WAREHOUSE MANAGEMENT SYSTEM 5.6 PRODUCTINFORMATION WAREHOUSEMANAGEMENTSYSTEM Material Handling and Storage Systems

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1 Material Handling and Storage Systems WAREHOUSE MANAGEMENT SYSTEM 5.6 PRODUCTINFORMATION WAREHOUSEMANAGEMENTSYSTEM5.6

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3 Uses and Benefits Warehouse Management System (WMS) 5.6 The Stöcklin Warehouse Management System combines all functions which are necessary to operate a fully automated warehouse The Stöcklin Warehouse Management System (WMS) manages articles, quantities and load carriers as well as the existing warehouse locations. The integrated Material Flow Controller (MFC) controls, monitors and visualizes the different material flow systems. Benefits of the Stöcklin WMS 5.6 Fast integration Standardized data acquisition Configurable Host (ERP) interface Optimized for the Stöcklin Programmable Logic Control (PLC) The StöcklinWMS is divided into functional components Easy to use Task-focused user interfaces Intuitively learnable application Visual overview on the entire warehouse systems comprising a wide range of software modules. According to the project requirements, the modules can be used separately or combined. The Stöcklin Warehouse Management System can be seamlessly integrated into the hierarchy of the systems used in an automated warehouse. The operational safety and quality of a software system depends decisively on its internal structure. So, for the conception and development of the Stöcklin Warehouse Management System many different requirements have been taken into account. Flexible and adaptable to individual needs Graphic display of working processes Parameterizable warehouse strategies Configurable user interfaces Individually definable reports

4 The Warehouse Management pyramid Leading System for storage- and stock removal orders and the article administration Configurable Warehouse Management System The different modules can be applied according to the funcitional requirements of the users Control Technology Operates the warehouse equipment

5 Order Management System (ORD) In the Order Management System (ORD) are all functions integrated for the most efficient operation of an automated Warehouse The Order Management System (ORD) combines all functions necessary to operate automated warehouses cost-effectively. Therefore, in the development process the focus was not to implement as many functions as possible, but rather to design the relevant features so that they are easy to use and highly reliable. Basically ORD, which interacts closely with LOC, the Location Management Module, has been designed to manage articles and storage quantities. This also includes the handling of lots (LOTCODE, SERIAL number etc.). For roll-in of goods the quantities of the articles are allocated to physical or logical load carriers. The nominal quantities of outgoing orders received from the ERP system are reserved according to e.g. First in, First out from the existing stock. Once the goods have been retrieved from the warehouse, an acknow ledgement is sent to the ERP system. With the StöcklinWMS, rollout and picking processes can easily be adapted and optimized for project-specific requirements. Thereby, defined targets like warehouse output or readiness to deliver and reliability have absolute priority. To achieve this, in an automated warehouse not only menu-guided picking workplaces, but also systems like Pick by Light, Pick by Voice or wireless terminals are used. Printed picking lists with barcodes for scanning may also be suitable. Functions of the order management system (ORD) SKU (Stock Keeping Unit) information and stockkeeping Stock receipt orders Stock receipt and palletizing process Rollin Picking orders Menu-guided rollout and picking System-aided picking Inventory For rollouts of goods the nominal quantities (retrieval orders) transmitted by the HOST are reserved from the existing stock according to First in, First out, First expiry, First out, emptiest load carrier (pallet or container), or other rules. The actual retrieval from the warehouse is then reported to the ERP system via the HOST interface.

