IntroToWHMGNT_ENGLISH

Athens 2003
Introduction to WHMGNT/PRO for MFG/PRO
Page 1 of 29
INTRODUCTION TO
WHMGNT/PRO for MFG/PRO:
Athens 2003

Athens 2003
Page 2 of 29
Contents
1 Introduction...................................................................................................... 3
2 Section 1: Standard Features.......................................................................... 5
2.1 Receiving .................................................................................................... 5
2.2 Put-away and Storage................................................................................. 8
2.3 Replenishment/Let-Downs .......................................................................... 9
2.4 Order Processing ...................................................................................... 10
2.5 Task Interleaving....................................................................................... 14
2.6 Shipping.................................................................................................... 14
2.7 Integration with Automated Material Handling Equipment. ........................ 17
2.8 Cycle Counting.......................................................................................... 17
3 Section 2: Special Features........................................................................... 18
3.1 OPEN ARCHITECTURE........................................................................... 18
3.2 MANAGEMENT REPORTING .................................................................. 18
3.3 WHMGNT/PRO: A Pull (event driven) System .......................................... 25
3.4 Enhanced performance when combined with MFG/PRO functionality....... 26
4 Conclusion ..................................................................................................... 29

Athens 2003
Page 3 of 29
1 Introduction
WHMGNT/PRO seamlessly integrates with MFG/PRO to form a unique and
extraordinary integrated front office tool. This integration is directly reflected by the
acquired functionality, some of which includes:
• warehouse automation,
• minimisation of stock volumes,
• optimisation of vehicle and staff mobility,
• optimisation of and interoperability with shop floor,
• effective and vast interface with Radio Data Terminals,
• effective space management and control,
• detailed job description
• effective use of functional areas
• minimisation of human intervention and therefore mistakes and
• detail monitoring of cost of each item’s transaction in terms of purchases,
movements, issues, sales and cycle counts, etc
The optimal target is rapid return on investment (ROI) through minimisation of items
stock cycle times, detailed traceability and discrete monitoring of stock movements
and maximisation of resources’ performance.
WHMGNT/PRO sub-system modules expand under the ‘Custom’ menu of the
standard MFG/PRO system, as presented below:

Athens 2003
Page 4 of 29
The sub-menus are under the general menu of ‘Warehouse Management’:

Athens 2003
Page 5 of 29
2 Section 1: Standard Features
2.1 Receiving
Receiving functions can be performed from either WHMGNT/PRO directly, hand-held
RF mobile computers or any combination of the two simultaneously and/or
sequentially. Breakdown and consolidation of incoming products are bar-coded for
put-away. It can generate and print any industry-standard bar codes.
Highlights of WHMGNT/PRO receiving capabilities include:
• Real-time link to MFG/PRO or any other contemporary enterprise system,
accommodating PO verification changes, introducing additional functionality
towards different expiration dates over different lots but FOR THE SAME
QUANTITY RECEIVED, which, in standard MFG/PRO is performed in two
different receipts. In addition, locations’ capacity becomes a constraint during put-
away procedure.
The next screen allows the user to manage the expiration date according to the
attributes of each unit received by inserting as many different lots, references,
locations and expire dates as necessary. Note that, the lot, quantity per and
expiration date has been modified to reflect the correct receipt:

Athens 2003
Page 6 of 29
• Product immediately available for order at the receiving dock.
• Electronically handle warehouse transfers via remote data terminals (RDT) in
three scans. The user is being notified for the existence of a pending pallet
transfer, via an asterisk that appears automatically after the receiver has been
printed, as shown below:

Athens 2003
Page 7 of 29
• All transactions are tracked and recorded to monitor errors and accountability as
shown below:
• Bar code creation and printing.

Athens 2003
Page 8 of 29
• Opportunity and planned cross-docking in case of just-in-time warehouse
operation.
2.2 Put-away and Storage
Since every warehouse task is performed in real time, slotting for put-away can be
assigned as soon as a product is lifted from a location. Storage parameters will be
assigned based on zone designations, cube size and weight, equipment assignments
and other criteria such as:
• Environmental properties such as secure or hazardous material handling,
• Rate of each location’s accessibility in terms of ABC analysis,
• Item’s ABC analysis,
• Item’s stacking factor,
• Location’s capacity, etc.

