FastTrak WM+

Warehouse management and control plus (WM+)

Integration made easy ™

 Glen Road Systems, Inc.

Founded in 1987, Glen Road Systems, Inc. has spent more than twenty years positioning
itself as a premier distribution center system integrator. Solutions are designed with
the pervasive belief that a warehouse system is only as good as it is reliable and
supportable. As a result, GRSI’s top priority is to design systems for which it can offer
superior support. Novel, value added features and a large install base in diverse
®
warehouses has molded GRSI’s core software offering, FastTrak WM+, into an
essential tool for optimizing warehouse operation and automation.

GRSI
401 East Elm St., Suite 100
Conshohocken, PA 19428
 Contents

FastTrak WM+ overview 3-4

System architecture 5-6

Warehouse management plus (WM+) 7-8

Warehouse management system (WMS) 9-11

Warehouse control system (WCS) 12

FastTrak tools 13-14

Order management system (OMS) 15-16

Packaging integration (PI) 17-18

FastTrak WM+
®

is the solution to:

• Inform
• Automate
• Coordinate
• Integrate
• Manage
Warehouse and distribution operations
“Clients for life...”

2
 GRSI FastTrak WM+ ®

GRSI FastTrak WM+ (warehouse management plus) consists of a WMS and WCS. It is software for inventory management,
warehouse automation, and system control from receiving to shipping. Automated equipment and computer-aided manual
transactions are handled in a coordinated manner aimed at optimizing the full warehouse with regard to accuracy, efficiency,
throughput, and resource utilization. The FastTrak WM+ is one suite of software controlling what heretofore might have been
separately controlled subsystems. The result is exceptional stability, minimal interruption, and superior end-to-end, ongoing
support for the entire warehouse process. The FastTrak WM+ is composed of two modules that work together in various
combinations.

Warehouse management plus Warehouse execution suite

(WM+) ( WES )
WM+ interfaces and facilitates communication between
enterprise software (ERP), warehouse management
systems (WMS), shipping systems, and equipment.
Single-point host communication simplifies design and
implementation, performs with exceptional stability and
reliability, and lends itself to superior support.
Warehouse control system (WCS)
WCS coordinates, controls, automates, and monitors
material handling equipment and fulfillment methods. The
FastTrak WCS includes support for conveyor sorting and
routing; automated storage and retrieval systems (AS/RS);
in-motion inventory; print and apply; in-motion manifesting;

Warehouse management wireless, voice, and laser picking; pick/put-to-light; and

system (WMS)
WMS seamlessly controls and integrates receiving,
putaway, storage, inventory management and planning,
picking, replenishing, and order check-out. The FastTrak
WMS utilizes light, bar code, voice-directed, and RF
picking and putting technologies. It coordinates and directs
resources and equipment including carousels, pick carts,
A-frames, PPTL modules, storage media, automated
guided vehicles, and other AS/RS. It tracks the movement
of inventory throughout the entire distribution center from
receiving to shipping. The FastTrak WMS also incorporates
slotting, cartonization, and vast reporting, diagnostics, and
optimization tools to view operator efficiency and error
troubleshooting messages.
RFID. Graphical user interfaces display real-time material
flow, messages, and performance metrics. Transactional
detail is logged for inquiries, reports, and audits.
Order management system (OMS)
OMS organizes orders for efficient and accurate picking by
combining both operator and automation-based fulfillment
methods. Features such as waveless picking, waving,
batching, and cartonization are standard mechanisms
used to optimize the fulfillment process. The FastTrak
OMS has a full range of inventory management features to
control putaway, storage, and pick location replenishment.
Additionally, a wide range of methods for resource
optimization are included. Targeted resources include
automation equipment, material handlers, storage media,
and diverse warehouse vehicle types.