6 Article Master Data Article Masterdata in edit mode

7 Storage process Storage processes may vary strongly because of the different types of goods which are to be stored in a warehouse. Accordingly, special workplaces need to be provided for the stock receipt. Substantial differences exist particularly between the workplaces of automatic and manual warehouse sections. It may not be clear in the beginning (by referring to the article or the order) in which part of the warehouse the received products are to be stored. In this case, e.g. the warehouse personnel must decide about the target location according to the given internal requirements. For this reason, the Stöcklin Warehouse Management System is provided with a high flexibility for operating the storage processes, which may be easy designed individually for each project. Order picking In automated warehouse sections palletizing or depalletizing robots or dedicated picking systems, may also be integrated. According to the individual requirements, delivery/packing or accompanying documents can be used. Extensive business rules and the common retrieval strategies FIFO, FEFO and LIFO can be applied according to the individual requirements. The picking orders consist of header data and the corresponding position data. The header contains data like the date of creation and delivery, the current order status and order-related data of the customer. The positions contain the individual articles with lot number as well as ordered and delivered quantities. Stock Receipt Usually, stock receipts are transmitted by the ERP system as preliminary notes generated on the basis of supplier orders. Stock receipts can also be created manually, whether planned or unplanned. The stock receipts are then saved in the StöcklinWMS as stock receipt orders waiting for the corresponding goods to be delivered. The stock receipt orders consist of header data and the corresponding position data. The header contains data like the date of creation and delivery. The positions contain the individual articles with batch number as well as ordered and delivered quantities. Menu-Guided Order Picking in the automated warehouse The load carrier is displayed with its partitions, if any. An arrow shows the operator the location of the load carrier from which the articles have to be picked. Afterwards, the picking screen is cleared and waits for the next load carrier to reach the picking station. Palletizing In the goods receiving area, the delivered items are checked and the quantities assigned to physical or logical load carrier (pallet, bin, tray, carton etc.) by the warehouse staff. If there are several warehouses, the goods may be registered in a common receiving area and then stored according to the accompanying documents into the corresponding warehouse.

8 Example: Roll-in user interface Example: Picking user interface for automated warehouses

9 Location Management (LOC) In order to manage the different types of warehouses and carriers optimally, STRategies have been implemented for roll-in (storage position search) and roll-out (route optimization) that enable an efficient operation of the entire warehouse: To achieve an enhanced performance for roll-in and roll-out smart rules and algorithms have been implemented. Multipledeep storage is supported, too. LOC optimizes the performance of total warehouse system so that, for instance, load carriers that belong together are stored on the same shelf while those which are to be retrieved earlier than others are placed in front. Another example: Based on how full the warehouse is overall, the search for a location for the first load carrier of a group is carried out in such a way that a rear rack location is assigned within a suitable aisle. Methods of storage location management fixed location system (static storage position allocation). A fixed storage location is assigned to the article master data Chaotic or dynamic storage. Unlike the fixed location system, with this method the system determines and allocates the best location for all incoming goods on the fly. This decision is based both on item-specific criteria (quantity, size, transfer frequency, compatibility etc.) and warehouserelated data (available space, free locations). Storage strategies The storage strategy is assigned as an attribute to each article. Different articles may have different strategies: Fixed-location storage FIFO/Chaotic storage Incremental storage strategy Replenishment strategy Capacity check The capacity checks can be defined according to the following aspects: quantity weight volume size The capacity check may be carried out for various locations together (e.g. a rack section with a determined cumulated load capacity).

10 Information about Carriers Carriers and storage locations The related information can be searched and displayed in detail both for carriers and storage locations. Navigation accesses to the articles stored on the carriers is available. The creation and modification of carrier types is easy by using the carrier configuration option. Other storage allocation strategies The StöcklinWMS permits the implementation of individualized allocation strategies within the system. These strategies comprise for instance: customized storage allocation article and warehouse area-related strategies for an optimized utilization of space and short distances for storage and retrieval Short transportation ways for roll-ins and roll-outs optimization by means of warehouse consolidation processes