Athens 2003
Page 9 of 29
2.3 Replenishment/Let-Downs
RF directed replenishment tasks are routed and dispatched by equipment
characteristics and forward pick area demand. Let-downs are timed based on pick
rates against actual inventory flow of the primary pick locations. Special features of
the replenishment function include:
• Changes to wave picking will automatically change replenishments
• Pick zone replenishment
• Emergency replenishments
This functionality is included in one selection under the RF menu:

Athens 2003
Page 10 of 29
2.4 Order Processing
WHMGNT/PRO allows for multiple wave picking to be easily constructed by the
warehouse manager, based on the changing priorities and demands of his/her
customer. Waves can be constructed on various criteria such as: pick-by-order, by
shipping route, by customer, by shipper, or by rules built to suit a company’s
business procedures. Some unique features of order processing include:
• Order consolidation, sequencing and verification via a user-friendly screen:

Athens 2003
Page 11 of 29
• Paper picking, which can be parameterised with respect to the columns
presented. Quantities are consolidated per pallet, location, item, load, etc. in
order to achieve wave picking. A sample of a picklist is presented below:
• RF picking, or any combination of the two simultaneously

Athens 2003
Page 12 of 29
• Task management on all pick functions:
• Assignment of stacking factor per location:

Athens 2003
Page 13 of 29
• Interface to carousels and other material handling automation
• Lot control, product rotation, and serial number tracking as per standard
MFG/PRO functions.
• Continuous monitoring for order shorts offering the user the opportunity to cancel
the line of the order, which includes the item of which the warehouse is short. It is
also possible to cancel the whole order if this is necessary at any time before
printing the invoice:

Athens 2003
Page 14 of 29
Even after the invoice print and post, the system allows the user, by entering a
small amount of information like the load number, ship-to address, customer,
effective date, etc., to backwards balance all inventory transactions automatically.
2.5 Task Interleaving
WHMGNT/PRO includes functionality that mixes dissimilar tasks such as picking and
put-away to obtain maximum productivity. For instance, it will direct a lift truck
operator to put away a pallet on his/her way to the next pick. In large warehouses this
can greatly reduce travel time not only increasing productivity but also reducing wear
on the lift trucks and saving on energy costs by reducing lift truck fuel/battery
consumption. This function is built into tasks like put-away, replenishment, order
picking, inventory control, etc. to maximize worker productivity and minimize
"deadheading". Unless the worker completes all tasks the system will direct the
operator to perform a different task in his area – as workers can login to different
warehouse zones or areas – such as a let down, consolidation, pick, load, etc. Task
Interleaving eliminates workers cruising down the aisles with "empty forks".
Therefore, depending on each company’s allocation of resources with respect to
different tasks, the system can be further parameterised to reflect each warehouse
needs.
2.6 Shipping
The primary purpose of WHMGNT/PRO shipping function is to verify the accuracy of
the picking process and to manifest orders to be shipped. Accuracy of picked orders
is confirmed by scanning bar codes with either RF mobile terminals or workstations
at the shipping/packing stations.

Athens 2003
Page 15 of 29
Some other shipping features are:
• Bill of lading creation

Athens 2003
Page 16 of 29
• Shipping label generation upon verifying the contents of each load.
• Repacking
• Interfaces with MFG/PRO or any other modern ERP system to trigger invoices.

Athens 2003
Page 17 of 29
2.7 Integration with Automated Material Handling Equipment.
WHMGNT/PRO supports the use of automated material handling equipment such as
carousels, ASRS units, AGVs, pick-to-light systems, or sorting systems. Since these
types of automation are very expensive and are usually a core component of a
warehouse WHMGNT/PRO was primarily developed to interface in real time with
such equipment.
2.8 Cycle Counting.
WHMGNT/PRO includes a cycle counting functionality. Cycle counting can be
performed using RF or other wireless terminals and devices, directly into the system,
or use MFG/PRO functionality towards this procedure. A typical cycle count can be
performed using RF as shown below:

Athens 2003
Page 18 of 29
3 Section 2: Special Features
3.1 OPEN ARCHITECTURE
WHMGNT/PRO was developed with an open architecture that allows the application
to interface not only with MFG/PRO but also with a number of ERP systems,
transportation management systems, or other supply chain applications. In addition,
it can easily interface with all major RF mobile terminals and input devices like bar
code scanners and voice recognition products. Of course, all costs involved in any
transaction are recorded to the MFG/PRO accounting and financial module.
3.2 MANAGEMENT REPORTING
WHMGNT/PRO monitors and tracks all of the activities in the warehouse. Apart from
standard MFG/PRO reports there is a large number of reports designated to cover all
warehouse as well as shop floor activities and turn these data into valuable
performance reports. WHMGNT/PRO management reporting capability offers the
tools needed to attain and maintain optimum performance in a warehouse and
inventory accuracy. A short set of reports that WHMGNT/PRO is capable of
producing is:

