o o o o
Effective use of the available space for better functioning of the processes in the warehouse. Consolidation of articles in different bins. Maximum utilization of bin capacity. Total percentage of empty bins.
INTRODUCTION:
RDC warehouse contains 51,589 bins which are to be utilized to the full extent for the effective functioning. Total area of the warehouse is 1,52,000 sq.ft. This should be properly utilized. For an ideal warehouse the percentage of empty bins should be 20% which should be maintained at rdc. Consolidation of articles helps in carrying operations easily.
Space utilization is the crucial aspect in the functioning of a warehouse, the proper utilization of space helps in improving the accommodation capacity. The percentage of empty bins helps in systematic functioning of the warehouse. Consolidation of the articles helps in producing more space. Maximum utilization of bin capacity helps in reducing the wastage of space
Effective space utilization is very much useful in utilization of the available resources to a full extent. Consolidation, increasing the percentage of empty bins and utilization of bin capacity contribute in achieving maximum utilization of the available space
o o o o
To understand the operational functions keenly. To suggest any further improvements for better functioning. For observing flaws in the process. For betterment of functioning process.
It helps in identifying the elements that result in the reduction in the capacity of the operation functions like put away, picking etc... Helps in providing a clear picture of the functions.
RESEARCH METHODOLOGY:
o o o
Information from the staff on the process being followed. Data of stock balance on the daily basis from WMS. Data from inventory cycle count.
o o
Only RDC warehouse is available for study. Manual errors occur frequently.
OBSERVATIONS: LOCATION MASTER BIN TYPE Category Fashion Sub Cat Apps Section Kids Ladies Mens Home Fashion 33880 Footwear GM Footwear Crockery Depot Luggage Plastic Toys and Sports Utensils Grand Shelving Decking Racking Total 7112 78 312 7502 8792 8792 17976 112 553 18641 2496 2686 1724 1339 605 1326 756 1988 4340 38220 960 36 5990 8676 881 1746 512 454 573 1088 320 2947 4693 3377 38312 2236 1793 1596 1178 2414 2036 2024 13277 51589
1596
RDC warehouse contains 51,589 bins which are to be utilized to the full extent for the effective functioning. Total area of the warehouse is 1, 52,000 sq.ft. This should be properly utilized. As mentioned in the above table the total number of bins in shelving are 38220, decking are 8676, racking are 4693. Major portion of the space is occupied in shelving especially by apparels. Hence the space utilization of bins in shelving is important. The utilization of the bins to the full extent is possible by consolidation of the bins containing same articles.
CONSOLIDATION
Consolidation is the act of merging items of same article number located in different bins. Consolidation process is carried out by the respected LOBs of the departments according to the need and availability of man power. Consolidation process helps in increasing the number of empty bins hence making it easy for the operations process to be carried out.
Grand Total
The above table provides the details of empty bins available.76% of the bins are occupied and out of this the percentage of bins occupied in the shelving are about 82% and 18% of the empty bins are available in the shelving area. For an ideal warehouse a minimum of 20% of the empty bins are to be available for the proper functioning of the process.
Apps Clothing Status of RDC Bangalore Family Capacity Defined Non Prepack Prepack 54875 Total BOH qty % Utilization Count of SKU
493,025 527427 319,860 393206 369,600 351188 210,880 172860 1393365 1444681
118% 6204 139% 5463 132% 5799 82% 1644 121% 19110
The above table explains the utilization of the capacity. Apparels occupy more space than the defined, hence are to be more concentrated.
BIN CAPACITY:
The total bin capacity in shelving is 141506.106 sq ft. Out of which the capacity of the bins varies among different bins.
Volume(sq ft) 2.88 2.882 3 3.24 3.6 4.318 5.76 5.763 8.637
count 526 9794 1709 15352 1653 3347 428 3256 1772
Sum(sq ft) 1512 28223.426 5124 49737.24 5947.2 14448.028 2459.52 18758.565 15296.127
% of bins 1.06 19.94 3.6 35.14 4.2 10.2 1.738 13.256 10.8
At RDC warehouse the he boxes are directly put into the bins hence preventing the total usage of the bins. The average of the bins is taken as 3.24 sq ft and accordingly the capacity is calculated.