Packaging integration (PI)

PI encompasses last-100-feet (L1F™) operations such
as packaging, literature and packing list insertion, sealing,
weighing, labeling, manifesting, and sorting. It combines
and automates all subsystems, packaging equipment, and
material handling equipment from any supplier into a single
unified process. The result is minimally attended, cost
effective, and accurate processing of orders.

3
Open architecture Full service warehouse
FastTrak is built on Microsoft .NET, Microsoft SQL Server,
and Microsoft Windows operating systems thereby
systems integration
Warehouse system integration has been GRSI’s core
facilitating compatibility with the support capabilities of
competency for over twenty years. Support for a wide
most enterprise IT departments. This architecture makes
range of equipment and consideration for options ranging
FastTrak highly scalable and able to provide solutions
from high-tech to low-tech has allowed GRSI to offer each
for both large and small operations,
client a solution that is ideally suited
satisfying diverse operational needs
Host ERP to its needs. Skills such as software
varying in terms of transaction
development, electrical controls
volume, number of users, and
engineering, system engineering,
automation control response time
Warehouse fulfillment center and device integration
requirements. The architecture
engineering,
allows FastTrak to maintain
Remote support enable GRSI
continuity with its past
FastTrak WM+ to provide
®

and its future.

Warehouse management system (WMS) complex
Fast Trak Warehouse execution system (WES)
Warehouse Control System (WCS)
Order Management System (OMS)
warehouse fulfillment

WM+ Cartonization
Packaging Integration (PI) Electrical controls
solutions. GRSI’s
structured yet flexible
WM+ is a extension
approach to projects,
of previous FastTrak Resources combined with its
release. WM+ • Voice and RF assisted operators
• Pick/put-to-light activities powerful software
manages inventory, • Conveyor routing and sorting
• Automated storage and retrieval equipment (AS/RS) tools, lead to successful
AS/RS, picking/putting, • Automated packaging equipment implementations.
storage, and replenishment • Specialized vehicles and static storage

operations to assure that 24x7 life-

they work as efficiently and as
effectively as possible. It is able to
control equipment and subsystems from any manufacturer.
The FastTrak WM+ integrates full-function, wall-to-wall
warehouse management system capabilities into the core
product. Previously, FastTrak provided these capabilities
as one-off customizations. FastTrak now handles the full
range of automation control and inventory management as
a single, highly integrated and supportable offering.
Integration made easy
cycle support
Support is part of every GRSI solution.
GRSI considers no job complete without provision for
comprehensive life-cycle support. FastTrak is designed
from end-to-end with this as an objective. Defensive
design methods assure that problems can be rapidly
diagnosed and resolved. Techniques to achieve this goal
include integrated scripting and diagnostic software, user
accessible data highlighting critical operational states,
remote system visibility for GRSI support personnel,
and monitoring tools. The GRSI team is dedicated to
support, and, as a result, has been highly successful
TM
in establishing a large install base of ongoing, satisfied
clients. GRSI believes that support, as much as if not more
than functionality, distinguishes GRSI from other system
providers.

4
 System architecture
Host systems:

ERP/WMS
• SAP • RedPrairie • HighJump
• Oracle • Infor • Legacy
• JD Edwards • Manhattan • More...

Single-point connectivity

FastTrak WM+
®

Ethernet backbone
Electrical controls

Inventory - WMS Equipment - WCS - WES

• Receiving • Packing/shipping • Conveyors

• Putaway • Manifesting • AS/RS

• Picking • Batching/waving • Carousels

• Replenishment • Cartonization • Scanners/cameras

• Robots • Scales

• Sorters

5
 Platforms:

HOST • Windows
• Unix
• IBM, RISC, or AS/400
• Mainframe

PLCs

Information
• Picking: light, voice, • Human machine interfaces

RF, and paper • Dashboard displays

• Robots • E-mail/browser alerts

• Print and apply • RF handhelds

• Document insertion • Diagnostics and reporting

• Packaging systems

6
 Warehouse management plus (WM+)
Automated pick systems such as storage and retrieval, high speed item sorters, and pick/put-to-light, involve large capital
investments and are central to the function of many modern fulfillment centers. The automation equipment must be operated
at peak performance and utilization in order to satisfy financial expectations. Special software tools and methodology are
required to achieve these goals in a fashion that is integrated seamlessly into to the overall warehouse operation. These
include coordinated order management, inventory management, and device control. FastTrak WM+ provides the total solution.
Furthermore, it provides the basis for comprehensive single-source warehouse operations support without artificial and
confusing divisions of responsibility amongst suppliers.

