Warehouse Management Activities "As Is" process map

6,110 views

Published on

This was my first project in mapping processes before we can implement improvement to the organization warehouse management system.
It is not perfect but I would like to share it somehow.

Published in: Business

Warehouse Management Activities "As Is" process map

  1. 1. Warehouse Management “AS IS” process Mapping Using BPMN Julien-Robert LECADOU : lecadou@gmail.com MCP / Dynamics AX MSc Operations and Project Management
  2. 2. System Architecture AOS - Dynamics AX Database SQL for Dynamics AX Client Legacy WMS Shipment and Production label Printer CSI Adaptor Application file server Page 1 SQL Database for CSI SQL Database for CSI Scan Gun devicesScan Gun devices
  3. 3. Warehouse Business Process Level 1 Receiving WarehouseWorkersWarehouseWorkersProductiondepartmentProductiondepartment Stretch Wrap Pallet Stretch Wrap Pallet Production startProduction start Production Order Production Order Store in PISOStore in PISO Train to Inbound Dock Train to Inbound DockImmediate Shipping ? Immediate Shipping ? No Keep in PISO areaKeep in PISO areaYes Space Available? Space Available? Yes No Store at inbound dock Store at inbound dock Move pallet to bulk area Move pallet to bulk area Stack items on Pallet Stack items on Pallet Only pallets marked with Target location “PISO” are shipped immediately Only pallets marked with Target location “PISO” are shipped immediately Page 2
  4. 4. Warehouse Business Process Level 1 Picking ShippingShipping Immediate Shipment? Immediate Shipment? Yes Store in PISO Area Store in PISO Area Picking ListPicking List Move to Bulk area Move to Bulk area Shipping Order Shipping Order Picking ListPicking List Shipping Order Shipping Order Type of order ?Type of order ? Assembly Pick Stretch Wrap Pallet Stretch Wrap Pallet Move to picking Area Move to picking Area Find Item in picking location Find Item in picking location Small assembling Small assembling ShippingShippingSmall Pick Stretch Wrap Pallet Stretch Wrap PalletItem relabelingItem relabeling Move to Picking Area Move to Picking Area ShippingShipping EndEnd Move to Picking Area Move to Picking Area Bulk Shipment ShippingShipping EndEnd EndEnd Register pallet location Register pallet location Note: level 1 the higher level of transaction , between the between the worker and the system Page 3
  5. 5. Note workerworker Stretch WrapStretch WrapCount Item on pallet Count Item on pallet StartStart EndEnd Stretch Wrapping Process Glue Label on Pallet Glue Label on PalletScan Item LabelScan Item Label WMS/SWI*WMS/SWI* Weight PalletWeight Pallet Match Good?Match Good? Print LabelPrint Label No Match Weight & Count to Product Reference Match Weight & Count to Product Reference If no scale available, disregard to weight match If no scale available, disregard to weight match Store Pallet info to WMSDM Store Pallet info to WMSDM Yes Store pallet infoStore pallet info WMS/ CSI : Warehouse Management System/ Stretch Wrap Interface Production ref. Worker: The worker could be warehouse worker or production worker Page 4
  6. 6. Retrieve production reference Retrieve production reference Find it ?Find it ? No Print data on Label Print data on Label Following information is printed : Production order , Production date Pallet Quantity Pallet Sequence Pallet content Target location Bar code Following information is printed : Production order , Production date Pallet Quantity Pallet Sequence Pallet content Target location Bar code Stretch Machine Form Scan Carton Label : (ex:XXXX-Y-ZZZZZ) Production Order Sales Order Line Square Pallet content Pallet Sequence Height Target location Scale Info Weight xxxxx LBS Quality (good/or No) Changed MM/DD/YYYY HH:MM:SS AM/PM Please Specify the following pallet attributes Pallet Square Pallet Height Pallet Extra Last Good: Weight : xxxxx LBS Age : 00:00:00 HH:MM:SS Total Pallet Qty = Print Label Cancel Pallet x + Stretch Wrap Machine Interface Production Order Production Date Pallet Quantity Pallet Sequence # Pallet content Target Location Label Sample PO-X-Plt Seq Printing Label Yes Page 5