RDC
INBOUND
OUTBOUND INVENTORY MANAGEMENT RETURNS
RECEIVING
CLUSTER PICKING
REPLENISHME NT
RTV-WH INITIATED
CYCLE COUNTING
CROSS DOCK
INVENTORY MOVES
BALANCE ON HAND
1. Inbound
1.1. Pre Receiving 1.1.1 Pre Receiving (From Vendor) Process Description: Pre Receiving process will enable warehouse to unload the consignment and
release transporter WMS imports PO, Inbound details from SAP Update date & time for ASNs ( either through inbound or by calling up the vendor from warehouse) Warehouse will have daily report of scheduled ASNs for the day Vehicle arrives at the gate of the warehouse. Truck driver submits the document to the security personnel PO , LR , Invoice, Inbound Copy, Quality report. Security verifies the documents and checks if the consignment is for the same warehouse. Security personnel write details in security inward registerKey Fields: Inward Date/Time, Truck No., LR Number, PO Number/Date, ASN Number assigns manual inward number. Driver submits the documents to inward clerk Inward clerk checks all documents for any discrepanciesPO and ASN are matching or not Invoice is correct ASN is created or not LR details is correct Inward Clerks recalls ASN number in WMS screen and updates detailsKey Fields: LR Details, Transporter code, Vehicle number, Number of boxes mentioned on LR, Dock Door Inward clerk assign available dock door manually and instruct driver to proceed for unloading. Driver parks the vehicle at the assigned dock door for unloading. Inward staff starts unloading activity While unloading inward staff weighs the carton(s) for LR weight verification if required and move the consignment to pre-receiving area. Inward staff segregates the all cartons based on ASN & keeps them on pallet in a lane/lanes (Pallet id validation based on pallet 10 digit numbering model: PL-10-999999 [Pallet (2 digit)-Warehouse (2digit)-No. Series (6 digit)] Inward staff starts scanning in RF Key Fields: ASN, , Lane id, Pallet Id
Inward staff counts & enters the number of boxes on pallet on RF screen Inward staff enters the count of damaged boxes on pallet on RF screen (if any). Once all the pallets are scanned, Staff confirms on RF (IGP generation screen) that scanning is over Inward clerk generates gate pass from WMS based on above confirmation. This will trigger IRN in SAP Inward clerk handover the gate pass to driver. Driver report back to Security personnel Security personnel update the security register. Key Fields: Gate Pass Number & Truck out time against the ASN number. SAP to send IRN host reference detail to WMS.
Exception Handling:
In case consignment is not for the warehouse then Security personnel will not allow truck to inward If inbound is not created for that consignment then truck will not be allowed to unload. Further category to be informed to create ASN While unloading if any of the carton(s) found tampered/ damage, has to be kept aside on a seperate pallet with ASN number mentioned on it for transporter damage process handling If document details are not matching then inward in- charge will take appropriate action
Business Rules:
One ASN = One Gate Pass Any delivery received without ASN, PO and Invoice will be rejected. Gate pass would not be generated until Pre- receiving is confirmed for complete IGP once printed cannot be changed. IGP created in WMS will flow to SAP for IRN confirmation.
Refer Chapter 4.1.2/ Refer Chapter 4.1.2/ Fig. No. 104/Page 90 Fig. No. 104/Page 90 of WMS User manual of WMS User manual
Appointment to be given on the Appointment to be given on the basis of W/H unloading capacity/ basis of W/H unloading capacity/ day/shift day/shift W/H to define a cut off time for W/H to define a cut off time for servicing vendor vehicles servicing vendor vehicles
Calls up the Vendor for giving appointment Calls up the Vendor for giving appointment and updates appointment and LR details in and updates appointment and LR details in WMS against the ASN WMS against the ASN
Refer Chapter 4.1.3/Fig. Refer Chapter 4.1.3/Fig. No. 106/Page 91 of WMS No. 106/Page 91 of WMS User manual User manual
Generate Schedule ASN report from WMS for the day at the start of the shift. Take print out of the report and mail the soft copy of the report to Inward security team.