Shipping systems
Packaging systems Inventory

Pick/put-to-light systems Computer networks

Conveyors and Data collection and

FastTrak WM+
®

sorters integration

Scanners and camera Scales and dimensioners

Printer AS/RS, robots,

applicators System interfaces and carousels

GRSI 24x7 support

• Single-point contact for support
• Rapid response
• Remote assistance
• Maximum up-time

7
 Why WM+
Efficient distribution centers need a tightly managed and integrated system
from receiving to order shipment

Automatic and Print and apply

Receiving Picking/putting manual packaging labeling Manifesting

FastTrak WM+
Inventory management Buffering Conveyor routing Shipping sortation Order
and tracking shipment

Integration made easy TM

Typical software solutions fail to utilize and manage equipment made by various manufacturers with multiple pieces of software
running independently. WM+ is the tool for complete warehouse integration. There is no finger-pointing. GRSI takes full
24x7x365 responsibility for the functionality, throughput, and uptime of its systems. GRSI writes a meticulously crafted functional
specification document for every client detailing the entire system’s processes, messages, layouts, communications, data
transfers, screen shots, and more.

FastTrak WM+ is an extremely flexible software suite that manages all warehouse processes, subsystems, and equipment with
complete visibility. The benefits of an integrated and streamlined system include:
- Increased throughput - Quick troubleshooting and support times
- Expandable and upgradable - Less operator training
- Decreased bottlenecks - Equipment runs at its full potential
- No finger-pointing - Maximize system uptime

Last-100-foot (L1FTM) packaging system

8
 Warehouse management system (WMS)
ERP/WMS integration Inventory management
FastTrak WMS interfaces to many ERP systems using FastTrak WMS inventory management features include
single-port connectivity. Some ERP systems include: inventory forecasting, allocation, receiving, stocking, check-
• SAP • Great Plains in, labeling, and tracking. It identifies and allocates inbound
• Sage • PeopleSoft inventory to the required areas of the warehouse and tracks
• Epicor • Homegrown its location. The inventory can be arranged and assigned
• Oracle • Microsoft by customer specific business rules, lot numbers, weight,
• JD Edwards • and others dimensions, fragility, cost, and others. This allows product
to be appropriately distributed to its proper location.
FastTrak WMS also enhances the functionality, speed, and
system controls of existing WMS systems. It interfaces FastTrak WMS utilizes multiple inventory and labor zones
to numerous WMS systems via single-port connectivity to provide batching, waving, waveless operating, picking
including: and passing, sequential picking, and replenishing.
• RedPrairie • HighJump
• Accellos • Legacy Recording and tracking inventory usage is critical for
• Infor • Homegrown replenishment. FastTrak WMS identifies and notifies
• Manhattan • and others operators, self-guided robots, AS/RS equipment, and
other in-motion inventory equipment when inventory is
FastTrak WMS and the ERP communicate order, inventory, running low. It provides the necessary tools and visibility to
and customer data through seamless integration. identify physical locations of static and in-motion inventory.
Replenishment times can vary throughout the day, week,
Equipment – AS/RS and and during peak and non-peak seasons. FastTrak analyzes

goods-to-man specialization inventory and resource usage, inventory locations, picking

requirements, and future workloads to replenish necessary
Software AND hardware integration is essential. FastTrak
inventory. FastTrak is highly flexible and customized to
WMS coordinates and controls all material handling
handle customer-specific requirements.
equipment from any supplier into one cohesive unit. It
allocates the necessary resources for optimal throughput
performance. The software can interface to pick/put-to-
light modules, voice picking, and RF devices. It is the
Batches
ideal software to manage AS/RS, in-motion inventory, and
Orders
goods-to-man operations. Its ability to control carousels,
Parcel
unit loaders, sorting transfer vehicles (STV), automatic
guided vehicles (AGV), vertical lift modules (VLM), and Items
other AS/RS greatly improve stock organization and
inventory flow.

