Westernacher Consulting and Services

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1 Westernacher Consulting and Services Are You Effectively Talking to Your Warehouse Solution? Neil Wightman Knowing where to go is im portant, but reac hing your goals is the real ac hievem ent. Version 2.2

2 In This Session You will get to know the basics of Pick by Voice (PbV) functionality as well as the benefits and advantages of pick by voice functionality compared to mobile with screen-based devices We will also introduce some of the unique features of SAP EWM and process control options to run process You will learn how PbV systems are integrated into SAP Management We will nstrate a voice- process 1

3 What We ll Cover Basic aspects of voice-controlled 2

4 What Is Pick by Voice About? Pick by voice primarily is about voice-driven order Pick by voice makes use of speech recognition and speech synthesis to interact with the operator The minimum equipment: A mobile computer connected via WLAN to the warehouse management system Headset with a microphone connected via radio frequency like bluetooth to the computer And you can connect optionally: Scanner devices, e.g., finger scanners keeping hands free Screen devices for multi-mode user experience Mobile printers to print labels during operation 3

5 What Is Pick by Voice About? Continued Picking tasks are transferred in real time to the mobile computer The task data is read to the operator The operator confirms commands by talking confirmations like okay Notes Real time does not mean that there is a real time connection to the WM system PbV systems sometimes make use of batch processing Batches of work are transferred via IDoc and confirmed via IDoc Of course, SAP EWM can be connected with PbV devices in real time Real time is helps a lot to optimize resources and to manage exceptions 4

6 A Very Simple Process Flow 1 2 Instruct operator to go to location Ask to pick the planned quantity 3 Instruct operator to go to packing Check Digit of Location Quantity OKAY Check Digit of Location 5

7 Some Complications for PbV Processes Picking Preparation Information Difference Handling & Physical Inventory Multi Order Picking Other Prepare boxes, cartons, pallets, pick & pack Number of items/open items Update actual quantity Split quantity into different boxes Skip orders Assign boxes to positions on device Weight and Volume Confirm empty bin Multiple picks from source bin Skip items Apply preprinted labels or print labels Confirm quantity after Assign or print item labels Exception execution, e.g., go to clearing 6

8 Benefits and advantages of Pick PbV Can Improve Picking Performance Significantly 1. PbV can contribute significantly to improve the operational efficiency 2. Cost of PbV hardware is in the same range as for handheld computers (plus 15 to 25%) 3. Performance increase per picker is reported by more than 15%, but some reports are much higher than this Traditional mobile device processing versus PbV Traditional mobile device processing accepted to save cost and to improve quality But many success stories prove that PbV is often faster than mobile device processing How to valuate the performance benefits of PbV: Is it 5% or 50%? Test it Ask for or buy hardware devices and connect them to SAP EWM! Analyse it Makes use of methods for working time analysis like Methods-Time Measurement (MTM) vs. It is about time to question the benefits of traditional mobile device! 7

9 Benefits and advantages of Pick Where Does the Performance Improvement Come From? 1. Parallelization of communication and processing speeds up the operation 2. Handling tasks for/with mobile devices get obsolete 3. Operators don t loose their focus if they do not need to switch Parallelization of communication is primarily related to walking and Walking distances need to be sufficient to establish the communication A single quantity pick is more advantageous over in several steps from one bin Additional physical moves are not needed anymore Moves to perform scans get obsolete Moves to verify tasks get obsolete Moves to enter data get obsolete vs. 8

10 Benefits and advantages of Pick PbV Can Increase Process Accuracy Significantly 1. Error rates are quite often reported to go down dramatically with PbV 2. Pickers can focus on the execution without interruption because of cross checking the content of a screen device Savings from better accuracy will already make the ROI 5 times less errors of PbV compared to traditional mobile device Calculate yourself: Number of cases per day multiplied by the error rate and by the error cost: Example 1: Traditional, cases per day, 0,5% errors and $10 per error and 250 days per year $ per year Example 2: Voice, cases per day, 0,1% errors and $10 per error and 250 days per year $ per year vs. 9

11 Benefits and advantages of Pick Comparison of Error Rates of Picking Methods 1. All case studies show significant reduction of error rates 2. Comprehensive comparisons are rare, but all come to the same conclusion Error Rates of Picking Methods Paper based 0.5 Pick to Label 0.49 Handheld Terminals 0.4 Pick to Light 1.17 Handheld Terminals with Pick to Label 0.08 Pick by Voice vs. Average Error Rate (%) Number of Installations Source: Andreas Lolling, Analyse der menschlichen Zuverlässigkeit bei Kommissioniertätigkeiten, Analysis of human reliability of operations, Shaker Verlag,

