Warehouse operations

wmsView plans and organizes relevant activities for receiving, stocking, cycle count, replenishment, picking, re-slotting, packing, and shipping. All activities are represented in the system in the form of tasks. These tasks are pre-planned whenever possible and generated by the system. Examples of such tasks include activities such as putting away a carton, picking an item from a stocking location and placing it in a shippable container, or cycle counting at a location. Stockroom personnel can perform pre-planned tasks in a productive and effective manner. Tasks are tracked by the system from the time the task is created to the time it is completed, as well as by individual who performed the task. This feature provides the basis for measurement of labor productivity and activity cycle time. Stockroom supervisors can designate personnel and priority levels for each task.

Stocking Locations

wmsView supports several different types of stocking locations:

Balance-on-hand location types are forward pick and primary reserve. The entire stockroom can be configured to use only one location type or it can be segregated dependent upon the physical setup, material handling equipment, velocity of items and space availability.

Forward pick locations are typically floor level locations that are easy to pick. These locations are reserved for a specific item at any given point of time and typically store high velocity items. Each location can have a minimum and a maximum amount assigned for backup replenishment purposes.

Primary reserve locations are often above floor level or off-site locations. Stock replenishes to forward pick locations on a first-in-first-out (FIFO) basis or other rotation rules such as LIFO, Expiration date and best fit which is selectable in Item Master when the balance-on-hand falls below the established minimum.

Receiving dock, truck (material handling equipment such as fork lift and order picker), container staging and shipping dock are other types of stocking locations. These are not pickable balance-on-hand locations. Rather, they enable wmsView to track item and container movement throughout the entire warehouse and supply chain.

The last type of location is the Work-In-Process warehouse, which is designed for tracking inventory of an area. This is typical a production line or a test station. Inventory is tracked as they are picked for these kinds of locations and the balance-on-hand is typically relieved through back-flushed or other regular means.

Unit of Measure

WmsView supports multiple levels of unit of measure. You can specify unlimited levels of unit of measure on the SKU level. You can also issue purchase orders, receive, relocate, order, and pick based on a valid unit of measure. By pick zone, you can also qualify the pick unit of measure and their transportability. The system can automatically separate picks based on unit of measure to allow for effective picking and transportation. Stock replenishment is also tied in with the separation logic in that higher unit of measure stock that is transportable will be allocated for replenishing to the lower unit of measure to satisfy demand.

Stock Tracking

wmsView supports the serialized and tag (license plate) methods of stock tracking. Using the serialization method of stock tracking, each part's serial number is scanned into the system. At all times, the system maintains the serial number for each part, which bin location it is stored in, and the container identifier (typically carton) that holds it. This feature enables product release-level purge management and warranty tracking. Purge management is a wmsView feature that allows you to rid your warehouse of undesirable inventory. Serial number tracking is typically used for expensive items such as circuit packs or electronic equipment. On the other hand, tag tracking allows you the flexibility to track items by carton or pallet. The term "tag" is synonymous to "license plate" and serves as an identifier for tracking purposes. For each tag in the system, wmsView knows the date the item was received, the lot number, the check-in packing slip number, expiration date and the supplier. This feature allows you to purge by vendor and received date range, lot and other criteria.

Stock Relocation

For unplanned relocation of inventory, you can move inventory by tag (license plate), by serial number and by location and part combination. This inventory can be loaded into the transportation vehicle and put away into the desired locations. The system tracks inventory while it is in transit from the source locations to the destination. In other words, this facilitates a true real time tracking of the stock movement.

Inventory Merge and Split

Stockroom personnel have the option of merging inventory tags at the same time they perform the put away function. On the SKU level, personnel can specify behavior of the merge operations such as automatic merge in forward pick locations for "nuts and bolts" types of small items. You can also specify other rules. For instance, you do not want to merge parts that have different lot number, shelf life etc. There are also options to split inventory into separate tags for organization of stocking or other purposes. After tags are split, all data following the original tag will be transferred to the new tag, a new bar-code label will also be printed.

Stock Age Management

You can specify the tolerance interval (number of days) during which different received lots can be placed in the same location. For example, stock received more than 90 days apart cannot be stocked in the same location. The date code for stock allocation is by location. All stock of the same item in the same location is treated as if they have the oldest date code. This is to facilitate effective stock picking. System directs picking from the oldest location first for both customer orders and internal stockroom replenishment.

Purge (Block) Management - Freeze stock

Purge management is a powerful wmsView feature that allows you to rid your warehouse of undesirable items and inventory. For any combination of part, release, vendor, receipt date or manufacturing date, the purge prime can freeze the stock that fits the criteria. If materials are waiting to be put away, the put away location is changed to the purge location. Only user with special purge capability can move purge inventory. Authorized personnel can relocate purged items from regular stock locations to designated purge locations for review and rework or send to the repair work center. As a purge is lifted, you can use the same screen to undo the purge of the stock. When stock is purged or frozen, the system does not allow picking of any of the parts except by authorized personnel.

