Configure and extend Oracle WMS to meet requirements of a Distribution Centric Warehouse

Vishal Choudhari

Agenda

• About HCL• Introduction to WMS• Inbound Material Flow• Outbound Material Flow

CORPORATE OVERVIEW

Rapidly diversifying geo-mix

US revenues 59.4%

Europe25.2%

APAC15.4%

Derisked across 500 customers

Top 5 32.2% of revenues

Top 10 42.3% of revenues

(66 Fortune 500 clients)

Service Offerings

Product Engineering

Application Development

Infrastructure Management

BPO

ERP,CRM,Portals, Content Management, Testing,

Domain Specific Packages

Enterprise Consulting

I nsurance Life SciencesMedia and Publishing Banking & FinanceRetail & CPGAutomotiveSemi-ConductorsAero-spaceMedia and Publishing Banking & FinanceRetail & CPGAutomotiveSemi-ConductorsAero-space

AS Watson Stores…….Federated Stores…. Safeway…….Coles Myer….Shoppers Stop... Jones Apparel Group…….Office Depot……

Technologies & CapabilitiesBusiness Areas

ERP / SCM/ CRM

EAI

Business Intelligence & Data Warehouse

Application Testing/SQA

Web Technologies COE, Client/Server Technologies COE, AS400 COE, & Mainframe COE

Application Development

Enterprise Content Mgmt.

Ecommerce/Enterprise Collaboration

Retail Supply Chain

Introduction to WMS

Interaction with other modules

InventoryOrder Management

Shipping &Execution

WarehouseManagement

PurchasingWork inProcess

Costing

Material Movem

ent Picking / P

acking / Shipping

Receiv

ing

Replenishment

WIP Com

pletionCost Group Mgmt

ArchitectureMobile

ApplicationsServer

OracleApplications Forms

Server

Application andDatabase Servers

3rd Party PrintingSoftware

Mobile HandheldTerminal

TelnetAccess

Applet ViewerAccess from

Browser

Inbound Logistics

Inbound material flow in warehouse

Inspect / Pack/ Consolidate

Outbound Staging Inbound Staging

Inbound Docks Outbound Docks

BULK / PALLET AREAFLOOR STORAGECASE AREA

RACK STORAGE

Receive ProductExpress Receipt using LPN

Put awayPut away rulesCustom Capacity Function

ReplenishReplenish Pick Faces from Bulk

Receiving Product

• ASN from supplier can contain pallet and carton level packing information

• Express receipt can receive complete pallet with all serial and lot number information with a single scan. Express receiving can be RFID enabled.

• Advanced Task framework can direct movement of material in receiving area

Pallet Numbers

Lot NumbersItem

Number

ASN# / Shipment NumberTranslated Advanced Shipment Notice Flat File

ASN can contain Packing Information

Put-away

• Configurable rules determines put-away locator• Full Pallets to Bulk storage area• Cases to Rack storage area• ‘A’ products to front of warehouse, ‘C’ products to back

• Capacity Function can be extended to meet business rules• Capacity by Quantity / Weight / Volume• What locators will product fit in• Bulk capacity specified in Pallet Floor spaces• Item dependent Pallet stackability

Express Receipt and Put away screens

System suggestedput away locations

ASN Number

Pallet Numbers

Express Receiving with RFID Tags

• Load of Pallet & Cartons with RFID tags on each• Drive Load through RFID reader in receiving dock• System access ASN to validate receipt• Trigger response – Green Light or Buzzer to confirm

success of failure

Cross docking

• Release 11.5.10 offers only Opportunistic Cross Docking. • From Inbound Stage To Outbound Stage for backordered

sales orders• From Manufacturing Job To Outbound Stage for

backordered sales order• From Inbound stage To manufacturing job

• Planned Cross docking is expected in Release 12.

Yard Management

Outbound Logistics

Outbound material flow in warehouse

Inspect / Pack/ Consolidate

Outbound Staging Inbound Staging

Inbound Docks Outbound Docks

BULK / PALLET AREAFLOOR STORAGECASE AREA

RACK STORAGE

Pick CasesPicking rulesCartonization Extension to build pallet

Pick Full PalletsPick by LPN

Consolidate & PackConsolidation LanesMove to Staging Lane

Ship ConfirmLoad to DockShip Dock Door

Picking

• Configurable Picking rule determines pick-from and drop-to stock locator• Full pallet picks from Bulk• Less than full pallet picks come from Case• Picking is in FIFO

• Picking Methodology determines task assignment• Bulk Picking• Pick by Zone• Pick by Label

A Picking Rule

Scan Barcode to confirm Locator

Scan Barcode to confirm Item

Drop parts to a consolidation location

Picking Task completed on mobile server

Control Board displays task assignment selected by Rules

Accept Next Task on mobile server assigns next picking task to user

Warehouse Control Board

Pick release allocates product, then fires packing algorithm

• Each full pallet pick gets one LPN label.

• Loose carton picks are assigned to pallets based on carton dimension and the required pallet dimension.

• Algorithm designed to create least number of mixed pallets while maintaining customer specific rules

Pallet Building through Cartonization

Pick Release

LPN # 1000000858BOX TYPE 01827

LPN # 1000000858BOX TYPE 01827

LPN # 100000858BOX TYPE 01827

LPN#10000000863

BOX TYPE 01827

Pallet Building through Cartonization

Pick Release

LPN # 1000000858BOX TYPE 01827

LPN # 1000000858BOX TYPE 01827

LPN # 100000858BOX TYPE 01827

LPN#10000000863

BOX TYPE 01827

For Carton picks

• Picker scans Label

• WMS displays stock locator where first carton on pallet should be picked from

• After that, WMS assigns tasks to picker one at a time until all cartons on pallet have been loaded

Pallet Building through Cartonization

Pick Release

LPN # 1000000858BOX TYPE 01827

LPN # 1000000858BOX TYPE 01827

LPN # 100000858BOX TYPE 01827

LPN#10000000863

BOX TYPE 01827

For Full Pallet Picks

• Picker scans Label

• WMS displays Stock Locator from which pallet should be picked

• Picker scans LPN on full pallet

Pallet Building through Cartonization

Pick Release

LPN # 1000000858BOX TYPE 01827

LPN # 1000000858BOX TYPE 01827

LPN # 100000858BOX TYPE 01827

LPN#10000000863

BOX TYPE 01827

Pallets are wrapped and dropped to staging lane

Pallet Building through Cartonization

• Large consolidation area not required• Build pallets while you pick• Limited investment in sorting equipment• Comply with retailer mandates for Pallet height• Generate Carton Level LPNs

WMS support for RFID compliance

• Ability to tie LPN labels with EPC tags• Built-in and customizable EPC generation routines

Associating LPN labels with EPC tags

• EPC Generation rule associated with LPN label type

• Label type associated with Business Flow

Automating Outbound Shipping

• RFID tags applied at Manufacturing or Pallet Building Stage

• For Assemble to Order environments, Direct Shipping can be used to bypass the pick-release, pick-confirm process.

Conclusion

What works well• Highly configurable Rules Engine for Directed Picking

and Put-awayWhat can be extended• Labeling elements• Capacity Function for put away rules• Pallet Building• Standard Pack SizeWhat’s missing• Planned Cross-docking

Q & A