells of the Rack from 1 to the number of levels in the actual bay [ rackgetnroflevels(obj rack,[optional the num bay]) ]. Sometimes the number of levels isn't the same in each bay, then you have to set the optional parameter of the Bay.

Because you have alread all your data in tables you can try to create a query. The command belongs to the Flexscript interface for SQL, but it works fine with tables, too. You find a tutorial in the manual. If you have specific questions what to do, you can ask a new question.

My personal hint is to build small models, to test how to accomplish a small part of the project. After that I insert my small model in the project model and test the progress. Then I am going to build the next small part of the project model. I know large models look impressive how much someone has achieved. But not the sum of objects in a model is the result. The result is a working process. And the process works even with a really small part of the complete project. Then when everything works to scale a small model to a really big one isn't so difficult anymore.