An Overview

WMS

Benefits

• Faster Turnaround times• Optimize your resources• Reduce Paper work• Seamless integration with transaction (ERP)

systems• Control Inventory

Modules• Receiving • Storage• Wave planning• Picking • Replenishment • Packing • Inventory control• Packing • Cycle Counting

Typical Warehouse Layout

STAGING DOCKING

RECEIVING ZONE

Typical Warehouse Layout

ACTIVE PICK ZONE

CASE PICK

PARTIALRESERVED

RESERVED

DEEPSTORAGE

PICK &DROP

ERP Integration

INBOUND OPERATIONSWMS

Flow of Information

Receiving

• Accelerate receiving process by – Identify inventory and improve tracking – Identify with our without In bound Order

numbers– Associate with ASN– Preassigned Tags or container labels

Advance Shipment Notification

• ASN – Received through EDI, Web service, ERP integration – Details of the shipment to the customer

• PO Numbers• SKUs, Quantity

– Lot Numbers

• Pallet /Container Numbers• Carton Numbers

– Verification of the ASN with actual receipts– Handling Shortages and breakages

License Plate Number

• Unique Identification and locator • Single LPN for a group of Items • Primary identifier to locate the inventory

across the warehouse • Increases receipt throughput and traceability

LPN Process

Inventory Hold

• Inventory “hold” – Special Handling – Seamless integration with QA and QC of ERP

module– Based on the rules defined in the ERP, the material

is under “Hold” for QC or identified for special handling

Put Away Inbound• Put Away

– Move from Staging area to final location– Location is decided based on

• Product Velocity – Fast moving , Slow moving • Storage constraints – Size, Weight, Hazardous, Climatic

control• Other user defined parameters

– System suggest put- away sequence for an optimized travel path

– Put away confirmation by the operator• “To LPN” if drop in another LPN

– Cross docking of materials

Release “Hold”

• “Hold” released after – Required events are fulfilled– Inspection– QC, QA approval

• Material classified as “Active”• Available to Issue

OUT BOUNDWMS

Wave Planning

Wave Planning

• Breakdown and pool orders– To manage and optimize– Picking – Packing– Replenishments – Shipping activities

• Create Batch or “Wave” of orders– Optimize quantity to be picked from each zone to

fulfill a “wave”

Wave Planning- Pick and Pack Orders

• Pick Wave created based on– Mode of transportation– Weight, Volume– LTL, FL – Customer Specifications– Shipment time restrictions– Order Prioritization• Pick “from” drop “to” tasks identified

• Fulfillment of order– Full LPN, Partial LPN– Cases– Loose packs in “active” zone

Wave Planning- Pick and Pack Orders

• Pack wave– Subtype of Pick wave– Honor material handling constraints – Create smaller Pack waves to meet material

handling constraints

Wave Planning- Replacement Orders

• Created after processing “pick” material requirement

• Create orders to move goods from “Bulk” to forward pick locations

• Activity can run parallel to pick and pack activity

Wave process

• Create a Wave– Select the criteria for orders to participate in the wave

• Customer, time, shipment etc

• Planning a wave– Check for resources – Items, Labor, material handling equipment

• Releasing a wave– On release the resources are allocated against the

wave.

Cycle Count

• Random Counts– Creation of Random cycle count order– Based on ABC classification and frequency of cycle

Cycle Count

• “Zero” Confirmations– Performed during day- to day operations– Creates cycle count order if “zero” inventory was

recorded – previous day / shift– Process similar to random count

Thank you

afrank@katalysttech.com