Vehicle arrives at main gate. Driver reports to security with consignment documents
Note set of document Note set of document contains PO, ASN, Invoice, contains PO, ASN, Invoice, and LR copy, Quality Report ( and LR copy, Quality Report ( In case of Apparels) In case of Apparels)
Security
No
Check whether the Consignment is meant for the Warehouse by checking warehouse site code/ address in PO
Security
Security
End Check whether an appointment has been given to the vendor vehicle (Schedule ASN report)
No No
Yes Yes
Security
SD person to Check whether the vehicle can be unloaded in consultation with Inward Incharge during the day/shift Send the vehicle back and inform category team via mail
Yes
Security Inform the truck driver about the probable unloading time
No
Inward In-charge
Check for any document Discrepancies i.e. LR, Vendor Invoice, PO, Inbound copy and QI Report
NO
No
Inward In-charge
Yes
Refer Chapter 4.1.4/Fig. Refer Chapter 4.1.4/Fig. No. 110/Page 94 of WMS No. 110/Page 94 of WMS User manual User manual
Inward In-charge updates ASN with LR details & assigns the dock
Note input details Note input details Transporter Code, LR Number, Transporter Code, LR Number, LR Date and Expected Number LR Date and Expected Number of boxes, Vehicle Number of boxes, Vehicle Number against each ASN against each ASN
Inward In-charge
Directs driver to dock the vehicle as per the assigned dock door
Security
Assigns token no. to the vehicle, mentions the token no. on the Inward register, enters consignment details in Inward register
Security
Security
Security
Security
Inward In-charge
Place the boxes on the pallet and move the pallet to pre-receiving staging area
Inward Staff
One Pallet = One ASN. Do not place carton of different ASN on one Pallet
Inward staff
Inward Staff
counts the no. of cartons kept on the individual pallet for that ASN
Inward Staff
Damage Carton
Condition of Carton
Ok carton
Enter the total No. of carton kept on the pallet in RF Handover the damage carton to vendor transporter Inward Incharge
Inward staff
No
Inward Incharge
Inward In-charge generates the IGP (Inbound gate Pass) Mail the details to Vendor with CC to FSCS SCM Inward Incharge
Inward Incharge
End
Handover 1 IGP copy to driver and attach one copy with consignment document and file it
Inward Incharge
Truck Driver
Update the Security Inward Register Stamp the Inward seal on the LR (consignor & consignee copy), enter the details in the stamped portion, Mention the Remark for any Shortage/ Damage sign the same. Handover the transporter LR copy to truck driver and release the vehicle
Security
Security
End
Pre Receiving (From MHUB) Process Description: Pre Receiving process will enable warehouse to unload the consignment and release transporter. WMS imports delivery details from SAP Updates the appointment and LR details in WMS against the ASN on the basis of pre-alerts received from FSCSL transportation Team Warehouse will have daily report of scheduled ASNs for the day Vehicle arrives at the gate of the warehouse. Truck driver submits the document to the security personnel STN, LR, Gate Pass Security verifies the documents and checks if the consignment is for the same warehouse. Security personnel write details in security inward registerKey Fields: Inward Date/Time, Truck No., LR Number, PO Number/Date, ASN Number assigns manual inward number Driver submits the documents to inward clerk Inward clerk checks all documents for any discrepancies Inward Clerks recalls ASN number in WMS screen and updates detailsKey Fields: LR Details, Transporter code, Vehicle number, Number of boxes mentioned on LR, Dock Door Inward clerk assign available dock door manually and instruct driver to proceed for unloading. Driver parks the vehicle at the assigned dock door for unloading. Inward staff starts unloading activity While unloading inward staff weighs the carton(s) for LR weight verification if required and move the consignment to pre-receiving area. Inward staff segregates the all cartons based on ASN & keeps them on pallet in a lane/lanes (Pallet id validation based on pallet 10 digit numbering model: PL-10-999999 [Pallet (2 digit)-Warehouse (2digit)-No. Series (6 digit)] Inward staff starts scanning in RF
Key Fields: ASN, , Lane id, Pallet Id Inward staff counts & enters the number of boxes on pallet on RF screen Inward staff enters the count of damaged boxes on pallet on RF screen (if any). Once all the pallets are scanned, Staff confirms on RF (IGP generation screen) that scanning is over. Inward clerk handover the gate pass to driver. Driver report back to Security personnel Security personnel update the security register. Key Fields: Gate Pass Number & Truck out time against the ASN number. SAP to send IRN host reference detail to WMS.
Exception Handling: In case consignment is not for the warehouse then Security personnel will not allow truck to inward. If inbound is not created for that consignment then truck will not be allowed to unload. Further category to be informed to create ASN. While unloading if any of the carton(s) found tampered/ damage, has to be kept aside on a seperate pallet with ASN number mentioned on it for transporter damage process handling. If document details are not matching then inward in- charge will take appropriate action.
