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.

1. Warehouse Management “AS IS” process Mapping
Using BPMN
Julien-Robert LECADOU : lecadou@gmail.com
MCP / Dynamics AX
MSc Operations and Project Management

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. 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. 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. 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. 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. 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. 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. 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. 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. Register Shipment Registration
RegisterRegister
Collect POD from
Driver
Collect POD from
Driver
Page 10