Athens 2003
Page 19 of 29
The most important ones, excluding those who are similar to MFG/PRO reports with
only minor alterations, are:
• Movements of a pallet since its entrance in the warehouse.

Athens 2003
Page 20 of 29
• Empty storage locations.
• Storage locations with remaining space.
• Quantity on hand per item, per lot and per status in all locations.

Athens 2003
Page 21 of 29
• Pallets per location.
• Outstanding inventory movements e.g. receipts not registered at storage
locations.

Athens 2003
Page 22 of 29
• Re-print Goods Received Note.
• Re-print receipt labels.

Athens 2003
Page 23 of 29
• Expired pallets.
• Pallet’s period of residence in warehouse.
• Changes in pallet’s inventory status.

Athens 2003
Page 24 of 29
• Split pallets using system’s resources,

Athens 2003
Page 25 of 29
or RF, with the ability to automatically print new barcode labels:
• Pallet and Location label and barcode re-print.
3.3 WHMGNT/PRO: A Pull (event driven) System
WHMGNT/PRO introduces a true flow business strategy. It supports event-driven
manufacturing and warehouse management and adjusts easily to changes in
demand, new product introductions or any change in the external environment that
directly or indirectly affects the entropy of the system.
WHMGNT/PRO is standardised with strategies developed on the basis of DFT. It
therefore formalises with the principles of flow manufacturing, which are focused on

Athens 2003
Page 26 of 29
eliminating waste, streamlining processes, building according to demand, and
continuous improvements.
By properly designing production lines and balancing the mix of products to a daily
demand rate in MFG/PRO, quality goods can be produced as ordered, at a rate that
falls within the required order-to-delivery response cycle time. As a result, the entire
supply process is pulled and sequenced from actual demand, which practically
means that each step of the production process is automatically executed via
interactive RF terminal communication, rather than using Kanban cards.
The menu screens are shown below:
For example, in case there is a released standard work order, there would be an
asterisk next to selection 11 To Production (left RF screen), demanding for materials
to be moved from the warehouse to the assigned buffer in front of the work centre.
Alternatively, a worker may use selection 14 Demand (left RF screen) in case he/she
desires to create demand for extra material to be transferred to production buffer,
generating, in effect, a pending movement to the warehouse workers.
Regardless of industry, type of manufacturing environment, or product volumes,
WHMGNT/PRO can be implemented successfully. It is most challenging to deploy its
modules in a shop that does highly configured or engineer-to-order products, yet they
are equally well with high-volume, more repetitive make-to-demand operations.
3.4 Enhanced performance when combined with MFG/PRO
functionality
WHMGNT/PRO, as mentioned above, utilises information entered in MFG/PRO. This
means that the characteristics of each item and location are maintained either at a
detail level or by grouping similar items and locations into categories. An example of
item characteristics at the detail level would include exact dimensions and weight of
each item in each unit of measure the item is stocked (eaches, cases, pallets, etc) as
well as information such as whether it can be mixed with other items in a location,
whether it is rackable, max stack height, max quantity per location, hazard
classifications, finished goods or raw material, fast verse slow mover, etc. Depending