Business Rules: One ASN = One Gate Pass Any delivery received without ASN, PO and Invoice will be rejected. Gate pass would not be generated until Pre- receiving is confirmed for complete IGP once printed cannot be changed. IGP created in WMS will flow to SAP for IRN confirmation.
SCM Team
Generate Schedule ASN report from WMS for the day at the start of the shift. Mail the soft copy of the report to Inward security team.
Vehicle arrives at main gate. Driver reports to security with consignment documents
Security
No
Check whether the Consignment is meant for the Warehouse by checking warehouse site code/ address in STN
Security
Security
Yes
End
SCM Team
Inward In-charge
Yes
No
No LR
No STN
No
Yes
Inward In-charge updates ASN with LR details & assigns the dock
Note input details Transporter Code, LR Number, LR Date and Expected Number of boxes, Vehicle Number against each ASN
Inward In-charge
Directs driver to dock the vehicle as per the assigned dock door
Security
Assigns token no. to the vehicle, mentions the token no. on the Inward register, enters consignment details in Inward register
Security
Security
Security
Security
Inward In-charge
Place the boxes on the pallet and move the pallet to pre-receiving staging area
Inward Staff
One Pallet = One ASN. Do not place carton of different ASN on one Pallet
Inward staff
Inward Staff
Inward Staff
Damage Carton
Condition of Carton
Ok carton
Enter the total No. of carton kept on the pallet in RF Handover the damage carton to vendor transporter Inward Incharge
Inward staff
No
Inward Incharge
Inward Incharge
Inward Incharge
End
Handover 1 IGP copy to driver and attach one copy with consignment document and file it
Inward Incharge
Truck Driver
Security
Stamp the Inward seal on the LR (consignor & consignee copy), enter the details in the stamped portion, Mention the Remark for any Shortage/ Damage sign the same. Handover the transporter LR copy to truck driver and release the vehicle
Security
End
Receiving:
Receiving process enables to receive consignment and update warehouse inventory status and GRN in SAP. Inward in charge handover pending receiving pallet movement report to inward team. Key Field :ASN number, Lane/Pallet id, Number of boxes Inward team brings pallet as per the pending receiving pallet movement report at the receiving bay. Inward team segreagate the stock as per SKU . Team opens the cartons(s) to verify quantity received 1. Sample Verification will be done as per vendor No validation in system on Verification based on vendor classification Inward team place carton on weighing machine and paste weight label on the box Verification process:(One box per SKU should be verified, Scan a SKU &Count all SKUs for a box) Single SKU Carton(s): Check if any carton(s) found with weight variance, Open the boxes and count the SKU If discrepancy found treat those box as rejected and keep them aside (Specific location for excess/ damage receive) *refer exception process flow If no discrepancy found then receive the carton. Multi SKU Carton(s): No weight verification, Qty Verification to happen while scanning. Scan/ Count all articles for receiving If exception found, Keep excess/ damage SKUs aside If no then receive the SKUs Receiving Single SKU UOM on pallet : Scan EAN Put boxes on pallet & count qty. as per order UOM Enter qty. & scan the pallet
Receiving Single SKU UOM in box : Take new box & paste box id Scan EAN Put SKU in Box & count qty. as per order UOM Enter qty. & scan the box id.
Receiving Multi SKU carton : Need to prepare separate SKU wise box : Take new box & paste box id Scan EAN Put SKU in Box & count qty. as per order UOM Enter qty. & scan the box id.
NO Need to prepare separate box : If the box id not present then paste a new box id on Box If each piece scan option is opted then , o Scan/Enter ASN o Scan box id o Scan all EANs If each piece scan option is not opted then, o Scan/enter ASN o Scan EAN o Count & enter qty. Scan box id. Inward team informs inward in-charge that receiving process is completed for one ASN Inward In-charge verify the receiving against ASN If shortage is there then inward incharge selects the correct reason code at ASN line level. Inward in-charge generates the GRN after closing ASN. This will create GRN in SAP. In case of single SKU/ Multi SKU boxes in the same ASN; 1. For all single SKU Boxes: Follow process#7 Receiving Single SKU UOM on pallet 2. On RF, Change the option to Each Piece Scan 3. In each piece scan option o Scan/Enter ASN o Scan box/pallet id o Scan all EANs Other Option of scan EAN & enter count of Qty can also be used.