11 Double/Multiple depth storage for large amounts of identical articles Stacker cranes may pick up several load carriers simultaneously in order to store or retrieve them from double/multipledeep racks. This requires rules and algorithms for a high-performance storage and retrieval. The type of storage decides on the performance level of the posterior retrieval. The critical issue is: e.g. how many rear containers are to be retrieved before retrieving one front container. If no boundary conditions are known, the RANDOM strategy can be implemented. This strategy is implementing, that there is no dependence between the carriers. Relocations are the result. To achieve an optimized double/multiple-deep storage, the load carriers have to be grouped (e.g. by articles, lots, goods receipt, etc.) or sorted by a clearly defined value, e.g. the storage date whereby also the retrieval strategy must be taken into account to ensure an optimum performance of the entire system. With regard to the retrieval strategy, the goods may be grouped or sorted by a determined value. When applying above strategies it is convenient to place matching carriers in the same storage location. The carriers which are to be retrieved first should be stored in front. Warehouse visualization for an optimum overview on the current warehouse occupation The warehouse visualization offers a view on the storage racks so its occupation with carriers (pallets or boxes) can be observed. Users can see at first glance the degree of occupation of a storage rack and the situation of the free storage locations. The color of the storage positions may represent the storage location type or the storage zone affiliation. By clicking on the storage location its detailed information is shown in the lower part of the visualization screen. In order to obtain an optimal view on the storage rack, it can be zoomed or scrolled, if too large. Single/double (as shown in the picture) or multiple-deep storage racks can be visualized. Taking into account the above, different search strategies are the result.

12 Warehouse Visualization

13 Material Flow Controller (MFC) User of intralogistic systems are focusing more and more on its logistic processes in order to gain long lasting competitive advantages, as well as to increase returns. Along the whole value chain of production, intelligent logistics solutions are needed in order to speed up significantly the flow of goods, and enhance the availability on time while still reducing costs. The main task of warehouse logistics is to maintain and smoothly process the different flows of information and materials. Existing cost saving potentials can be realized only through permanent optimization of the logistics processes. Stöcklin took this essential requirement as a commitment to integrate an innovative solution into the Warehouse Management System in order to ensure an efficient control of the complex material flow processes any time. The project practice would look like this: With the Workflow- Explorer, a component of the StöcklinWMS, the Stöcklin project team can customize the system directly and efficiently for the customer s needs without loosing time for writing software codes. The graphic user interface of the Workflow Explorer also enables to recover previously used processes and storage strategies immediately. This helps for quick adaptations on a current business situation. Stöcklin Logistik is focusing on this technology and procedure for many reasons. For the customer they have positive effects on the project duration and costs. Another advantage is the fact that the future software versions can be installed without relevant effort because the strategies and procedures are not written directly into the software code. Each operation has its own characteristics, and therefore it must map the warehouse users business processes 1:1 and fully support them. Thus, the system architecture is designed to visualize precisely these specific processes and characteristics without any programming.

14 Control desk with 2D-Visualization

15 The system always under control with the control desk The control desk allows the comprehensive operation of the Stöcklin Warehouse Management System 5.6: Control desk with 3D-Visualization Functions of the control desk Information on the material flow (visualization 2D and 3D), on load carriers, articles, storage locations, picking orders, orders and picking lists Control of the material flow (manual load carrier roll-out, rollout of unknown load carriers) Manual operation of automated sections Correction of material flow and transport orders as well as changes of priorities Information necessary for the operation of the system (used by Stöcklin personnel for system maintenance and support) Comprehensive information on the master data administration of the identity management Creation of system queries (Quick Queries) and reports

16 Stöcklin Energy Management (SEM) The Stöcklin energy concept comprises a series of features and actions within the Stöcklin Warehouse Management System and the Stöcklin Control system, which are deployed to actively save energy. In times of steadily rising energy costs, Stöcklin Logistik has focused its development projects more and more on active energy saving. The features already available allow to save a total of up to 20% of energy. Nevertheless, the actually achievable power savings depend substantially on the applied storing strategy and the required warehouse output as a function of time. Furthermore, in this context the optimum deployment of the used ERP system is crucial. A large part of the energy saving potentials must be implemented already in these systems. Thus, it is very important to synchronize all important subsystems (ERP system, warehouse management system, control and drives) optimally to achieve the desired energy saving goal. The warehouse users will be able to control the subsystems and take operative decisions in a way that really important energy savings will be achieved. Stöcklin Energy Concept works in two directions, not only to save energy but also to reduce and avoid energy costs and total energy delivery costs: - Reduction of energy consumption in kw/h - Avoidance and reduction of current peaks In the end, active energy saving cannot be reduced to the technical aspects of warehousing only. If the operator of the warehouse does not share this attitude, the systems will only profit of a part of its energy saving potential. For that reason Stöcklin Logistik gives great importance to the training of warehouse staff in order to achieve that all involved persons get the right feeling for an energy-saving warehouse operation.

