Integrated Warehouse Management System - In Depth

iWMS (Integrated Warehouse Management System) is a new separate module that extends the current de Facto S5 offering to provide a fully Integrated ERP / WMS system for the control of all types of products within a multi site or multi warehouse environment. Central to this are the powerful iWMS features and functionality.

iWMS is designed to enable the setting up and operation of a large variety of tasks regarding the control and management of Stock. Tasks which are created either manually or automatically from an ERP transaction such as Sales Order Picking may then be prioritised, assigned a user and also assigned equipment to carry out the task. The Warehouse staff then receive their tasks and action them using wireless Handheld devices. Each stage of the iWMS task(s) updates de Facto S5's Stock module.

iWMS Task Record - An iWMS Task may be created either manually or automatically via de Facto S5 ERP and from the Handheld device if the user is so authorised.

The structure of the individual Task Record includes such data as Job Number, Task Type, Equipment type, Start Time/Date, Finish Time/Date, Target Time/Date, Action, Actioned by, ERP type, ERP system, etc.

iWMS Task Details - Each task will comprise of a series of movements. These will generally consist of data provided by the ERP system in the form of instructions to the iWMS user or else data which has been input or scanned in by the iWMS user.

Task Functions - these include Manage, Build Movement Details, Suggest, etc.

The Management Console window displays a table of all iWMS tasks currently in progress. The lower part of the window consists of a table for the individual task details. The main task table may be sorted by any column heading and provides filters by Warehouse, Job type, User, Equipment and Status. A total is displayed for the Job Size column.

By selecting single or multiple tasks in the console window, actions from the drop down menu of iWMS Management Console commands can be applied to one or more tasks at the same time.

This allows certain functions within the S5 system to create Tasks within the iWMS. For example, a Purchasing department can enter an Order on to their computerised accounts system. The details of this order are then made available to the Warehouse operators who use Handheld devices to scan bar codes of the received items and put them away. The Goods Received Notes (GRN) can then be seen by the payments office who can utilise it to input the Purchase Ledger invoice.

Replenishment Based Tasks are tasks created to identify locations flagged as restricted to replenishment products, (the Unit's of Measure (UOM) and max / min quantities) with a view to finding products in order to re-stock or replenish the location to the required level.

The location Vista written for this should return a location code, product code, UOM, minimum quantity, maximum quantity.

The locations selected from the Vista will populate the WMS Task Location Replenishment window with a prompt to locate Stock that can be used for fulfilling the location requirements.

Demand Based Tasks are planned tasks which are created in order to locate product physicals to fulfil the demand caused by expediting records.

For example, a Sales Order has been inserted for a quantity of 10 units of product 'ABC'. There are a number of physicals stored in locations in the Warehouse and the Stock for picking is kept at another location. The user can insert a Demand Based Task where the Build Movement Detail Vista searches for available products in the same Warehouse that could meet that order. The task rules could then complete the task details to enable the required 10 units of 'ABC' to be moved to the picking location.

Stock Based Tasks are tasks built from a Vista which search physical records to, for example, select Stock that needs to be moved from one location to another. An example of this could be a Putaway task that moves Stock from the temporary location it was unloaded to into its correct location.

As de Facto S5 Logistics usually locks physical batch records, this is not complementary to the way a iWMS user may select a batch to pick from. In order to resolve this issue, Tracking Controls have been extended at the product level. The previous 'compulsory tracking' check box on product records has now been replaced by a new drop down menu with the following options:

1) N/A - Even if a product is flagged as using tracking the insertion of a tracking number is optional in any Stock movement.

2) Compulsory - As in previous versions of S5. Tracking data must be entered on receipt and cannot be amended during despatch / WMS confirmation. All products previously flagged as compulsory will retain this setting upon upgrading. The ERP system remains in full control of the batches to be picked.

4) Record Only - Tracking data is recorded only at picking confirmation and despatch stage with no validation except, for example, serial tracked Stock returned on a Purchase Order credit. If the Stock was bought in without a Serial Number it can be returned without entering one. Note, the Works Order Quick Process cannot be used for transactions with Record Only Stock.