Exception Handling: Receiving excess or damage from vendor: Create new ASN with reference to original ASN Do receiving as per standard process. Do GRN and move the stock to relevant location using RF. This will not update SAP. In the rare of own transport Delivery shortage ZSIT will be made in SAP by warehouse team. In WMS GRN will be made only to the extent of the physical receipt of the goods Business Rule: One ASN = One GRN = One Invoice WMS to disallow receiving more than expected qty mention in ASN. There will not be vendor tolerance validations against the PO for ASN while receiving. In case of any discrepancy found then entire case to be rejected while receiving Single SKU carton. In case of any discrepancy found then entire case to be rejected while receiving Single SKU carton. Receiving to be done as per mentioned UOM in ASN. Excess/Damage ASN will have link with original ASN Pending receiving report will print those ASNs for which IGP has been made and receiving has not been started. WMS to capture reason for Short receive. New Inbound will be created in case of Excess Receiving from vendor with the reference of old Inbound. SAP to capture old inbound number GRN reversal will not be allowed in WMS. WMS will do pre-allocation as soon as GRN is completed in case of vendor ASN receiving WMS will send pre-allocation data to SAP for soft allocation. Incase of PO is blocked in SAP; WMS should not be able to receive against it. WMS to Capture ASN number in lottable 2 for GRN made. SAP to Send GRN HOST reference along with SKU and MAP details to WMS for each GRN made.
Receiving process
Pallet moving to pending for receiving area
Start
GRN
Generate Pending Receipt Pallet Movement Report at the start of the shift and take print out of the report Select the consignment to be moved by checking the ASN no. for that consignment in the pending receipt pallet movement report Look for the pallets having the pallet ID mentioned in the pending receipt pallet movement report against the given ASN
Report to Print All ASN Details for which Gatepass is generated and Receiving is not started
MHE Operator
MHE Operator
Yes
Move pallet to pending receiving staging area with the help of BOPT/HPT
MHE Operator
MHE Operator
No
Scanning/ pallet moving task of all the pallets belonging to one ASN completed
Yes
Yes
MHE Operator
Inward incharge to Hand over the documents corresponding to ASN for which the receiving activity has to be started to the receiving team
Inward In charge
Note : Ensure that all the boxes belonging to one SKU is kept on one pallet
Segregate boxes SKU wise for the ASN for which the receiving activity has to be started
Receiving Team
Receiving process A
Receiving Team
Receiving Team
Receiving Team
Weight of the carton tallies with the SKU weight of verified carton
Note : Exception : (Excess / Rejected) 1. Open New ASN for Excess / Damage Receive 2. Receive excess or Damage SKU / Carton in this New ASN 3. Keep the received ASN at specified location (Refer Exception process flow)
Process ends
Yes No
Yes
Receiving Team
Receiving process B
No
Check receiving condition Inward staff Receiving multi SKU Cases (As per UOM)
Pallet
Receive in?
Cases
Inward team member takes new box & pastes box id Inward Scanner
Yes
Scan EAN, Put box(s) on pallet and count qty as per order UOM Enter Qty and Scan pallet
No
Scan EAN, Put SKU in Box and count qty as per order UOM Enter Qty and Scan Box id
Refer Chapter 4.2.2/Fig. No. 130,131/Page 108 of WMS User manual
Yes
Yes
Inward Scanner
informs inward incharge that Receiving process complete for one ASN Inward Scanner
Receiving process
Refer Chapter 4.2.4/Fig. No. 145/146,147,148/ Page 91 of WMS User manual
Yes
No
Inward in-charge to close ASN and move the stock to relevant location using RF by scanning box ID/pallet ID and Location ID
Once Receiving is complete for one ASN, Inward incharge verify for ASN to be closed
Excess Stock will either be Return through RTV (1) or Stock adjustment Against Fresh ASN (2)
Shortage
Yes
Inward incharge selects the correct reason code at ASN line level
No
End
Refer Chapter 4.2.5/ Fig. No. 156/Page 124 of WMS User manual
Give reference of GRN number on Invoice copy and file the LR, vendor Invoice copy, Inbound copy, PO and QC Inspection Report, IGP
Inward Team
Inward Team
Note down GRN number and date in the Inward Register against the IRN details of the consignment End
Security
Process Starts
Refer Chapter 4.2.4/Fig. No. 145/Page 118 of WMS User manual
Enter the owner number (0101), select the type of ASN as vendor WH ASN and save the data
Refer Chapter 4.2.4/Fig. No. 146/Page 119 of WMS User manual Refer Chapter 4.2.4/Fig. No. 146/Page 119 of WMS User manual
Enter the ASN no in which the excess was found as reference in UDF 4
Enter the Vendor code from whom the Excess quantity is received in UDF 2
Enter the article code for which excess is received from vendor in Item tab
Select drop down for Location tab and select STAGEEXCES as location and save the detail
Enter new for next line article ( if any ) in the same ASN (or else exit)
Do receiving against new ASN. Receive the material in location stage excess " Move " the stock from location " STAGEEXCES " to location in special zone created for vendor excess material ( with help of HHT )
Process end
1.1.
