© 2012 Material Handling Industry®. Copyright claimed as to audiovisual works of seminar
sessions and sound recordings of seminar sessions. All rights reserved.
Welcome to Session 315
Sponsored by: Presented by:
Tom Kozenski
Colman Roche
WMS, WCS or Both? Determining Your
Distribution Center Technology Strategy
How did WMS Applications
Begin? • In order to get the proper perspective, we
should start at the beginning
• Tier 1 WMS vendors evolved as
automation integrators in the mid-70‟s
• Software was primarily custom and built to
spec (and often to automation spec)
• The primary benefit from a WMS was
providing near-100% Inventory Accuracy
– That is why RF-based scanning was
prevalent
WMS – Phase II • With maturity came additional capabilities
• WMS applications developed strong
capabilities for system-directed operations
– Task Interleaving
– Configurable Workflows
• WMS accounts for all movements and
coordinates all operations
– A black-box approach is not preferred
– Benefits from using WMS Allocation routines
– Unique deployments are the exception
• 3-deep ASRS
WMS Phase III
• Eventually, we started to build “packaged”
WMS software
– But automation integration was still an area of
customization
– These costs were high and ongoing
– Had to be rebuilt/retested for every upgrade
or change in logic
– The WCS was an essential piece of software
that managed the communication to WMS
WMS Today • Today‟s WMS architecture allow for more
intimate data-sharing
– Can emulate real-time (sockets, web services)
– WMS can imitate certain WCS controls with
embedded EAI integration tools
• Small components of logic is ideal
• Inputs from PLC‟s, in-line scanners, …
– Feedback mechanisms from WMS to automation
can be 1-way downloads or require
confirmations back to the WMS
– We see both used in single deployments
What to look for…… • Maintaining “productized‟ integrations are
a viable option, but……
– Requires a commitment from both vendors
– It can be hard to find a common ground
• Automation vendors can have multiple
communication protocols, transaction layouts
– With SOA architecture, you can expect a
lower overall multi-year TCO
• Less custom code, more configuration
– A globally deployed WCS is another option
but carries additional costs and complexities
Evolution of WCS
Basic conveyor controls Simple point-to-point delivery
More advanced conveyor controls Route to multiple points
Conveyor sorters to multiple points Data collection from totes & packages
Intelligent routing
High-speed sortation Shoe sorters
Discrete sorters – cross-belt, tilt tray
WCS Evolution by Function
• Convey through pick modules
– Pick-to-light, routing, barcode scanning
• Convey cartons from rack storage
– RF, automatic diverting, auto ID
• Convey to shipping lanes
– Diverting, sequencing, queuing
• Convey through carousel zones
– Carousel picking, automated batches,
pick sequencing
Where Has WCS Fit?
Managerial Function
• Planning & direction
– Weekly, daily planning
• Supervisory control
– Task oversight
• Warehouse associate
– Picking
– Packing
– ….
Hierarchy
WCS
WMS
Switch to PC or
screen shots
The WCS‟s Role
• Provide the link between the non real-time
host and the real-time MHE control system
• Relieve the WCS from real-time
requirements
• Manage decision points to determine the
most efficient routing of product
• Interface with inputs (scanners, weigh
scales, etc.) and outputs (conveyor
motors, print & apply labellers, etc.)
WCS – Primary Tasks
• Allocate work to MH sub-systems
• Provide real-time direction to operators &
MH equipment (MHE) controllers
• Dynamically assign cartons to divert
locations
• Report results to WMS
• Gather data to gauge operational
performance
WCS
• Handles product
• Handles real-time material handling tasks
– Equipment control
– Routing
– Point-to-point tracking
• Collects data
• Schedules operations, locally
• Manages tasks
WCS Architecture Evolution
• PLC-based I/O control
• Added data capabilities to track & control
– Virtual PLCs with database management
• Expanded databases to fulfill orders
• Built on zone-based order processing, with
conveyor as transport between zones
• Added automated MHE fulfillment
• Increased managerial functions, incl.
maintenance management
What does WCS touch?
+ =
WCS Compare to Tier 3 WMSs
Tier 3 WMS – lower volumes
• Picking: paper directed
• Rider truck, cart picking,
by hand
• Discrete order picking
• 1+ storage types
• Manual consolidation
• Location addresses
• Record putaway locations
• Fixed forward pick
locations
• Batch processing
Historical Differentiation
Data
management
MHE
Control
Nominal separator:
Handling “Real Time”
Processes
Over Time …
WMS
WCS PTL, auto ID, pick modules,
routing, barcode scanning,
carousel picking
Nominal separator:
Handling “Real Time”
Processes
Over Time …
WMS PTL, auto ID, picking tasks,
….
WCS PTL, auto ID, pick modules,
routing, barcode scanning,
carousel picking
Nominal separator:
Handling “Real Time”
Processes
Comparisons
Function WMS WCS
Handle pick, pack functions X X
Provide direction to operators via RF, PC X X
Interface with ERP X some
Wireless manifesting X some
Wave processing Tier 1,2
Process returns X X
Comparisons
Function WMS WCS
Process returns X X
Manage energy of MH equipment X
Monitor MH equipment for maintenance
needs
X
Route orders through pick zones X
Real-time interface to MH equipment some X
Selection Process
• Preparation
– Understand your processes
– How well do they work?
• (don‟t select based on poor processes)
– Map your functionality
• Take a close look at your business
Selection Process
• Decide what you are trying to achieve
– Understand your objectives
– Rank them in order of importance
• Analyze your objectives
– Business, warehousing
– Divide them into competencies
Selection Process
• Decide how to evaluate
– Features
– Capabilities
– Architecture – how it will help/hinder
• Consider offerings from a feature-
advantage-risks-benefits (farb) approach
• Create an evaluation tool based on your
needs and organization
Summary
• Use „best practices‟ steps
• Ask plenty of questions
– Architecture & decision process of WMS/WCS
– Strong and weak points
– Characteristics of reference customers
– Background of the WMS/WCS team
© 2012 Material Handling Industry®. Copyright claimed as to audiovisual works of seminar
sessions and sound recordings of seminar sessions. All rights reserved.
For More Information:
Tom Kozenski ([email protected])
Colman Roche ([email protected])
Visit MHIA.org/SCE