Athens 2003
Page 27 of 29
on the structure of items as well as their diversity towards their product mix it appears
that in most cases the operations will be benefit by creating groups of similar
products in MFG/PRO.
After setting up the physical characteristics of products and locations we need to
specify the relationships between the locations, i.e. which location to pick from,
replenish from/to, and put-away to, and in what sequence these events should occur
(WHMGNT/PRO is all about “directed” movement). This is done by assigning specific
logic to the various combinations of item/order/quantity/location information that will
occur.
Some of the logic that can be used in WHMGNT/PRO in determining actual locations
and sequences follows:
• Location Sequence. We can define a flow through the warehouse and assign a
sequence number to each location. In order picking this is used to sequence the
picks to flow through the warehouse. In put-away the logic would look for the first
location in the sequence in which the product would fit.
• Zone Logic. By breaking down the storage locations into zones there is the
ability to direct picking, put-away, or replenishment to or from specific areas of
the warehouse.
• Fixed Location. This logic can be implemented using predetermined fixed
locations per item in picking, put-away, and replenishment. Fixed locations are
most often used as the primary picking location in piece pick and case pick
operations, however they can also be used for secondary storage. Fixed location
for an item is predefined in item master files in MFG/PRO.
• First-in-first-out (FIFO).
• First-expired-first-out (FEFO)
• Last-in-first-out (LIFO).
• Pick-to-clear. WHMGNT/PRO has the ability to implement this logic in which the
forklift workers are directed to pick from locations with the smallest quantities in
hand, i.e. pallets that are not full, etc. This logic is used for increased space
utilisation.
• Reserved Locations. This is used when you want to predetermine specific
locations to pick from/put-away to. An application for reserved locations would be
cross-docking where you may specify that certain quantities of an inbound
shipment be moved to specific outbound staging locations or directly to an
awaiting outbound trailer. Other application would be the reservation of a specific
dock for an inbound quantity shipment before putting-away to inner warehouse
locations.

Athens 2003
Page 28 of 29
• Pallet Exchange: WHMGNT/PRO offers the possibility to the RF user to pick a
pallet other than that reserved by the system for a specific order, so long as the
parameters that define the specific inventory – expire date, item number, lot,
inventory status, pallet number, etc. – are either identical for the alternative pallet
or within a range specified for each item by the warehouse manager. This is
extremely useful in warehouses that operate under the physical constraints
generated by a Drive-In system, in which the forklift user would not want to pick
the pallet that lies at the back of the rack but, alternatively at the front, expecting
all phantom inventory movements to take place automatically and unnoticeably.
In WHMGNT/PRO it is possible to combine logic methods to determine the best
location. For example, the warehouse manager may chose to use pick-to-clear logic
within first-in-first-out logic when there are multiple locations with the same receipt
date. Depending on the functional as well as business operation of the warehouse it
is also possible to change the logic based upon current workload. During busy
periods the warehouse manager may chose logic that optimises productivity while
during slower periods he/she switches to logic that optimises space utilization.

Athens 2003
Page 29 of 29
4 Conclusion
The effects of implementing WHMGNT/PRO are profound. In addition to the direct
and measurable results, such as cost savings and error reduction, the system also
generates a number of positive side effects. The main results include:
• A significant decrease in errors on invoices and despatch notes. Due to the high
complexity of individual shipments (each consisting of modest quantities of many
products) and the large number of product codes, the procedure of issuing
invoices and despatch notes is highly error prone. This in turn leads to high error
correction costs. With the installation of the system, the errors are virtually
eliminated.
• Improved accuracy in customer order execution. Just as with invoices and
despatch notes, there are frequent errors in the execution (preparation,
packaging and shipment) of customer orders. This generates considerable costs
(for the replacement of mistakenly shipped items, re-shipment of omissions and
so on). These errors that can cause customer dissatisfaction are eliminated.
• Greater accuracy in data acquisition, improved overall inventory monitoring and a
considerable reduction in inventory losses.
• The streamlined operation of the warehouses eliminates the need for a large
number of administrative staff. Warehouses can operate with just one instead of
many employees, thus slashing a major overhead. Similarly, the total operating
costs of the warehouses can be reduced.
• The lead-time for preparing and shipping a customer order can also be reduced.
• The system ensures that strict FIFO priorities are kept, so that only fresh
products (where applicable) are shipped and products with expiry dates (e.g.
pharmaceuticals) do not remain in the warehouse for long.
• Accurate lot tracking is possible, allowing the efficient withdrawal of a defective
lot. This enables the rapid recall of any defective product batches, which
previously was almost impossible because of the administrative overheads.
The implementation of such a system is an example of how a single technology can
effectively enable the redesign and streamlining of a core business process.
Ultimately, it is a real time data acquisition system that embraces flow manufacturing,
allowing radical change to the whole process.

IntroToWHMGNT_ENGLISH

Recommended

Recommended

More Related Content

What's hot

What's hot (11)

Viewers also liked

Viewers also liked (14)

Similar to IntroToWHMGNT_ENGLISH

Similar to IntroToWHMGNT_ENGLISH (20)

IntroToWHMGNT_ENGLISH