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IntelliTrack® WMSAn Overview and
Approach
IntelliTrack® WMSAn Overview and
Approach
Powerful, Full Featured, Affordable
IntelliTrack WMSAgenda
• WMS Basics• Top Three Warehouse Problems• Benefits of a WMS• Implementation of a WMS
IntelliTrack WMSWarehouse Basics
Majority of problems in a warehouse occur due to lack of CONTROL:
• Inventory• Operation• Management
... A WMS is the solution. It has the capability to optimize the warehouse and warehouse operation. It is an operating tool that is based on the needs of a warehouse operation and provides for its management.
IntelliTrack WMSWarehouse Basics
A WMS is the integration of these enabling technologies:
• Bar Coding• Radio Frequency Technology• Hardware (PC & Network)• Software
– WMS Functions– Other
IntelliTrack WMSWarehouse Basics
• Bar Coding
–Labor reduction (no keying)–Data acquisition accuracy
•Scanning•RF Validation
IntelliTrack WMSWarehouse Basics
• Radio Frequency
– Information availability• Real time updates• NO information delay
(ZERO lead times)
–Labor pacing• Directed puts & picks
–Material tracking• Locator verification• Cycle counts
IntelliTrack WMSWarehouse Basics
• Software (Management)– Employee transaction activity logs– Item/product history log– Report generation– Terminal Messaging– System security– Host Interface: Import & Exports
IntelliTrack WMSWarehouse Basics
WMS software supports the basic five operations in a warehouse
• Receive Product• Store Product• Pick Product • Ship Product• Inventory Management
IntelliTrack WMS Warehouse Basics - RECEIVING
Receiving Stage
•Purchased items•Finished goods•Returns
IntelliTrack WMSWarehouse Basics - PUTAWAY
Receiving Stage
Final Location
•Build/Move Pallet•QA•Location & lot control•Cross dock•Basic space management
IntelliTrack WMSWarehouse Basics - PICKING
Warehouse Location
Truck/Carrier
1
IntelliTrack WMSWarehouse Basics –
PICKING & Ship Confirm (2 step)
Shipping Stage/Packing
Warehouse Location
Truck/Carrier
1
2
•Raw material•WIP picking•Finished goods•Products•Pallets
IntelliTrack WMSWarehouse Basics
IT WMS provides for:• Accurate Receiving
– Validation to PO– FIFO and Lot Tracking– Immediate update and accessibility– Available to Putaway queue– Blind receiving– Build & Move Pallets– Serial # Tracking– Cross Docking
IntelliTrack WMSWarehouse Basics
IT WMS provides for:• Accurate Picking
– Validation to Sales order– Confirm Item and Location– FIFO and Lot Tracking– PreRoute Picking
• Minimize travel
– Primary location– Record Activity in Locator System– Batch/Wave Picking
IntelliTrack WMSWarehouse Basics
IT WMS provides for:• Inventory and Storage Control
– Stock locator– Quantity by location– Cube – Space management– Lot number by location– Serial # Tracking– Counts: Cycle and Physical
• Update immediately
– Replenishment points and quantity– Directed moves/transfers (re-warehousing)– Real Time updates of all item activity
IntelliTrack WMSWarehouse Basics
IT WMS provides for:• Shipping
– Routing to specific shipping lanes– Packing slip– Bill of lading generation– ASN to customer– Packing validation– Manifesting– Billing information
IntelliTrack WMSTop THREE Warehouse Problems
INVENTORY INACCURACYResults:• Lost Sales• Back Orders• Excessive Inventory• Missed Schedules• Low Labor Productivity• Excessive Expediting• Excessive Freight Costs• High Obsolescence
IntelliTrack WMSTop THREE Warehouse Problems
INVENTORY INACCURACYResolution:• Physical Counting• Cycle Counting• Confirm Location• Confirm Item• Require Accountability
IntelliTrack WMSTop THREE Warehouse Problems
POOR PICKING INFORMATIONResults:• Too Much Information• Not Printed In Shortest Path Sequence• Hand Written Confirmation• Print is Difficult to Read• Non- Standard units Quantity
IntelliTrack WMSTop THREE Warehouse Problems
POOR PICKING INFORMATIONResolution:• Paperless Picking
– Frees the Picker’s Hands– Utilizes Shortest Path– Electronically Sorts and Traces Orders– Electronic Pick Confirmation– Increases Picker Productivity
IntelliTrack WMSTop THREE Warehouse Problems
Find Product11%
Travel57%
Pick Product18%
Process Order11%
Get Order3%
POOR SLOTTINGThe placement of a product in a facility for the purpose of material handling and efficiency.
Thompkins & Associates May 1999
IntelliTrack WMSTop THREE Warehouse Problems
PROPER SLOTTING WILL:• Minimize Travel Distance• Reduce Labor
Requirements• Improve Throughput• Minimize Replenishment• Increase Picker
Productivity• Increase Picker Accuracy
• Lower Fixed Labor Costs– Operator NOT searching for product or open
space– Optimized picking path– Slotting– No manual data collection
• Reduced Inventory Costs– Eliminate excess/safety inventory (25 - 30%)– Physical count costs are reduced by 30 to
60%– Moving to cycle counts– Reduction in inventory write-offs
IntelliTrack WMSWMS Benefits Summary
• Reduced Data Errors and Its Associated Cost$– NO data entry
• Better Quality Control – Warehousing & Manufacturing– Lots & FIFO– No production overruns– No production disruption due to
material outages
IntelliTrack WMSWMS Benefits Summary
• Improved Customer Service– Current status– No backorders– Lost sales due to inaccurate
inventory• Competitiveness
– Cheaper– Faster– Satisfied clients
IntelliTrack WMSWMS Benefits Summary
IntelliTrack WMSWMS Benefits Summary
OPERATION BENEFIT COST SAVINGS
Reduce or Eliminate Physicals 30-50% of current cost
Eliminate Safety Stock 10-30% of inventory value
Reduce Shipping/Pick/Returns Reduce Operation Costs $35-$125 per return
Eliminate Location Search Reduce Labor
Eliminate Manual Data Collection Real time data / reduce labor
Eliminate Data Entry Accurate data 1/300 in error - $25 to $95
Eliminate Information Delay Reduced lead times
Improved Customer Service
Increase Sales
IntelliTrack WMS WMS Implementation
• Systems Requirements and Design Study (SRDS)– Blueprint for Success
• Configuration• Enhancements• Implementation• Integration• Training• Cutover Support• More
1. SRDS2. Project Plan
1. Time Line2. Milestones
3. Kick-off4. Install Base WMS5. Install RF Back-bone6. Printers7. Deliver Enhancements8. Train User9. Live – Cut-over
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