  7. 7. Legend ALUFPlasticsALUFPlastics LoaderLoader Shipping Process TruckDriverTruckDriver WarehouseManagerWarehouseManager WarehouseWorkerWarehouseWorker Picking ticket Picking ticket Verify conformance Verify conformance Print LabelPrint Label Adjustment needed?Adjustment needed? No Sometime time the order is not conform the quantity, so there are adjustments needed to be made. Sometime time the order is not conform the quantity, so there are adjustments needed to be made. Make adjustments Make adjustments Yes Items Picked from the storage location Items Picked from the storage location Pallets transferred to Picking Area Pallets transferred to Picking Area Print Ship SheetPrint Ship Sheet Print Bill of Lading Print Bill of Lading Scan item new location Scan item new location Picking list w/ Item location Ask Warehouse worker to start Picking Ask Warehouse worker to start Picking Provide Ship sheet to warehouse Loader Provide Ship sheet to warehouse Loader Provide Bill of Lading to Driver Provide Bill of Lading to Driver Deliver OrderDeliver Order Return Proof of delivery Return Proof of delivery DeliveredDelivered Approve and sign Bill of Lading Approve and sign Bill of Lading Return Bill of Lading as POD Register PODRegister POD WMSDBWMSDB CSI Database Receive Ship Sheet Receive Ship Sheet Bill of Lading Include Customs Items ? Include Customs Items ? Yes Retrieve Customs Items from order Retrieve Customs Items from order No Look up for Customs Items Look up for Customs Items Customs Item Picking list Customs Item Picking list Customs Items on Ship Sheet Customs Items on Ship Sheet Yes Load truck w/ Ship Sheet Load truck w/ Ship Sheet No Stage all PalletsStage all Pallets Picking list only concerns stock items not Customs Items. Customs Items picking List are added at the time ship sheet is printed. Picking list only concerns stock items not Customs Items. Customs Items picking List are added at the time ship sheet is printed. Ship Sheet Scan Pallet location Scan Pallet location Register Pallet new location Register Pallet new location Make adjustment Make adjustment Page 6
  8. 8. Scaling Process Flow WorkerWorker Drop pallet on scale Drop pallet on scale Place LabelPlace Label Remove Pallet Remove Pallet Applications&DeviceApplications&Device WeightIndicator*WeightIndicator* Weight PalletWeight Pallet *Digital weight indicator : Mfg: Totalcomp ;model: T500E Digital Scale indicator StretchWrap Interface StretchWrap Interface Send weight info to SWI Send weight info to SWI Read Scale and Display on screen Read Scale and Display on screen Page 7
  9. 9. WarehouseworkerWarehouseworker Count Item on pallet and key in Count Item on pallet and key in StartStart EndEnd PalletizationDetailed process Glue Label on Pallet Glue Label on PalletScan Item LabelScan Item Label ApplicationsPlatformApplicationsPlatform WMS/CSIWMS/CSIStretchwrapinterfaceStretchwrapinterfaceStretchPlatformStretchPlatform Weight PalletWeight Pallet Print LabelPrint Label No If no scale available, disregard to weight match If no scale available, disregard to weight match DatabaseDatabase Yes Drop pallet on scale Drop pallet on scale 3 min3 min Send weight info to SWI Send weight info to SWI Read Scale and Display on screen Read Scale and Display on screen Send pallet info to WMS Database Send pallet info to WMS Database Match Weight & Count to Product Reference Match Weight & Count to Product Reference fair Tolerance?fair Tolerance? Retrieve order info from CSI Retrieve order info from CSI Receive Pallet weight Receive Pallet weight Stretch WrapStretch Wrap DatabaseDatabase Remove pallet from Platform Remove pallet from Platform Page 8
  10. 10. Product Relabeling Retrieve item from Location Retrieve item from Location Picking ListPicking List Kill Pallet and clear from Location Kill Pallet and clear from Location Replace Items LabelReplace Items Label Page 9
  11. 11. Register Shipment Registration RegisterRegister Collect POD from Driver Collect POD from Driver Page 10

×