12 Benefits and advantages of Pick Other Benefits and Advantages of Pick by Voice Eyes and hands-free is a big advantage, e.g.: Better ergonomics for heavy and large items Temperature: Frozen areas and gloves and handling of mobile devices Better overall safety Less user training Operators usually need less training It is easier to move operators to other areas Improvements in speech recognition make voice pattern obsolete Initial speech training effort for devices will become obsolete vs. Multi-modal devices combine lightweight displays with PbV capabilities 11

13 What We ll Cover Basic aspects of voice-controlled 12

14 Picking process control with SAP SAP EWM Is the Right System for All Warehouses and Industries EWM offers functions and features for optimizing warehouse logistics for a broad range of industries and classes of warehouses Warehouse Centric Network Logistics Transportation Centric Production Distribution Center Spare Parts Management Hubs and Yards Embedded Logistics Core Warehousing Operations Customs Handling Transportation Integration Shipment Consolidation Value Added Services Supply to production Reverse Logistics Cross-Docking Order entry processing & fulfilment Warehouse Automation Inventory Planning/Deployment 13

15 Cross and Supporting Functions Inbound Processing Storage & Operations Outbound Processing ARE YOU EFFECTIVELY TALKING TO YOUR WAREHOUSE SOLUTION? Picking process control with SAP SAP EWM Function Map Inbound Delivery Processing Slotting Outbound Delivery Processing Unloading & Receipt on Dock Rearrangement Route Determination TU & Vehicle Appointment Unloading & ROD Catch-Weight Bin Determination Internal Routing Deconsolidation Cartonization Quality Inspection Inventory Counts Replenishment Scrapping Batch Management Scrapping Best-Before Serialization Consignment Storage Conditions TU & Vehicle Appointment Wave Management Picking Execution Kit to Order Pallet-Building Packing / Consolidation Staging Consolidation Loading Repacking Resource Management Goods Issue Putaway Labor Management Shipping Cockpit Cross-Docking (Planned & Opportunistic) Alerts & Exceptions RFID Labelling, Tagging, Kitting, Value Added Services Warehouse Automation & Material Flow Control Mobile Device Integration 14

16 Picking process control with SAP SAP EWM Core Concepts: Process-Oriented Storage Control Picking and Dynamic Material Handling Steps with Interim Movements Picking Packing and Consolidation Value-Added Services Staging Loading Pick & Pack Staging Loading Process Control is independent from execution: Paper, Mobile Terminal, Voice 15

17 Picking process control with SAP SAP EWM Core Concepts: Waving and Warehouse Order Creation 1. Wave Management: The batch of work for lists for paper, mobile computers, and voice 2. Warehouse Order Creation: Groups of tasks for efficient processes Order items Outbound Outbound Delivery Outbound Delivery Order 1 Delivery Order 1 Order 1 Wave Management Wave Wave Picking Task Creation WT 1 WT 2 WT 3 Item Filter Warehouse Order Creation Rule Subtotal Filter Warehouse Orders WO1 WT 1 WT 2 WT 5 WT 4 WT 5 Size Limits Sorting Rules Packing Profile WO 2 WT 3 WT 4 16

18 Picking process control with SAP System Guided Picking with SAP EWM A simple process for two orders requiring packing consolidation after The same process will be shown with pick by voice afterwards Picker logs in at his device Picking operation mode is started First order is started Picker confirms tasks EWM guides picker to packing 17

19 What We ll Cover Basic aspects of voice-controlled 18

20 Connecting ASRS, Conveyors, and Pick-to-Light to SAP EWM Voice functionality with SAP EWM EWM can control complex automated storage and retrieval systems as well as automated material flow systems like conveyors SAP Management with MFS SAP NetWeaver < 7.5 SAP Management with MFS SAP NetWeaver >= 7.5 SAP Management any SAP NetWeaver RFC SAP Plant Connectivity IDoc TCP/IP Socket 3rd party MCU TCP/IP Socket TCP/IP Socket TCP/IP Socket PLC1 PLC2 PLC3 PLC1 PLC2 PLC3 PLC1 PLC2 PLC3 19

21 Connecting Mobile Devices with SAP EWM Voice functionality with SAP EWM Mobile devices like handheld computers or Pick by Voice systems are connected via HTTP/HTTPS. Sub-systems with IDocs are not very common anymore. SAP Management with MFS any SAP NetWeaver SAP Management any SAP NetWeaver IDoc 3rd Party System HTTP/ HTTPS 3rd Party Protocol Device1 Device2 Device3 Device1 Device2 Device3 20