17 Easy operation and overview with 2D and 3D visualization To render the 3D visualization of the Stöcklin Warehouse Management System, the positioning data of the individual material flow objects like pallets or containers are recorded at regular intervals by the system and converted into a dynamic animation. The warehouse section selected via the zoom function can be turned and tilted in any direction by means of sliders to allow an optimum view. The selected sections may be stored in the system and re-used if necessary. Furthermore, the information content of the 3D visualization is considerably higher. The status information of the material flow objects and stations is provided through color changes. The colors allow a quick identification of faulty system parts which are displayed in red on the screen. Thus, the personnel at the control desk are able to make the correct decisions in critical situations quickly, in order to recover an error-free operation promptly. Especially customers with wide spread material flow systems, which are difficult to overlook, benefit from the high visual information content of a control desk equipped with 3D visualization. The great advantage of the 3D visualization compared to the 2D visualization system, which can be used additionally, is the better perceptibility of the events in the plant, as they are very similar to the real appearance. A clear overview on vast or complex warehouses is made possible with 3D visualization. It offers also additional advantages for servicing, plant maintenance and repair. The 3D visualization guarantees a comfortable, reliable and cost-effective operation of the Stöcklin Warehouse Management System from the control desk. Control desk with 2D-Visualization

18 Graphical display of the energy consumption Report of Stöcklin enegery Concept

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20 Stöcklin Logistik AG Förder und Lagertechnik CH-4143 Dornach Stöcklin Logistik AG Förder und Lagertechnik Büro Jona CH-8645 Jona Stöcklin Logistik GmbH Förder und Lagertechnik DE Netphen Stöcklin BV Material Handling and Storage Systems NL-5835 AC Beugen Stocklin C.A.S. Material Handling and Storage Systems GB-Aston Oxon OX18 2DQ STOCKLIN LOGISTICS Stöcklin spol s r.o. Flurfördermittel und Komponenten CZ Zlín stoecklin@zln.cz Stocklin Logistics Sarl. Technique de manutention et de stockage F Le Bourget slf@stocklin-logistics.fr Stöcklin Logistica do Brasil Ltda. Material Handling and Storage Systems BR-Moema-São Paulo-SP ernesto.grassl@stocklin.com.br YOUR GENERAL CONTRACTOR FOR TOTAL SOLUTIONS TURNKEY MATERIALS HANDLING AND STORAGE SYSTEMS CLOSE TO YOU For more than 80 years, the Swiss Stöcklin Group has been providing worldwide innovative logistics solutions to the highest standards. We provide a successful completion of turnkey systems, professional project management, clearly defined systems interfaces and closely coordinated partnerships. Stöcklin stands for long-term, ongoing development of propriety systems and products, high-quality and predominantly Swiss manufacture, and the highest standard of customer service. Our range includes: manually and automatically controlled warehousing for pallets and small parts Conveying and order picking systems Control systems, warehouse management and material flow systems Refurbishment and retrofitting of existing installations 24 hours support service Stöcklin Logistics de México Material Handling and Storage Systems MX Tlalnepantla Estado de México info@stoecklin.com.mx Stoecklin Logistics Inc. Material Handling and Storage Systems GA Atlanta info-us@stoecklin.com Stocklin Sidus Material Handling and Storage Systems RUS Samarskaya oblast office@sidus.ru Material Handling and Storage Systems 06/2015 DE/EN