IT Warehouse Management - XLRI PGCLSM
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  • 1. Postgraduate Certificate in Logistics & Supply Chain Management (PGCLSCM) Warehouse Management November 2012 Disclaimer: These are opinions of the presenter. They are not associated or affiliated to any company. Some of the material in this presentation are procured from the Internet and may contain Copyrights. These are used here for Education purposes only. This material is not intended for distribution or reproduction. This material is not intended for use in any commercial manner.
  • 2. Amazon’s Swansea Fulfillment Center • Video - http://www.youtube.com/watch?v=_R3kr_m4 czY • 800,000 Sqft, 4th DC/FC in UK • Economy/Jobs – 1000 jobs in 1st year. • Speed to setup • Delivery opportunities to entire Europe, Infrastructure, Talent, Government Support
  • 3. Warehouse Management - Essence • Define and manage complex warehousing structures • Optimize material flow using advanced putaway and picking techniques • Process goods receipts, goods issues and stock transfers quickly and easily Accuracy + Speed = Efficiency
  • 4. Typical WMS features • Warehouse Layout and Structure • Optimized movement of goods (Inbound and Outbound – Receiving and Shipping) • Inventory Tracking and Control • Printing and Documentation • Employee Safety • Lean Principles
  • 5. Inside the Warehouse • Warehouse Location Storage Area – Receiving, Sorting, Shipping, Open Yard, Picking, Packing, Labeling Storage Type – Bulk, Open, High Rack, Shelf Storage Section – Lean and TPM Storage Bin – Smallest unit of space. Contains multiple quantities of product
  • 6. Amazon’s Warehouse processing • http://www.youtube.com/watch?v=i6H7nfHjHtY • Inbound Receipts – Yellow bins, Updated inventory into Systems, Sorted and placed into Sections • Order Fulfillment – Red Bins, Customer Orders picked and scanned • Packaging – Orders consolidated, Labeled • Auto-Dispatch – Conveyor sorts by barcode destination
  • 7. Inbound - Receiving and Put Away • Video - http://www.youtube.com/watch?v=ZN6-- Xi5lKo • Receiving • Identification, Sorting • Palletization, Labeling • Inventory Update (Online) • Shelving (Put Away), Warehouse slot barcode • Checking, Documentation Complete, ERP Update
  • 8. Fulfillment - Picking • Video - http://www.youtube.com/watch?v=G3GOXR- pXrw • Shipping Order Receipt • Selection – full/Partial batches from stock • Optimized picking list • Assigned to operator
  • 9. Fulfillment - Shipping • Video - http://www.youtube.com/watch?v=0E- Wy1fOdOw • Optimal picking route or automated • Barcode crosscheck with Warehouse slot • Consolidation, Packing • Labeling, Sorting • Shipping, Archival
  • 10. Amazon’s Christmas Season • Video - http://www.youtube.com/watch?v=Z2Bs0nqVyqs • Hours from Customer Order placement to Order picking from the right FC • Product placement and sorting into Bins • Blue lights – Customer order Ready to Pack • Automatic labeling, • 15000 jobs during holidays
  • 11. Technology Enablers in WM • Labeling - Barcode Scanners • RFID for Inventory – Dock doors, Sections, Bins • Voice-Directions – Picking, Put Away (Voxware) • Sorting Conveyor belts • Automated Order Picking (Kronos)
  • 12. Beverages Industry • Video - http://www.youtube.com/watch?v=TsLpBpX9f ok • Euclid – Coors • Advance Shipment Notification triggers Planning to receive and stock • Wireless Handheld or Voice • Warehouse operator performance measurement
  • 13. Accord Voice WMS • Video - http://www.youtube.com/watch?v=yy53EMEmx_ c • SPAR – Receiving, Putaway, picking, replenishment, dispatch and stock management • 5% of overall cost reduction, 15% improvement in pick rates, accuracy of 99.97% • 6+ months breakeven on costs. • Speech-to-data, Voice Learning, Hands/Eyes free
  • 14. Voice Controlled WMS - VoxWare • Video - http://www.youtube.com/watch?v=kZFGe-Ggnr4 • Food Distribution, 18 DCs • 50K cases inb/out each per night, 70 trucks in fleet • Wireless Belt - Two-way voice (direction, response) confirmation • TPM – 3 per 1000 mistakes to 0.45 per 1000, Half training time
  • 15. Automated Order Picking - Krones • Video - http://www.youtube.com/watch?v=yU6Owsq ETzI • Food industry – From Homogeneous pallets to Mixed pallets • Organize 400 SKUs at 4000 units/hr • Depalletization, sorting, stacking, box packing • Palletizer Looks too good to be true :-o
  • 16. Automated Order Picking – S-Pemant • Video – http://www.youtube.com/watch?v=lQDtp7d7 cnA • S-Pemat by SSI Schafer • Product Dispensers • product rate up to 180000 pieces per hour and 240000 order picks per day. • environmentally friendly and minimizes current costs
  • 17. Warehouse of the future • Video - http://www.news10.net/video/126664371400 1/0/Robot-staffed-warehouse-of-the-future- is-now
  • 18. Conclusion - Warehouse Improvement • Layout – Receiving, Sorting, Shipping • Optimal Storage (racks, bins) and Easy Access • Inventory tracking and tracing • Voice/RFID based picking • Automated Fulfillment Process • Lean and TPM concepts • Integrated to Transportation Plan