22 Voice functionality with SAP EWM Online Integration of PbV and SAP EWM WLAN Network Access points for PbV devices Connection to the LAN/ WAN infrastructure Optional: Middleware Administration and Configuration of PbV-Devices Central Online Connection Access Point (optional, depending on scenario) Client to SAP EWM SAP EWM Server HTTP/HTTPS Web Server SAP GUI Dynpros translated to HTML SAP EWM SAP ERP 21

23 Thin vs. Thick Client Voice functionality with SAP EWM Although SAP EWM is foreseen to integrate with thin clients, it is worth considering thick or half-thick clients Thick Client Entire business and workflow logic controlled by the client. All user interaction is handled by the client Picking confirmation per list/warehouse order or per list item/warehouse task Usually no real-time processing and restricted exception handling Synchronization middleware or Z services to integrate with SAP EWM IDoc or RFC Thin Client No business logic, only control of input and output Any user interaction controlled by EWM Confirmation is done in real-time in SAP for each task Real-time processing and full exception handling No middleware necessary HTTP via ITSmobile Half-Thick Client Business logic on the client and in SAP EWM User input validation in the task Confirmation is done in real-time in SAP for each task Real-time processing but limited SAP interaction No middleware necessary RFC 22

24 HTML Transformation of Dynpros for PbV SAP GUI Standard PbV Logon Screen Display profile *1 to switch to PbV mode for the resource Transformation into HTML SAP Generator Mobile Device with Speech Input to be used Configuration of SAP EWM for Pick by Voice functionality and live PbV makes use of the same ITS mobile HTML transformation as normal graphical devices Browser View of the Dynpro 23

25 System Guided Picking by Voice st Screen/Pick HUs Source Screen BAdIs for PbV Configuration of SAP EWM for Pick by Voice functionality and live Browser View of the Dynpro Modify Screen Field Voice Properties Maintain Voice Properties Command List All available commands are provided to the PbV System Commands are configured as for normal mobile transactions (RF Framework) 24

26 Configuration Sequence 1 Create an ITSmobile Service 2 Generate Dynpros for System 3 Guided Picking Configuration of SAP EWM for Pick by Voice functionality and live Create a resource and a user and connect it to /SCWM/RFUI_PBV 4 Connect and Configure PbV Hardware 25

27 Configuration of SAP EWM for Pick by Voice functionality and live System Guided Picking with SAP EWM A simple process for two orders requiring packing consolidation after This is the standard voice workflow for SAP EWM Picker logs in at his device Picking operation mode is started First order is started Picker confirms tasks EWM guides picker to packing 26

28 Where to Find More Information John Harper, Distribution Center Order Picking Technologies Compared (MWPVL International). Voice in Action Videos from Vitech Roger Byford, David Maloney, The Talking Warehouse: Understanding How Voice Unleashes Higher Performance in Product Distribution (Vocollect, Inc., 2013). Follow Supply Chain Management SAP Management SAP 9.4 Application Help SAP Library (Language) SAP Management (SAP EWM) Radio Frequency Framework Pick by Voice 27

29 7 Key Points to Take Home 1. It is about time to question the benefits of traditional mobile device and to consider Pick by Voice as the right option to optimize 2. PbV hardware costs are in the same range as other mobile devices 3. ROI of Pick by Voice is made by accuracy and efficiency 4. Pick by Voice is one of the features of SAP Management, which is the powerful system for all types of warehouses and logistics requirements 5. SAP EWM handles system guided and system guided voice in the same consistent way, the core process control is applicable for all process areas and devices 6. Pick by Voice systems can be integrated in different ways into SAP EWM; the standard option is to make use of thin clients connected via HTTP and ITSmobile 7. Even bespoken PbV solutions can be integrated in real time into SAP EWM 28

30 Your Turn! Neil Wightman Head of Supply Chain, Middle East Phone: Mobile: +44 (0) neil.wightman@westernacher.com 29 Westernacher Consulting ME FZ-LLC Building 12, 1st Floor, Dubai Internet City, Dubai, United Arab Emirates Phone: Web: info@westernacher.com License no

31 Disclaimer SAP and other SAP products and services mentioned herein as well as their respective logos are trademarks or registered trademarks of SAP SE (or an SAP affiliate company) in Germany and other countries. All other product and service names mentioned are the trademarks of their respective companies. Wellesley Information Services is neither owned nor controlled by SAP SE. 30