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“Waveless” Order Processing -...
Transcript of “Waveless” Order Processing -...
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Presented by:
Jeff Lammert, Client Executive
Systems Engineering
Art Eldred, Client Executive,
Systems Engineering
Dan Perry, Senior Engineer
“Waveless” Order Processing:
Why Wave Picking is Hurting Your Business
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Definition: Wave, Autowave & Waveless Processing
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Wave Processing: (from a lean perspective) A collection of unrelated work efforts that are
combined together and the combined group is treated as an entity, the entity beginning
when the first work effort for any member of the group is initiated and the entity is
complete when all the individual efforts on all entity members are deemed finished.
Autowave Processing: (continuous flow systems) The release of additional waves for work
efforts are controlled by systemic triggers. The systemic triggers detect the completion of
all individual efforts on all entities of a combined group of work.
Waveless Processing: (continuous flow systems) Efforts required to fulfill an individual
order are related and thus each of those efforts must complete before the order is
complete. However, while the overall efforts of fulfilling many individual orders may be
performed at the same time there is no connection or dependencies between the efforts.
The efforts for each order start and complete independently from the efforts on ALL other
orders.
Source: WV Commerce Department Newsletter
Plan, Correct, Exception Monitor, Plan, Correct, Exception Correction, Plan, Correct, Exception Monitor, Plan, Correct
E-commerce Havoc on the
“Waveologists”
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Traditional Wave Processing
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Wave 2 Wave 3 Wave 4 Wave 5 Wave 6 Wave 74
Waveless Processing
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Waveless6
How does waveless work?
Revolving Batch Size
For Every Order Completed 1 is Initiated
Efficiency of Batch Picking with Waveless Processing
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Waveless ≠ Batchless
• Waveless does not mean batch-less
• Larger batch size = Greater pick efficiency
– Larger batch = Greater pick density = Less distance between picks
= Less travel time
• In no case will waveless picking be less efficient than wave-
based picking Waveless Waves
Batch size Constant, revolving Diminishing as wave completes
Order prioritization Continuous At time of waving
Order introduction Continuous Only at beginning of wave
Order completion Continuous Skewed to end of wave
Impact on downstream processes
Level, continuous flow of work to packing & shipping
Uneven flow skewed to end of the wave
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Waveless Processing – Revolving Batch
Two Loops, 5+ Orders
SAME DISTANCE OF TRAVEL • 1 Additional Order • 6 Additional Pieces
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Benefit of
Waveless Prioritization
Wave #1 Wave#2 Expedited Wave Wave#3
Ord
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Priority Order
Priority Order
“Wave-less” Continuous Processing
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New Orders Priority Order
Priority Order
Shipping Cut-off Time
New Orders
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Waveless is not new!
Notable Waveless Businesses:
Amazon, Kiva Systems Users, American Eagle,
Forever 21, Target, Levi
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Waveless Via the WES
Warehouse Execution System
• WES Synchronizes and Optimizes Across Processes and ALL WORK
Resources
• Reduce IT Complexity – Reduced systems and interfaces
– Reduced modifications
– Centralized business rules / order attributes
– Simplified upgrade pathway
– Lower level WCS is pure machine control
Traditional Siloed Infrastructure WAVELESS WES
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Sort #1 to Put-Walls - Ecom Sorter #1 to Put-Walls Expedite Sorter #2 to Retail Put to Store
Singles – Case Pick
Ecom Rush Wave #14
Wave #13
Wave #12
Wave #11
Waveless via the WES
Sort #1 to Put-Walls - Ecom Sorter #1 to Put-Walls Expedite Sorter #2 to Retail Put-To-Store
Singles – Case Pick
Fulfillment Center Workflows
30m 2hrs 1.5hrs 2hrs
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WES
WES
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•Most exception orders are due to “late” items
•By definition late items do arrive - but in a wave based system they are after the wave is
closed
•Waveless systems have NO wave closing
•Chutes remain assigned to an order until either the last item arrives or the chute “times out”
•In waveless systems chute timeouts can be quite long since chutes are dynamically
assigned and some chutes complete early and can be re-used. This reduces the
immediate need for the late item order chute. This added time allows many late item
orders to close without additional problem resolution activity.
Waveless Exception Handling Wave vs Waveless
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• Automatically compensates for changes in:
• Work requirements
• Work priorities
• Work resources
• Resource availability exceptions
• Plan is built incrementally as work progresses
• No need to “un-plan” in order to create a new plan
• Recognizes that most tasks are exception free while those that have exceptions just take additional time
to resolve
• Takes advantage of exception “opportunities” when possible
Key to Waveless Processing is
Dynamic Optimization
Benefits of Waveless
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For More Information:
Speaker: Jeff Lammert, [email protected]
Speaker: Art Eldred, [email protected]
website: www.vargosolutions.com
Or visit MODEX 2016 Booth #4978
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