Warehouse Management Activities "As Is" process map

Warehouse Management “AS IS” process Mapping

Using BPMN

Julien-Robert LECADOU : [email protected] MCP / Dynamics AX MSc Operations and Project Management

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 devices Scan Gun devices

Warehouse Business Process Level 1 Receiving

War

eho

use

Wo

rker

s W

areh

ou

se W

ork

ers

Pro

du

ctio

n d

epar

tmen

tP

rod

uct

ion

dep

artm

ent

Stretch Wrap Pallet

Stretch Wrap Pallet

Production startProduction start

Production Order

Production Order

Store in PISO Store in PISO

Train to Inbound Dock

Train to Inbound Dock Immediate

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

Warehouse Business Process Level 1 Picking

ShippingShipping

ImmediateShipment?

ImmediateShipment?

Yes Store in PISO Area

Store in PISO Area

Picking List Picking List

Move to Bulk area

Move to Bulk area

Shipping Order

Shipping Order


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

Shipping Shipping Small Pick

Stretch Wrap Pallet

Stretch Wrap Pallet Item relabeling Item relabeling Move to Picking

Area

Move to Picking Area Shipping Shipping

End End

Move to Picking Area

Move to Picking Area

Bulk Shipment

Shipping Shipping

End End

End End

Register pallet location

Register pallet location

Note: level 1 the higher level of transaction , between the between the worker and the system

Page 3

Note

wo

rker

w

ork

er

Stretch Wrap Stretch Wrap Count Item on pallet

Count Item on pallet

Start Start End End

Stretch Wrapping Process

Glue Label on Pallet

Glue Label on Pallet Scan Item Label Scan Item Label

WM

S/SW

I*

WM

S/SW

I*

Weight Pallet Weight Pallet

Match Good?Match Good?

Print Label Print Label

No

Match

Weight & Count to Product Reference

Match


If no scale available, disregard to weight match


Store Pallet info to WMSDM

Store Pallet info to WMSDM

Yes

Store pallet info Store pallet info

WMS/ CSI : Warehouse Management System/ Stretch Wrap Interface

Production ref.

Worker: The worker could be warehouse worker or production worker

Page 4

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 locationBar code

Following information is printed :Production order ,Production date Pallet Quantity Pallet Sequence Pallet content Target locationBar 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

Legend

ALU

F P

last

ics

ALU

F P

last

ics

Load

er

Load

er

Shipping Process

Tru

ck D

rive

r Tr

uck

Dri

ver

War

eho

use

Man

ager

W

areh

ou

se M

anag

er

War

eho

use

Wo

rker

W

areh

ou

se W

ork

er

Picking ticket

Picking ticket

Verify conformance

Verify conformance

Print Label Print 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 Sheet Print 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 Order Deliver 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 POD Register 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

Scaling Process Flow W

ork

er

Wo

rker

Drop pallet on scale

Drop pallet on scale Place LabelPlace Label Remove

Pallet

Remove Pallet

Ap

plic

atio

ns

& D

evic

e A

pp

licat

ion

s &

Dev

ice

We

igh

t In

dic

ato

r*

We

igh

t In

dic

ato

r*


*Digital weight indicator : Mfg: Totalcomp ;model: T500E

Digital Scale indicator

Stre

tch

Wra

p

Inte

rfac

e

Stre

tch

Wra

p

Inte

rfac

e

Send weight info to SWI


Read Scale and Display on

screen


screen

Page 7

War

eho

use

wo

rker

W

areh

ou

se w

ork

er

Count Item on pallet and key in

Count Item on pallet and key in

Start Start End End

Palletization Detailed process

Glue Label on Pallet

Glue Label on Pallet Scan Item Label Scan Item Label

Ap

plic

atio

ns

Pla

tfo

rm

Ap

plic

atio

ns

Pla

tfo

rm

WM

S/ C

SIW

MS/

CSI

Stre

tch

wra

p in

terf

ace

Stre

tch

wra

p in

terf

ace

Stre

tch

Pla

tfo

rmSt

retc

h P

latf

orm


Print LabelPrint Label

No



Database Database

Yes



3 min3 min




screen


screen

Send pallet info to WMS

Database

Send pallet info to WMS

Database

Match


Match


fair Tolerance? fair Tolerance?

Retrieve order info from CSI

Retrieve order info from CSI

Receive Pallet weight

Receive Pallet weight

Stretch Wrap Stretch Wrap

DatabaseDatabase

Remove pallet from Platform

Remove pallet from Platform

Page 8

Product Relabeling

Retrieve item from Location

Retrieve item from Location


Kill Pallet and clear from Location

Kill Pallet and clear from Location Replace Items Label Replace Items Label

Page 9

Register Shipment Registration

RegisterRegister

Collect POD from Driver

Collect POD from Driver

Page 10