History

9
RFID
FastTrak interfaces with RF access points to communicate
information from scanned RF tags throughout the
warehouse. Item and order movement is tracked and
recorded by FastTrak. RFID increases visibility and enables
clients to wirelessly track items.
Displays
Kitting
FastTrak WMS consolidates items originating from different
areas of the warehouse to fulfill and complete orders. It
releases batches to multiple picking operations to fulfill
these orders in a timely manner.
Returned orders
FastTrak WMS allows returned orders (RMAs) to be
received back into the warehouse and generates the proper
paperwork for the order. Returned items may be designated
to a specific area of the warehouse.
FastTrak incorporates user-friendly HMIs, dashboards,
reporting, and troubleshooting tools. Operators can view
the location of orders, error messages, and workflow
data using these screens. Notifications are browser
based and accessible by any PC or cell phone with
Internet connectivity. Management is able to remotely

Picking technologies analyze reporting data to see operator efficiency and

perform benchmark comparisons. The error percentages,
FastTrak WMS and OMS work to efficiently manage
throughput rates, transactional data, and order information
various picking technologies including pick-to-light
are also available for viewing.
and RF, paper, and voice picking. FastTrak can batch,
superbatch (batching of single-item orders, which is ideal
for e-commerce solutions), and wave items for maximum
Cartonization
FastTrak includes cartonization software that uses SKU
performance. FastTrak also records inventory and
and order data with business rules to make improved
manages replenishment.
packaging decisions. It examines the dimensions, fragility,
weight, position, and special needs of each item in an order
and the interaction of items in the order to determine the
order’s packaging requirements. The software selects the
best suited packaging available using material inventory
data. Cartonization lowers material and freight costs,
decreases order returns, reduces labor, and increases
throughput.
Slotting
The slotting process improves picking productivity,
reduces “walk” labor, provides space utilization, improves
replenishment, and adjusts for peak and seasonal
demands. It manages multiple locations for the same
SKU and provides lot and serial number controls. It is
an organization tool, which complements replenishment,
picking, and packing. This provides a significant number
of cost-reduction scenarios when integrated with GRSI’s
cartonization and shipping programs. Graphic and
history displays, report verifications, SKU history, slot
management, and alerts provide a tool to manage and Scanning the volume of

grow within the size limitations of each client’s distribution the order using DimScanTM

center.
10
 Warehouse management system (WMS)
ASN
FastTrak links orders to advance shipping notices
(ASNs) in the standard EDI format. The ASN contains
order, customer, and shipment information. The ASN is
communicated to appropriate distributors and customers
during the shipment process.

Shipping and manifesting

FastTrak WMS works as a middleware that interfaces to
shipping systems, ERPs, or existing WMSs. It records and
communicates order, shipping, cost, tracking, carrier, and
address information between the systems. It connects to
various shipping systems including UPS, FedEx, USPS,
Clippership, DHL, Purolator, Canadian Post, and multi-
carrier software including Logicor, CMS Worldlink, Agile,
Pitney Bowes, and others. GRSI provides a wide range of
manifesting solutions with direct connection to all carriers.

In addition to managing the information flow, FastTrak also

controls all equipment involved with shipping operations
including weighing, calculated void-fill inserting, shipping
label printing and applying, and carrier sorting.

