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Operations Training


       SBISA, LLC
  Grand Rapids, Michigan
WCS Training Syllabus
 Introduction Training
 Date/Time: Monday, November 28th
          Shift 2: 12:00PM –2:00PM
     ...
Who’s Who
 Who are the players and what do they do?
 SBISA, LLC
   Conveyor and Controls
   Grand Rapids, Michigan
 P...
Agenda
    Terms
    Conveyor Control Overview
    Warehouse Control System Overview
    WCS Order Processing
    Car...
Terms
 Lots of new Terms
 Ask Questions about any term not
  understood?
 Glossary of Terms in handout




Monday 11/20...
Conveyor Controls Overview
 Control Panel
          Big grey box under platform
 System Start
 System Stop
 Reset
 E...
Warehouse Control System
 Warehouse Control System (WCS)
   PC Server in Computer Room
   Runs background programs
   ...
WCS Order Processing
    Orders Allocated to Pick Lines on Epicor
    P1/P2 Orders pulled into PTL (P1/P2 PTL Server)
 ...
Carton Induction
 Cartons Erected and bottoms taped
 Bubble wrap added to bottom of carton
 Carton Labels applied to ca...
Zone Routing
 Pick Module Transfers (5)
          Carton Id Barcode Scanned
          Route Determination
             ...
P3 PTL Picking
 After Carton/Tote diverted to zone
    Zone is called area on PTL

 Scan Carton Id to Launch
    Using...
Jackpot Area
 Zone 10 is Jackpot Area
          Transfer Left at Transfer #5
          No Reads
 No Reads
 Missing Pi...
Batch Order Picking
 Single line orders grouped into batches by SKU
 Batches are cartonized to Totes (Large/Small)
 Tot...
Batch Pick/Sort
 Select red totes from conveyor
 Scan Carton Id (from tote label)
 Tote contains only 1 item for multip...
Pack Induction
 Scan Carton Id
 Contents List printed for each carton
 Packing List printed for last picked carton for
...
QC Operations
 Compare contents of carton to printed carton content list
 Exception Conditions
          Missing Produc...
Fill & Seal
 Add craft paper and insta-foam as required to
  protect carton contents
 Seal carton
          Run through...
UPS Station and Shipping
 Place carton on scale
 Scan carton on UPS World Ship station
 Shipping Label printed and appl...
Questions
 Questions!!!
 Tour
 More training tomorrow




Monday 11/20/2004          19
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Day 1 Training Wcs

