It may surprise people, but there are basic WMS applications today still using wired

computer terminals on the dock or in an office. The dockworkers still use paper tally
sheets for recording the counts from the physical check-in process, and clerks in an
office, or the dock personnel themselves, enter the data into the system. These
systems may use wired barcode scanners, or print barcode labels used in other parts
of the process. The rapid cost drop of Radio Frequency Data Terminals wireless
integrated scanner terminals makes replacement of the legacy wired terminals
easy.

The introduction of R/F terminals and barcode label printers changes the receiving
process. Almost any consumer product now carries a UPC barcode, and most
manufactured parts carry some form of a barcode on the packaging. It used to be
only Tier 1 WMS systems used UPC scanning for receiving check in, but that
functionality is available in some of the most basic systems.

Only a decade ago using Advanced Shipping Notices (ASN) to replace the Packing
Slip was a rare function in Tier 1 WMS applications. Now, more of the basic systems
accept ASN. A decade ago if you want to support Electronic Data Interface your
systems depended on expensive proprietary EDI networks. Now, through the AS1
protocols, EDI over the internet rules, and EDI is now a basic expectation.

Advanced shipping notice (ASN) is a document that provides detailed information

about a pending delivery. The purpose of an ASN is to notify the customer when
shipping occurs and provide physical characteristics about the shipment so the
customer can be prepared to accept delivery.

An ASN, which is usually sent over the Internet in an electronic data information
(EDI) or extensible markup language (XML) format, provides information about when
an order will be shipped, which items are being shipped, how many of each item is
being shipped and physical characteristics about the shipment such as the
shipments weight, the number of boxes and a description of how the shipment units
are packaged. An ASN also tells the customer which mode of transportation is being
used for shipping and provides carrier information.

I continue to be surprised by at how many companies are still not requiring Advanced Shipment
Notices (ASNs) from their suppliers. Advanced shipment notices provide details on the timing,
contents and packaging of forthcoming deliveries. Although ASNs have been around for decades
the benefits of these EDI documents are still not widely understood. In this post, I will examine the
benefits to a retailers distribution center operations.

Without ASNs, the receiving process at a distribution center suffers from a number of
inefficiencies. The root cause of these challenges is the lack visibility into what shipments are going
to arrive and when. As a result, warehouse managers cannot properly plan their labor schedule;
cannot implement cross-docking techniques and cannot monitor inventories in-transit.
A basic component of identification in the Bar Code based R/F WMS warehouse is
the pallet license plate. This is a label with a combination of human readable
information and a bar code. The license plate is nothing more than a unique
identifier for the pallet, like the license plate on a car. Scan the license plate on the
pallet, and the system displays the information about the pallet, where it is, how
much product is on the pallet, even the last warehouse operator to touch the pallet.
Almost all R/F based WMS systems print license plates as part of the warehouse
process. There are two basic paths for initiating the license plate, either on demand
as part of the actual receiving process, or uses pre-printed generic labels applied to
the pallet and then scanned to tie the plate to the goods on the pallet.

Put-A-Way changes in todays WMS world. The WMS systems maintain a map of the
warehouse, tracking every storage location by the dimensions, capacity, type and
status (empty or in use) and the type of material handling equipment needed to
access the location. The systems also maintain a Parts Master for every SKU in the
warehouse, providing the case quantity, dimensions, weights, and ti/hi for each
product. Many systems direct the stockers where to put the inbound pallet. Some
will provide the stocker the aisle where the products pick location is, and the stocker
selects the proper reserve location.

WMS processes for stocking can take a series of different paths, even within the same
WMS. That is a subject for a future article.

http://www.wearethepractitioners.com/library/the-practitioner/2013/02/20/basic-
inbound-warehouse-management-system-functions

Put-away practices

Put-away is the process of moving material from the dock and transporting it to a warehouses
storage, replenishment, or pick area. Best-practice companies manage the put-away area by
calculating resource and space requirements based on expected receipts and current backlogs.
Best practice is to put away product the same day its received, because not doing so affects
space, causes congestion, increases transaction errors, and makes product more susceptible to
damage. In a busy warehouse, it is easy to let product put-away fall behind other tasks such as
picking, replenishment, shipping, and loading. But pulling away resources from put-away tasks can
affect fill rates by not having product in pick racks. This can bring about congestion in staging
areas that overflow into aisles. Delaying put-away may also result in product damage as the
merchandise is moved, again and again, to make way for higher priority receipts. Proper staffing of
the put-away team will support down stream processes of picking and shipping, and in the long
run lead to better customer order fill rates.

The put-away process is typically managed by one of, or a mix of, the following methods; staging
product from the receiving area, based on the purchase order, based on the part number, or based
on a put-away zone or by using direct delivery (put-away) to the storage location. The most
efficient practice is to put-away directly from receipt to its final location and is often the primary
method used in best practice companies. This process uses the least space for staging and product
is handled less and ready for use sooner. Direct put-away programs require a more sophisticated
WMS system that has the ability to assign locations from an ASN or upon receipt to the dock.
Assigning locations and using direct put-away can be optimized the by use of automated conveyor
systems that are capable of sorting and diverting materials by zone and location.