FastTrak WMS provides the central software module and

interfaces with 3PL providers, outsource operations, and
distribution networks with warehouses that span multiple
facilities. The software is also highly involved with reverse
logistics management.

11
 Warehouse control system (WCS)
Main screen
The WCS main screen is a data-oriented view of
warehouse operations. Users can view the flow of
individual parcels through each subsystem, interactions
between FastTrak and the host system, and transactions
involving automated and computer-aided processes.
Dropdown menus
Users can access configuration, diagnostic, and reporting
tools from the drop down menus on the main screen.
Buttons, indicators, and
statistics
Using the buttons on the bottom of the main screen, users
can start, stop, and pause subsystems with the click of a
mouse. The status of each subsystem is displayed using
a three-color code. Underneath the buttons are real-time
performance statistics.
Process logs
Each action performed by the automation system upon a
container (parcel, tote, package, pallet, etc...) is recorded.
Actions might include transfer of a container into a pick
zone or sorting of a package to a shipping lane. The
unique identification of the container, specific location of
the action, action detail, time stamp, and process duration
are displayed on screen for routine monitoring. This data is
also recorded for subsequent reporting and auditing.
Transaction logs
Radio frequency scan and voice transactions, as well
as pick/put-to-light transactions are recorded. The data
describing each
transaction is available
on screen for routine
monitoring and is
also recorded for
subsequent reporting
and auditing.
Exception log
Any automation process or transactional error that results
in exception handling by a machine or an operator is
recorded. The exception data is displayed on screen to
help in resolution of specific exceptions. In addition, the
on-screen data is used as an aid for identifying trends
that represent reoccurring system performance or data
problems.
12
 Tools
Configuration Browser based messaging
Users can configure key operational characteristics Custom notification levels alert users about system
including timeouts, error count thresholds, and heartbeat events and errors. Messages with configurable wording
intervals. and multilingual support are sent when processes
are completed, started, or stopped; errors occur; or
performance lags behind a set threshold. Notifications are
browser based and accessible remotely by any computer or
mobile device with internet connectivity.

Host interface
FastTrak is able to connect to any ERP or WMS host
operating on any platform. This powerful connection
features configurable source and destination endpoints
using TCP/IP sockets, FTP, shared tables, and remote
function calls.

Diagnostic and messaging

Diagnostic tools allow users to view critical operational data
including communication between FastTrak and PLCs, and
communication between FastTrak and the host system.
Tests can diagnoses issues with digital I/O, serial, and
socket communication.

Monitor system
operations with a PDA
or smartphone!

13
Human machine interface Dashboard
( HMI ) The dashboard is a graphic representation of pending
versus processed workload. Users can allocate work by
HMIs display a graphic warehouse representation that
dragging and dropping tasks to different resources.
shows real-time behavior of each subsystem, details about
each parcel, and process performance. HMIs allow users
to monitor and control operations.

Spreadsheet reporting
All process, transaction, and exception log data is available
as spreadsheet reports. These reports can be used for a
wide range of purposes including operator productivity,
machine performance reliability, audit trails, inventory, and
shipments. Reports are created by stored procedure calls
to the FastTrak database from within the spreadsheet
environment. A wide range of standard reports are
available as well as custom reports to meet specific user
requirements.

14
 Order management system (OMS)
Real-time data
OMS interfaces with the host in a fashion that assures
dynamic order, SKU, and replenishment data is current.
Drill downs
The OMS main screen shows active batches and their
progress. Batches drill down to individual orders and items.
Parcel data is accessible by right-clicking any item. Historic

Batching data shows the movement of items from picking to packing

Batches are designed either to accomplish an immediate to shipping.

business requirement such as consolidation of priority

shipment orders, or to provide an efficient pick walk path
through a limited region of the warehouse. Batches can
be designed based on custom criteria including shipping
carrier, packaging type, or pick cart/truck capacity. Batches