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Day 1 Training Wcs

  1. 1. Operations Training SBISA, LLC Grand Rapids, Michigan
  2. 2. WCS Training Syllabus  Introduction Training  Date/Time: Monday, November 28th  Shift 2: 12:00PM –2:00PM  Shift 1: 2:30PM - 4:30PM  Attendees: Managers, Supervisors  Training Location  Start in training room  Move to Pick Module for tour Monday 11/20/2004 2
  3. 3. Who’s Who  Who are the players and what do they do?  SBISA, LLC  Conveyor and Controls  Grand Rapids, Michigan  PCC  Lightning Pick PTL  Germantown, Wisconsin (Milwaukee Area)  QC Software  Warehouse Control System (WCS)  Cincinnati, Ohio Monday 11/20/2004 3
  4. 4. Agenda  Terms  Conveyor Control Overview  Warehouse Control System Overview  WCS Order Processing  Carton Induction  Zone Routing  P3 PTL Picking  Jackpot Area  Batch Order Picking  Batch Pick/Sort  Pack Induction  QC Operations  Fill & Seal  UPS Station and Shipping  Questions Monday 11/20/2004 4
  5. 5. Terms  Lots of new Terms  Ask Questions about any term not understood?  Glossary of Terms in handout Monday 11/20/2004 5
  6. 6. Conveyor Controls Overview  Control Panel  Big grey box under platform  System Start  System Stop  Reset  Emergency Stop Monday 11/20/2004 6
  7. 7. Warehouse Control System  Warehouse Control System (WCS)  PC Server in Computer Room  Runs background programs  Hosts WCS Database  WCS screens accessible from selected PCs  WCS Security  Requires Username and Password  Must be setup by administrator on WCS  Access granted to user by menu, screen and/or function  Templates available  (Supervisor, Carton Inductor, etc.) Monday 11/20/2004 7
  8. 8. WCS Order Processing  Orders Allocated to Pick Lines on Epicor  P1/P2 Orders pulled into PTL (P1/P2 PTL Server)  P3 Orders pulled into WCS  Single line orders  Batched together by SKU  Cartonized to one or more totes (Large and Small)  Carton Labels generated for each tote  Multi-line Orders  Cartonized by order into one or more cartons based on defined SKU dimensions and defined box dimensions.  Carton labels generated for each carton Monday 11/20/2004 8
  9. 9. Carton Induction  Cartons Erected and bottoms taped  Bubble wrap added to bottom of carton  Carton Labels applied to carton  Size Requirement on carton label  Carton placed on P3 conveyor line  Carton Label Printing Controls  Reprint Labels  Start/Stop Label Printer  Other Advanced Features  Ship Alones  Different Label Format  Labels delivered to pick zone Monday 11/20/2004 9
  10. 10. Zone Routing  Pick Module Transfers (5)  Carton Id Barcode Scanned  Route Determination  Left, Right, Straight  Based on assigned pick locations  Picks sent to PTL when carton divert confirmed  Standalone picks are sent to PTL when carton id label is printed. Monday 11/20/2004 10
  11. 11. P3 PTL Picking  After Carton/Tote diverted to zone  Zone is called area on PTL  Scan Carton Id to Launch  Using wireless scanner associated to zone  Bay lights and location lights operate just like P1/P2  Place carton back on conveyor when picks complete in area  Carton goes back to same transfer for next route determination (left, right, straight)  Order Confirmed when last pick for last carton Monday 11/20/2004 11
  12. 12. Jackpot Area  Zone 10 is Jackpot Area  Transfer Left at Transfer #5  No Reads  No Reads  Missing Picks  Zone Full Monday 11/20/2004 12
  13. 13. Batch Order Picking  Single line orders grouped into batches by SKU  Batches are cartonized to Totes (Large/Small)  Totes Inducted and Routed to Zone containing picks  By definition these totes will only go to one area (picks for only one SKU)  Use PTL to pick required quantity to satisfy all orders in the batch.  Place tote back on conveyor  Tote delivered to Batch Pick/Sort Area for processing Monday 11/20/2004 13
  14. 14. Batch Pick/Sort  Select red totes from conveyor  Scan Carton Id (from tote label)  Tote contains only 1 item for multiple orders  Packing Lists generated for each order  Pack content to carton (or bubble pack) and insert packing list.  Apply carton id label from packing list to shipping container  Required for scanning at UPS Station  QC Requirements?  Carton ready for manifesting Monday 11/20/2004 14
  15. 15. Pack Induction  Scan Carton Id  Contents List printed for each carton  Packing List printed for last picked carton for order  Place Documents in Carton  Carton Ready for QC Monday 11/20/2004 15
  16. 16. QC Operations  Compare contents of carton to printed carton content list  Exception Conditions  Missing Product  Replace with product from pick location  Pick was confirmed otherwise carton would be at jackpot  Excess Product  Remove excess quantity and replace in pick location  Right quantity was confirmed in PTL  Wrong Product  Remove wrong product to assigned pick location  Picker confirmed the proper quantity from the assigned pick location but either picked from wrong location or placed into wrong carton Monday 11/20/2004 16
  17. 17. Fill & Seal  Add craft paper and insta-foam as required to protect carton contents  Seal carton  Run through semi-automatic taping machine  Carton delivered to UPS Station Monday 11/20/2004 17
  18. 18. UPS Station and Shipping  Place carton on scale  Scan carton on UPS World Ship station  Shipping Label printed and applied  Carton delivered to shipping  Shipping  Manual segregation process Monday 11/20/2004 18
  19. 19. Questions  Questions!!!  Tour  More training tomorrow Monday 11/20/2004 19

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