Best practice companies also use their warehouse management system (WMS) to manage travel
time from receiving to storage areas, pick locations and replenishment areas; so that the best put-
away route can be selected. The end result is put-away travel paths that are sequenced based on
the shortest route for the product in the load, with reduced aisle conflicts and congestion. Many
WMS programs also support task interleaving; most best-practice companies make use of this
capability in their warehouses to reduce non-productive travel time. The put-away process is
critical and significantly affects overall warehouse efficiency.

Best-practice companies identify products using some form of barcoded or RFID label. Product
identification labels, zone or location labels and pallet license plates should all be utilized in the
put-away process. Both bar code and RFID can work equally as well to identify product, with
barcode labels far more common in todays warehouses. The advantage of RFID is that it works
better in harsh environments, it has a fast read from almost any position, and the tag can hold a
lot of information that can be changed as the product flows through the warehouse. Barcode labels
however have been used for years, successfully, to identify and manage the flow of materials in
the warehouse.

Many companies have some type of process to manage expedited materials once they have been
received. In a manual process the product might be flagged as hot and placed in a special
expedite staging area, so that the put-away team can move the product to the required location
as quickly as possible. This can be a hit or miss arrangement and is less than effective. Best
practice companies the cross-docking process is managed by the WMS system. Cross-docking, as
it relates to put-away and material handling, is the process of moving specific products to support
an open order or replenishment request, with minimal handling and delay. The WMS system flags
the product for cross-docking by matching it to an open order or replenishment requirement, at
the time of receipt, or when the advance ship notice (ASN) is received. The product may still end
up in a special staging area but the system is keeping track of it and will prioritize it over other
material. The task to move the material is sent to the lift truck or hand held RF device for
movement directly to the point of use. This is a far more effective system to get priority product
moved.
Good housekeeping must be part of any best-in-class warehouse, as best practice processes
cannot succeed in a workplace that is cluttered, disorganized, or dirty. Poor workplace conditions
lead to waste, product damage, and safety issues; such as extra motion to avoid obstacles, time
spent searching for things, delays due to defects, machine failures, or accidents. Establishing basic
workplace conditions is an essential first step in creating a safe and productive warehouse
environment.

http://multichannelmerchant.com/opsandfulfillment_warehouse/best-practices-in-
material-handling-and-put-away-01042007/

Best Practices for an Efficient Warehouse Layout

JULY 3, 2013 BY TOM REDDON

One of the most important factors in

warehouse efficiencyfor both the owner and employeesis the physical layout of the warehouse itself. A poorly
conceived set up and floor plan can lead to hours of backtracking and/or down time. Since every successful
warehouse requires the use of forklifts, most of the layout considerations should be made with these vehicles in
mind.

An often overlooked factor in warehouse efficiency is lighting. If indoor lighting is insufficient, multiple problems
can arise. Smaller scale issues might include inventory and distribution delays due to difficulty in reading item
numbers. Larger scale issues could be as serious as forklift collisions. Optimizing indoor lighting is an easy way
to avoid a wide range of setbacks.

Space is also key in maintaining an efficient environment for forklift operation. That doesnt simply refer to the
square footage of the warehouse. Its possible to have a very large facility with little operable space. The idea
here is to provide as a wide of a path as possible for your forklift operators. One easy way to do this is to keep all
stored products and packages up against a wall. If your inventory and/or space limitations require the
construction of aisles, then make sure you have plenty of space between rows for a forklifts to maneuver without
being cramped. The width between aisles will largely depend on the type of forklifts you are using as models
vary in terms of turning radius, elevation and reach. Once youve identified the forklift models in your warehouse,
construct your aisles accordingly. This will not only speed up work flow, it will also go a long way in avoiding
accidents..

Width between aisles isnt the only important consideration in the layout of your aisles. Logical and proper
labeling is also key. As much as possible, try to stack items of a similar kind or category in the same aisle, and
make sure each aisle is clearly labeled so employees know which items can be found there. This will avoid hours
of confusion and backtracking that can result when employees are not sure where to find specific inventory
items. Creating short cuts through aisles can also help to streamline storing and delivery. Putting gaps in the
middle of aisles will allow employees to make a direct a path to the items they need without having to walk or
drive forklifts around entire aisles to get there.

Another way to propagate both speed and safety is by regularly maintaining the warehouse floor. Pot holes,
cracks and debris are all hazards to a forklift. They will slow down the work rate as operators are forced to avoid
them, sometimes even needing to stop and reverse course to do so. But they can also cause more than timing
inconveniences. Uneven surfaces can cause forklifts to teeter and even fall over, resulting in expensive repairs
to both the forklift and its cargo. Such instances can also result in employee injury. So it is imperative to keep a
clean, even floor in the warehouse.

Many layout considerations that promote forklift efficiency might seem obvious, but they are no less important.
Making sure forklift operators have a safe and efficient work space is a great way to boost production and prevent
losses.

http://www.nfe-lifts.com/efficient-warehouse-layout/
http://www.aalhysterforklifts.com.au/index.php/about/blog-
post/10_quick_tips_to_minimise_downtime_and_increase_warehouse_productivity