Put away
PUTAWAY process enable to place received consignment in the respective location considering Space Optimization, Minimum Effort and With SKU/ MC Consolidation Process Steps: Based on load Put away member decides move the items to bulk location or normal Putaway location. BULK location: Log on to RF & Select the MOVE option Manually move the pallet to bulk location
Scan location and pallet id Normal putaway location: Put away team member scans the pallet or box id. System guides to IN location for put-away zone In case of put away for 1st or 2nd floor of mezzanineThe IN location is defined on ground floor separately for 1st & 2ndFloor. The Put away team member will leave the pallet at the respective IN locations of 1st & 2ndFloor and scan to confirm. Put away reach truck member to scan box id or pallet id to confirm the floor and will move physically to respective Floor of Mezz. Bin Management team moves the pallet to final location based on put away strategy suggested by system. (Follow normal process steps to confirm put away) If suggested location is non mezzanine then, User moves pallet to IN location and scan IN location for confirmation User open put-away option in WMS Bin management team scans Pallet id/Box id and SKU from IN location System guides the put-away location based on the put-away strategy of the SKU & WMS also to suggest quantity of SKU User goes to system suggested specific location confirm by scanning the location and qty placed Follow the process until receiving bay and IN location is empty
Zone
Zone 1 Zone 2
Fixed pick
FP1 FP2
Strategy
Strategy1 Strategy2
SKU
Sku1 Sku2
Zone
Zone 1 Zone 2
Fixed Pick
FP1 FP2
Every fix pick will be associated to Zone. This will be stored in SKU-Zone table. (In case of new SKU without dimension data, warehouse to update the dimension data before put away.) Every Zone will have default put away strategy. This will be stored in put away strategy table. Fixed Pick to be defined for all SKUs created in WMS. (Excel Upload) Once the article is created in WMS, default putaway strategy will be attached to that SKU based on fix pick location & corresponding zone.
Exception Handling: If Bin management team member enters Qty. different than suggested then, Capture correct reason code WMS to trigger cycle count for a specific reason.
Business Rule: Putaway will not take place unless GRN is done For items with fixed-pick locations, Put away will always be to reserve locations except when the balance stock of that SKU in warehouse is zero. Put away team member must ensure that different floors/sections items are not placed on pallet.
Put-Away Strategy:
Strategy 1 - No fixed pick location, Do not mix MC, Mix SKU Put away strategy for items in specified zone Search for same SKU, search for capacity available more then or equal to put away qty, If found WMS to suggest that location (Fill such locations is ascending order of available qty starting from location with exact fit) Search for EMPTY Location, If found WMS to suggest that location Search for same SKU, search for capacity available, If found WMS to suggest that location (Fill such locations is descending order of available qty) Search for Different SKU in same MC, search for capacity available, If found WMS to suggest that location (Fill such locations is descending order of available qty) WMS to suggest UNKNOWN location
Strategy 2 - Pick location Fixed by SKU, Reserve Mix SKU, Do not mix MC
If balance qty in specified Zone (as mention in strategy) is equal to zero WMS to suggest the Fixed Pick Location
If balance qty in specified Zone (as mention in strategy) is not equal to zero Search for same SKU, search for capacity available more than or equal to put-away qty, If found WMS to suggest that location (Fill such locations is ascending order of available qty starting from nearest location based on co-ordinates) Search for Different SKU, search for capacity available more than or equal to put-away qty, If found WMS to suggest that location (Fill such locations is ascending order of available qty starting from nearest location based on co-ordinates) Search for EMPTY Location, If found WMS to suggest that location Search for same SKU, search for capacity available, If found WMS to suggest that location (Fill such locations is descending order of available qty starting from nearest location based on co-ordinates)
Search for Different SKU in same MC, search for capacity available, If found WMS to suggest that location (Fill such locations is descending order of available qty starting from nearest location based on co-ordinates) WMS to suggest UNKNOWN location
If balance qty in specified Zone (as mention in strategy) is equal to zero WMS to suggest the Fixed Pick Location
If balance qty in specified Zone (as mention in strategy) is not equal to zero Search for same SKU, search for capacity available more than or equal to put-away qty, If found WMS to suggest that location (Fill such locations is ascending order of available qty starting from location with exact fit) Search for EMPTY Location, If found WMS to suggest that location Search for same SKU, search for capacity available, If found WMS to suggest that location (Fill such locations is descending order of available qty starting from location with exact fit) WMS to suggest UNKNOWN location
Documents Used:
List of newly created articles To view the articles for which Fix Pick location/Zone is not defined. (Dashboard)Alert to be given by system for newly created articles.