Kitting

wmsView provides parts explosion for kits that you are committed to build. Then, stock may be allocated for kit building in customer service priority sequence. Kit orders may be released for processing when all shortages are satisfied. Alternatively, they may be released ahead of schedule where level loading is a requirement.

Forward Pick Replenishment

At scheduled intervals (usually nightly), the system examines each forward pick location. If balance-on-hand is less than the minimum (typically three to four days of inventory), wmsView generates replenishment tasks to fill the location up to the maximum inventory allowed (typically seven to ten days of inventory).

Execution of Replenishment Tasks
wmsView allows the warehouse supervisor to assign personnel to replenish by zone and by aisle. When in system-direct mode, and based on the supervisor's assigned priority, the system directs operators to pick in sequence from the primary reserve locations until the truck is full. The system then directs personnel to put away the material in forward pick locations in the put away sequence.

Replenishment - Minimum/Maximum Quality Check
wmsView provides reports which compare actual quantity pulled within a specified date range against the minimum and maximum inventory allowed of forward pick items. This option provides important feedback to the stockroom personnel allowing them to adjust the minimum and maximum inventory necessary to accommodate changing demands.

Replenishment on demand
When situation occurs that forward pick location do not have sufficient inventory to satisfy demand, replenishment task will automatically be generated without waiting for the next planned replenishment cycle. This is to insure high order fulfillment rate in an effective manner.

Space and Velocity management

The system, based on collected activity, will recommend actions to manage velocity, space and consequently re-slotting. SKU(s) with upward velocity trend will be recommend to move to forward pick areas and / or open up more face pick locations. SKU(s) store in multiple locations but fit into consolidation rules will be recommended to merge to save space.

Work load and labor performance management

Work load management give you the visibility of all tasks and allows you to assign tasks and set priorities in a way that manages work loads in an orderly and systematic fashion. The system records all tasks, creation of those tasks, who performed them, and when the task was completed. This information is viewable on the wmsView inquiry screens. A report is available per operator listing the tasks they performed, at what time the task was performed, as well as the status this task.
Task visibility
All tasks have visibility in the system and they are summarized on one screen. These tasks includes receiving, put away, replenishmnet, cycle count, relocation, picking, packing and truck loading.
System Direct
The warehouse supervisor has the ability to assign different tasks and priorities to personnel. When an operator logs into the system via system direct mode, they are directed to perform the tasks based on priorities set previously by the warehouse supervisor. For example, supervisor John Smith can assign Jane Davis to perform all replenishment tasks in zone 01 and 02, and then to perform all cycle count tasks of zone 01 and 02.
Labor Productivity
The system records all tasks, creation of those tasks, who performed them, and when the task was completed. This information is viewable on the wmsView inquiry screens. A report is available per operator listing the tasks they performed, at what time the task was performed, as well as the current status this task.
Cycle Time Measurement
wmsView uses detail tracking to provide the basis for cycle time measurement for both inbound stock processing and outbound order fulfillment. This option is very instrumental for recognizing trends and setting goals.
Task Interweaving
Instead of a person making one round trip to simply put material away, the solution can ask them to put "Item X" away and to do a cycle count in "Location Y" on the return trip. We can interweave other tasks as well. This reduces inefficient "deadheading" in the warehouse.

Task and labor standard
wmsView has plans to provide task and labor standards by task, zone, and labor proficiency level.

Cycle Count and Physical Inventory

Cycle Count Tasks
There are two kinds of cycle count tasks; scheduled count and demand counts.
  1. Scheduled counts are based on ABC classification. You can specify the number of days to count per classification. For example, count all "A" items in 30 days, all "B" items in 60 days, and all "C" items in 240 days.

  2. The system generates demand counts whenever a balance-on-hand problem is detected. For example, a picker unable to complete a pick task due to BOH or when balance-on-hand of the location is lower than a user-specified parameter (normally lower than three), the system confirms the count. If the confirmation is negative, a cycle count task is generated for the location.

You can also manually generate cycle count tasks by other parameters such as zone, aisle, or activities of a date and time range.

Execution of Cycle Count Tasks
For system-generated tasks, the supervisor can specify, by priority, by individual name, who counts which zones. The system then directs personnel to count in location sequence. Tasks are performed using hand-held or truck mounted radio frequency terminals. At any time, authorized personnel can count any location on demand. At time of counting, the location is locked from other activity. In other words, you cannot count and pick at the same location at the same time.

Cycle count reports
There are various cycle count reports available within the system that provide important information on a daily and monthly basis.

Row Audit
System generated various row audit reports for end users to verify inventory.

Physical inventory
This module allows for traditional form of data entry physical inventory to satisfy the paper audit requirements of some auditors. Forms can be printed per location for personnel to write down the inventory and data entry into system. There is no restriction on number of counts. Counts are completed only when audit.

Excess and Obsolesence

Definition of Excess and Obsolete can be specified through the system and alerts will be generated for the supply management folks to work with Suppliers to rid the material at the earliest possible moment.