Welcome to Session 315 WMS, WCS or Both? Determining Your Distribution Center Technology Strategy

Transcription

1 Welcome to Session 315 WMS, WCS or Both? Determining Your Distribution Center Technology Strategy Presented by: Sponsored by: Tom Kozenski Colman Roche 2012 Material Handling Industry. Copyright claimed as to audiovisual works of seminar sessions and sound recordings of seminar sessions. All rights reserved.

2 How did WMS Applications Begin? In order to get the proper perspective, we should start at the beginning Tier 1 WMS vendors evolved as automation integrators in the mid-70 s Software was primarily custom and built to spec (and often to automation spec) The primary benefit from a WMS was providing near-100% Inventory Accuracy That is why RF-based scanning was prevalent

3 WMS Phase II With maturity came additional capabilities WMS applications developed strong capabilities for system-directed operations Task Interleaving Configurable Workflows WMS accounts for all movements and coordinates all operations A black-box approach is not preferred Benefits from using WMS Allocation routines Unique deployments are the exception 3-deep ASRS

4 WMS Phase III Eventually, we started to build packaged WMS software But automation integration was still an area of customization These costs were high and ongoing Had to be rebuilt/retested for every upgrade or change in logic The WCS was an essential piece of software that managed the communication to WMS

5 WMS Today Today s WMS architecture allow for more intimate data-sharing Can emulate real-time (sockets, web services) WMS can imitate certain WCS controls with embedded EAI integration tools Small components of logic is ideal Inputs from PLC s, in-line scanners, Feedback mechanisms from WMS to automation can be 1-way downloads or require confirmations back to the WMS We see both used in single deployments

6 What to look for Maintaining productized integrations are a viable option, but Requires a commitment from both vendors It can be hard to find a common ground Automation vendors can have multiple communication protocols, transaction layouts With SOA architecture, you can expect a lower overall multi-year TCO Less custom code, more configuration A globally deployed WCS is another option but carries additional costs and complexities

7 Evolution of WCS Basic conveyor controls Simple point-to-point delivery More advanced conveyor controls Route to multiple points Conveyor sorters to multiple points Data collection from totes & packages Intelligent routing High-speed sortation Shoe sorters Discrete sorters cross-belt, tilt tray

8 WCS Evolution by Function Convey through pick modules Pick-to-light, routing, barcode scanning Convey cartons from rack storage RF, automatic diverting, auto ID Convey to shipping lanes Diverting, sequencing, queuing Convey through carousel zones Carousel picking, automated batches, pick sequencing

9 Where Has WCS Fit? Managerial Function Planning & direction Weekly, daily planning Hierarchy WMS Switch to PC or screen shots Supervisory control Task oversight WCS Warehouse associate Picking Packing.

10 The WCS s Role Provide the link between the non real-time host and the real-time MHE control system Relieve the WCS from real-time requirements Manage decision points to determine the most efficient routing of product Interface with inputs (scanners, weigh scales, etc.) and outputs (conveyor motors, print & apply labellers, etc.)

11 WCS Primary Tasks Allocate work to MH sub-systems Provide real-time direction to operators & MH equipment (MHE) controllers Dynamically assign cartons to divert locations Report results to WMS Gather data to gauge operational performance

12 WCS Handles product Handles real-time material handling tasks Equipment control Routing Point-to-point tracking Collects data Schedules operations, locally Manages tasks

13 WCS Architecture Evolution PLC-based I/O control Added data capabilities to track & control Virtual PLCs with database management Expanded databases to fulfill orders Built on zone-based order processing, with conveyor as transport between zones Added automated MHE fulfillment Increased managerial functions, incl. maintenance management

14 What does WCS touch? + =

15 WCS Compare to Tier 3 WMSs Tier 3 WMS lower volumes Picking: paper directed Rider truck, cart picking, by hand Discrete order picking 1+ storage types Manual consolidation Location addresses Record putaway locations Fixed forward pick locations Batch processing

16 Historical Differentiation Data management Nominal separator: Handling Real Time Processes MHE Control

17 Over Time WMS Nominal separator: Handling Real Time Processes WCS PTL, auto ID, pick modules, routing, barcode scanning, carousel picking

18 Over Time WMS PTL, auto ID, picking tasks,. Nominal separator: Handling Real Time Processes WCS PTL, auto ID, pick modules, routing, barcode scanning, carousel picking

19 Comparisons Function WMS WCS Handle pick, pack functions X X Provide direction to operators via RF, PC X X Interface with ERP X some Wireless manifesting X some Wave processing Tier 1,2 Process returns X X

20 Comparisons Function WMS WCS Process returns X X Manage energy of MH equipment Monitor MH equipment for maintenance needs Route orders through pick zones Real-time interface to MH equipment some X X X X

21 Selection Process Preparation Understand your processes How well do they work? (don t select based on poor processes) Map your functionality Take a close look at your business

22 Selection Process Decide what you are trying to achieve Understand your objectives Rank them in order of importance Analyze your objectives Business, warehousing Divide them into competencies

23 Selection Process Decide how to evaluate Features Capabilities Architecture how it will help/hinder Consider offerings from a featureadvantage-risks-benefits (farb) approach Create an evaluation tool based on your needs and organization

24 Summary Use best practices steps Ask plenty of questions Architecture & decision process of WMS/WCS Strong and weak points Characteristics of reference customers Background of the WMS/WCS team

25 For More Information: Visit MHIA.org/SCE Tom Kozenski Colman Roche 2012 Material Handling Industry. Copyright claimed as to audiovisual works of seminar sessions and sound recordings of seminar sessions. All rights reserved.