Put Away
GRN done Start Put Away
Bulk or Normal put away location? Bulk location Normal put away location
BOPT/HPT Operator
BOPT/HPT Operator
Select IN LOC Move option in Putaway to move Pallets from RECEIVING Location to IN LOCATION
BOPT/HPT Operator
Scan the LPN number (Pallet id or Box id) to be moved from the Receiving location to the IN Location
BOPT/HPT Operator
BOPT/HPT Operator
Yes
No
Put away In-charge assign Put away task to put away team member
Select Assisted PA option in Putaway menu to putaway from IN Location to Fix Pick/Fast Pick Zone
Put away team member Scan pallet id/ Box Id and SKU from IN location
Confirm TO LOCATION by scanning location id by RF or enter the location id and enter Putaway QTY
Yes
Note : After Put away of all the articles on the pallet, do Inquiry of the pallet in HHT to verify the same pallet is empty
No
1.1.
End
SAP push delivery to WMS as per schedule Delivery Types STO, SO, RTV, Emergency Order , Cross Dock Order Orders get Pre-Allocated once received in WMS based on warehouse stock SAP gets soft commitment once pre-allocation is done in WMS Inventory Not Available in Warehouse:Pre Allocation is not possible due to less inventory, Generate Wave and assign order to wave as per schedule If GRN is done in between, perform pre Allocation and Allocation If GRN is not done then creates back order and wait for inventory for Pre Allocation and Allocation SAP order line will be frozen Pre Allocation done and Allocation Pending But in Wave:Generates Replenishment task Allocation is done Wave is release SAP order line will be frozen. Pre Allocation done and Allocation Pending due to not in the Wave:These orders are included in next scheduled wave for that order. Allocate and Release order SAP order line will be frozen. Wave Picks orders scheduled for the day Based on Store delivery Matrix
Incase over allocation is not turned on (Standard Process); then hard allocation qty will be to the extent of the pick face qty. (i.e. hard allocation qty= Pick face Qty) When Over allocation is turned ON; entire pre allocation qty will be hard allocated based on allocation strategy as follows; o o Fix pick Location: If allocation is allowed from receiving staging, replenishment tasks for fix pick location will be generated from the receiving staging location and also reserve location if stock is stock available. Fix Pick Location: If allocation is NOT allowed from receiving staging, replenishment for fix pick location will happen from reserve only.
o Non Pick Location: Turning on over allocation does not affect such locations. Once the allocation of order is done, WMS to send data to SAP & SAP order line will be frozen. Release the wave and create pick task for the warehouse staff
For Batch Pick Orders : WMS pulls fast moving SKU from SAP order(s) after pre-allocation & creates separate order. Creates a separate wave for these orders. Allocate order based on available stock Release and create Batch Pick Task
Cross Dock :Pre-Allocation and Allocation for cross dock will happen on GRN for that PO. Crossdock order will not have a wave
Order Processing
STO Types 1. Normal Orders 2. Cross Dock 3. Customer Sales Orders 4. Emergency Orders
Start
Wave creation
Pre Allocation Will happen as soon as Orders are Imported from SAP
No
Yes
Interface Sent to SAP of Pre Allocation Qty
NO
Wave to Run as per daily YES schedule Check Orders for Scheduled Shipment Date Generate New Wave Attach Orders No Schedule for Next Wave run
Yes
No
No
Do Putaway
No
End
End
Process starts
1)WMS to maintain storewise transit time & processing time for the warehouse 2) WMS to maintain storewise rhythm dates 3) WMS also to maintain the exclusion list(holidays ,sundays etc)
No
Yes
System checks next available rhythm date & makes it actual shipment date
Process ends
Outward Team In-charge informs respective outward team member for pick task Assign Handheld device to respective team member for picking Picker logs in Handheld device Picker enters the user login id and password and selects cluster picking option User gets default picking area & default sequence of picking. WMS identifies priority order & suggests number of stores for picking based on user selection ( Min-4 , Max.- 6) If picker wants to override then picker updates the stores with reason. Picker picks empty boxes & pastes labels on it. Picker places boxes on the pallet and moves them to picking location assigned WMS suggests 1st pick location, SKU,EAN & number of quantities to be picked. Single SKU Location: Scan the location Count & enter the quantity Place the SKUs in correct box Scan the box id Mix SKU Location :Each piece scan : Scan the location Scan all same SKUs Place the SKUs in correct box Scan the box id
Mix SKU Location :No Each piece scan : Scan the location Count & enter the quantity Place the SKUs in correct box Scan the box id Box filled? If no then picker continues with the next task If yes then picker puts the box in OUT location.
