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AIM Warehousing v3'0: Managing Wave Picking

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3 Steps in executing this NEW FUNCTIONALITY ... Step 2: Wave Replenishment. Step 3: Wave Release. Checking on Wave Status... RF Containerization ... – PowerPoint PPT presentation

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Title: AIM Warehousing v3'0: Managing Wave Picking


1
AIM Warehousing v3.0 Managing Wave Picking
Pick Planning
  • Kyle Bethke
  • kyb_at_qad.com

2
Introduction Agenda
Advanced Inventory Management
3
Agenda
  • Release History and AIM Overview
  • Opportunities and Challenges
  • Lean Distribution
  • Lean Warehousing Step 1 Batch picking
  • Lean Warehousing Step 2 Wave Planning

4
AIM History of Releases
  • Current Releases AIM 2.3a (Oct 04)
  • Batch (Wave) Picking
  • Next Release AIM 2.3b and AIM 2.3b SSD
  • New MFG/PRO SPs supported in 2.3b sub-release
  • Minor enhancements
  • language support (FR, DU, GE, SP, PL, PO)
  • Next AIM v3.0 and AIM 2.4a SSD
  • Wave Planning
  • RF Containerization
  • RF Truck Loading
  • Truck Shipment
  • RF Bar-code Identifiers
  • AIM v3.0 is the biggest release for many years

5
Warehouse Management Scope through v3.0
RF Task Management
Maximum Flexibility
Other Features
Carrier Lane Management
Receipts
Picking
AIM
New - Wave Planning
RF Container Move Ship
Put-away Logic
Flexible Replenishment
Cross Docking
6
Warehousing Costs
Total Warehouse Costs
7
Lean Distribution
  • Objectives
  • get an agile, synchronized and responsive to
    customer needs system
  • Serve customers faster, with less space, less
    inventory and with more accuracy
  • Eliminate waste in warehousing operations, e.g
    Pick Tasks

Pick Task Simplification
8
Lean Warehousing
  • Eliminate Waste
  • Time
  • Reduce Travel distances by using a Forward
    Picking Area
  • Reduce Travel distances by organizing the travel
    path sequences
  • Reduce truck Waiting time at the dock (consistent
    with US HOS regulations)
  • Organization
  • Spread order lines to fulfill accross workday
    based on Truck appointments
  • Avoid aisle congestion by spreading workers in
    the warehouse
  • Space
  • Reduce Shipping Zone space requirements
  • Reduce Inventory requirement by Streamlining
    Picking Operations
  • Streamline operations
  • Synchronized Replenishement of Forward Picking
    zone to avoid picking interruptions
  • Spread the workload accross the entire working
    day based on truck schedules

9
The QAD Solution
Advanced Inventory Management
10
Lean Warehousing
  • Lean Warehousing Step 1 Batch Picking
  • Available since AIM 2.3a
  • Enhanced in AIM 2.3b
  • Lean Warehousing Step 2 Wave Planning
  • Will be available in AIM v3.0
  • In production at an Eaton Distribution Center,
    Cleveland TN
  • General Availability April 06

11
Lean Warehousing Step 1 Batch Picking
  • Dedicated for companies working with small items,
    small volumes but lots of Order lines

Pick Path
6
5
4
3
2
A
B
C
D
1
Push Cart with Totes or Boxes
12
Batch Picking Enhancements (2.3b)
  • User Location stock is moved to the Cart (User
    Location) upon picking
  • Multi-Box Picking ability to pick multiple boxes
    to reach the quantity required
  • Enhanced visibility on what is on the User Cart
  • Drop off/All at any time during Batch Picking
    process to empty the cart

13
Lean Warehousing Step 2 Wave Planning
  • Functionality dedicated for Warehouses
    Distribution Centers
  • A Wave is a collection of Orders we want to
    pick/ship at a certain point in time
  • The Objective of Wave Planning is to have a
    continuous throughput across replenishment,
    picking and shipment activities
  • 3 Steps in executing this NEW FUNCTIONALITY
  • Wave Selection we create the wave and select the
    orders which belong to the wave (often by
    Carrier, appointment)
  • Wave Replenishment We move to the picking area
    all the stock required for the wave
  • Wave Release we create the picking tasks and
    assign them to the pickers
  • Additional Objectives
  • Shipping Lane Management
  • Workload Calculation per working aisle

14
Lean Warehousing Step 2 w/o Wave Planning
  • Worst case scenario
  • Warehouse w/ Picking Everywhere
  • No Travel Sequences
  • No Order Prioritization Increases Travel
    Distances

15
Lean Warehousing Step 2 New Wave Planning
  • Better Case Scenario
  • Reduced Picking area Forward Picking Area
  • Replenishment from Reserve Area (Separate or
    above Forward Picking Area for Fast Movers)
  • Decreased Travel Distances
  • Decreased Extracting Time (Items in accessible
    levels only)
  • Organized Travel Picks through Travel Sequences
    (Batch Picking)

16
New Wave Planning Execution
Reserve Area
Picking Area
Shipping Lanes
Step 1 Wave Selection
Docks
17
Wave Replenishement
18
Reserve Area
Optimized Pick Sequence
Pick Face
Pick Face
19
Other Key features of Wave Planning
  • Allow Selection and handling of Sales Orders
    (incl. Customer Schedules) and Distribution
    Orders in one common flow
  • Allow to have carrier at SO/DO Line level
  • Different Pre-shippers by carriers
  • Selection of Orders by Carrier/Route/Profile on
    top of Due Date/Order/ship-to
  • Entire visibility of the Wave Status
  • When a Wave is Ready/Complete/Need replenishment
  • How many open/complete tasks per Wave

20
Also available in v3.0
  • RF Containerization
  • For both SO and DO (!)
  • Recommended Pallet for consolidation
  • Check on the pre-shipper (SO)/Ship-to (DO)
  • Allows scan a box in one location to containerize
    on a pallet in another location
  • Allows Box removal
  • Order Status Detail Inquiry
  • Show the status of all orders (e.g. on a Wave)
  • Allocated/Picked/on Cart/Consolidation/Packed/Stag
    ed/Loaded
  • Drill-down on containerization structure
  • RF Container Move
  • Movement of a container with all containers and
    detail allocation
  • Used for truck loading e.g.
  • RF Bar-code prefixes
  • Allows define barcode prefix (up to 4 digits) for
    each barcode type
  • Generic requirements in some industries

21
But what does it look like?
22
Step 1 Wave Selection
23
Wave Status Reporting/Inquiry
24
Step 2 Wave Replenishment
25
Step 3 Wave Release
26
Checking on Wave Status
27
RF Containerization
28
RF Container Move Truck Shipment
29
Lean Warehousing and Hours-of-Service (HOS)
Regulations (US)
  • Effective January 2004
  • The new rule impacts how time is accounted for
    during a drivers day and week
  • May result in cost increases for the trucking
    industry which will undoubtedly be passed along
    to the customer
  • Estimated carriers to be hired in the US 84,000
  • Wal-Mart estimates 24m investment in new trucks
    and personnel
  • This means shippers have to become more
    efficient
  • Live load and unload appointments
  • Excessive driver time at the dock to load/unload
  • Miscellaneous waiting time (i.e. paperwork)
  • Those who make an effort to help out when their
    carrier arrive will be less impacted by cost
    increase on trucking companies

30
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33
Thank You!
  • Contact kyb_at_qad.com
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