5) Default - Like compulsory above, but the tracking number can be changed when processing a planned WMS picking task. Take an example where the task is to pick product 'A' with the serial number '01'. However when processing the task that item is not available but one with serial number '02' is. Processing using the Handheld windows allows the Serial Number '01' to be changed to '02'.

1) Next Task - Shows a screen confirming the equipment type, job type, size and other summary data. The next job will have been selected using the rules detailed in the iWMS Management Console specification prioritised by target date and time.

2) Select Task - The Select Task window displays a list of task type, size and ERP reference. Below the list the assigned target date for the selected task is shown. The job list is displayed in the order in which the jobs should be undertaken.

3) Recall Parked Job - The Select Task window will display the list of tasks previously parked. The list will be similar to the 'Next Task' window where the task list is displayed in the order in which the jobs should be done, i.e. oldest task first. Where there are no parked tasks a message is displayed.

4) New Task - Displays a list of all Task Types the user has access to and allows the user to create a new task.

5) Processing tasks using the Handheld windows - The build up of the processing screen is in stages so that there is more room available for each stage of data entry.

After any form of valid and complete scanned input, the system automatically moves down/onto the next stage of data entry. All scanning operations are configurable using a customer specific scanning format which holds all of the data scanning input and the data validation code.

Operations take place in three stages:
Step 1 - Take From
Step 2 - Move What
Step 3 - Onto / Into What

6) My Load - My Load is the users 'temporary' location in the mobile Warehouse into which tasks place Stock unless a specific destination has been defined for that task. For example, when unloading Stock from a delivery the items may be left on the loading bay for checking before putting away in the correct locations. In this case a Receive type task will check the Stock and quantities in, and unless a 'Next Task' has been set up to move it, the items on the loading bay will be placed into My Load.

Opening My Load displays all the Stock currently held in the users temporary location.

Each of the below enquiry functions may be activated by either data input or scanned input. Each provides a Label Printing function which will prompt for the required data input and allows selection of the required printer if there are multiple printers of the correct type available.

1) Product Enquiry - Product Enquiry provides the ability to display a list of locations, package ID's and Stock levels for the selected product. The display includes the Warehouse, Location, Stock quantity and Locked quantity. A drill down is available to jump to a location or package enquiry for the selected product.

A Picture function is available to allow a specified Filing Cabinet picture of the product to be displayed.

2) Location Enquiry - Location Enquiry provides the ability to display a list of Product Codes, Package ID and Stock levels for the selected location. The display includes the Product Code, Package, Stock quantity and Locked quantity. A drill down is available to jump to a product or package enquiry for the selected.

3) Tracking Enquiry - Tracking Enquiry provides the ability to search for a specific Tracking ID for a specific product and to then show the location(s) of that ID. The screen gives the option of displaying the full tracking data. A Label option provides the ability to print a specified quantity of product labels.

4) Package Enquiry - Package Enquiry provides the ability to search for a specific package and then to show the product(s) in that package and its location. The screen gives the option of displaying the 'Tracking Code' and 'Pick by Data'. A further option gives the ability to display the full Tracking Data. A Label option provides the ability to print a specified quantity of package labels or package contents lists.

Packaging Constraints is a function that defines which products (down to Units of Measure level) may be packed into which particular packaging item. For example, product items which are single Units of Measure may be packed into small boxes, small boxes may be packed into larger cartons and these large cartons and products in Case quantity Units of Measure may be packed onto pallets.

Another use of Packaging Constraints could be to define Packaging Types such as insulated frozen food containers, padded envelopes for postage or polystyrene lined cartons for TV's. Product Units of Measure could then be flagged accordingly. As an example scenario, Packaging Constraints could be set up so that only Ice Cream can be packed into frozen food containers, and while a pocket TV could be packed into a padded envelope for despatch, a 32" wide screen version can only go into a polystyrene lined carton.

The iWMS has the following technical infrastructure requirements:

• Remote Access Server running Windows Server 2000/2003 and Citrix.
• Cabling/connection infrastructure between Remote Access Server and Wireless Access Points.
• Wireless Access infrastructure to provide suitable wireless coverage within the required physical areas.
• RF units:
  • Hand Held or Fork Truck Mounted
  • In-built or tethered laser scanner (range to suit customer requirements)
  • Windows CE or Pocket PC device that supports a Citrix client.