User moves the pallet to consolidation location. User logs onto RF & selects the packing option. Packer scans the box id & measures & inputs the weight. WMS Prints Shipping Label & Packing List (optional) User pastes shipping label on box Packer puts the BOX on fresh Pallet & Scans the Shipping label & Pallet ID. This marries pallet with store and hence prevents putting other stores boxes on that pallet. Once the pallet is full or all the boxes are scanned the pallet is ready for move. Todays Delivery? If yes, then packer moves it to the shipping lane & scans pallet id & shipping lane. If No. then packer checks the volume of pallet , o If pallet is full then packer moves the pallet to pack & hold location & confirms the move by scanning pallet id & location id o If pallet is not full then packer moves it to put to store location & confirms the move by scanning the box id & location id. The move can box wise or pallet wise.
Exception Handling:
Picker does not find SKU in system suggested location Picker skips the task and specified reason code System suggest new task for picking. Picker then pick from new location and continue. This skipped task is then lost. In order to complete the skipped task, the allocation has to be done manually and picking through RF assisted option. Picker finds qty. mismatch at picking location. Picker updates the qty. picked & selects the correct reason code.
Business Rules:
WMS to calculate the Store Priority based on Store Matrix for Cluster Picking. Picker to have option to override the displayed consignee. Picking to be done always in the order line UOM. Incase of actual picked qty is less then suggested qty, WMS to spilt the task and show the new task created with pending qty. Reason code to be selected while short pick
WMS to trigger cycle count for a specific reason selected during SKU not available & qty mismatch. Short pick qty will be unallocated from the order line. Every Zone to have a Default Packing Consolidation Location WMS to print a Packing List (optional) and Shipping Label for each Box packed While consolidation at packing area One Store = One Pallet
Batch picking
Process Description:
Batch picking process enables warehouse to pick the fast moving SKUs in a batches.
Process Steps:
Picker logs into RF & selects batch picking option , area & sequence of picking. Picker logs into RF & selects batch picking option , area & sequence of picking. Picker confirms by scanning the location, SKU & updates the quantity Picker puts the qty. into pallet confirms by scanning the pallet id Pick completed? If yes then , Picker moves the pallet to staging area of put to store If no then picker continues task given by WMS.
Batch Picking
Picking and Put to store
Wave creation
Start
Picker Confirms by Scanning the Location, SKU and Updates Qty Picked
Picker puts the Qty into the Pallet and Confirms by Scanning the Pallet ID
No
Pick complete Yes Picker Move Pallet to Inward Staging area of Put To Store
Put to Store
Put To Store Sorting user Scans the Pallet
PTS User make sure pre-labeled box(s) are available on un-packed pallet at store location Put To Store User Confirms by Scanning the Location, Updates Qty for one box
1a
1b
Yes
No
Helper moves the Pallet to packing Location and Brings new pallet at PTS location
WMS suggests New Task for SKU (new box for same store or new store) * Repeat steps 1a & 1b
No
Yes
Process Ends
Put to store
Starts
Helper
Packer
Packer
WMS Prints Shipping Label & Packing List, Paste the label
Puts the BOX on Pallet Scan the Shipping label, & Pallet ID
Packer
No
Todays delivery?
Yes
Packers Scan the Pack & Hold Location ID and Confirms the Move
End