Orders
Parcel
Items

History

Super batches
Super batching is a labor effective method to pick large
quantities of single-piece orders. When items picked
in a super batch reach the outbound process, FastTrak
automatically assigns individual pieces to an outstanding Inventory
order using a reverse lookup. FastTrak inventory management supports rules-based
putaway, replenishment, and picking. These sophisticated
Sorting, wave, and waveless activities are tailored to optimize the use of complex

management automated material handling pick areas and conveyor

routing between them. Tasks are interleaved as appropriate,
FastTrak coordinates wave and waveless picking by
and idle machine time is used for routine counting and re-
assigning pickers to designated zones of a warehouse.
stocking. FastTrak cartonization breaks multi-carton orders
Picked items from different zones are consolidated into
into a carton fulfillment plan that minimizes pick area visits
their respective orders downstream. Waveless picking and
for each individual carton of the order. Cartons are released
sorting provides a streamlined flow of orders through the
to balance workload amongst the pick areas. FastTrak
distribution center. Consolidation can be accomplished
provides automated post-pick carton consolidation.
using a wide range of high-speed sorting technologies or
pick/put-to-light systems.

15
Cartonization
Cartonization decreases material, labor, and freight, cost with sustainable solutions. Cartonization is designed to analyze
orders and automatically determine their packaging needs based on business rules. For each order, the associated costs,
benefits, and sustainability of all possible packaging options are analyzed to create a cost model. The model compares
the cost of packaging materials, labor, equipment, freight, damage claims, and other related costs from picking to delivery.
These factors and the client’s goals guide the cartonization system to make packaging decisions for each order. Using
software to make these important packaging decisions takes the
pressure off operators, improving throughput and consistency.
The cartonization system is able to determine packaging
needs as soon as orders are placed, so picking
and consumables replenishment can be done with
complete packaging foresight. To make these decisions,
FastTrak determines and stores essential item information.
Basic information is gathered via a dimensioning and
weighing system. Additional data, based on business
rules, is fully customizable for each item. Some of the
data the cartonizaton system analyzes includes:

• Dimensions (LxWxH) • Business rules

• Weight - High-end item
• Fragility scale - Priority customer

Inform, automate, coordinate, integrate, and manage

• Receiving
• Stocking
• Picking
• Packing
• Shipping
• Sortation
• Packaging automation
• Conveyor routing
• Advanced shipping notice
• RFID
• In-motion order fulfillment
• In-motion print and apply
• In motion manifesting

16
 Packaging integration (PI)
In-motion packaging system
GRSI integrates all L1FTM functions including product, pack list, and document inserting; scanning and tracking; conveyor
routing; carton closing and taping; shipping label printing, applying, verifying, and manifesting; and shipping carrier sorting.
FastTrak coordinates all operations into a streamlined in-motion packaging system.

Carton closing
and taping
Dynamic document insertion
Cold seal
induction

Shipping label printing,

applying, and verifying

Pack list insertion and

verification

Cartons with LPN bar

codes
Cartons are automatically erected, each with
a unique license plate number (LPN) bar
code. FastTrak uses this unique LPN to track
packages throughout processing.
Carton induction
Picked orders arrive at carton
induction. An operator scans each
order’s bar code and scans the
carton’s LPN. FastTrak associates the
carton with the order.

17
Cold seal line
When multi-piece orders arrive at the cold seal line, the operator scans each order’s bar code and FastTrak associates the
order with an LPN printed on the cold seal substrate. The order is wrapped in the cold seal substrate and identified by its
LPN during subsequent processing. For single piece orders, the item bar code is scanned and FastTrak uses a reverse
lookup to associate the item with an outstanding order.

Merge
Sealed cartons are merged
with cold-seal orders for
shipping operations.

Shipping carrier sorting

In-motion weiging and

scanning

Void fill and sealing Shipping label printing,

An operator inserts the proper
amount of void fill. The carton is
conveyed to an automated carton
sealer.
Integration made easy
applying, and verifying
Final packaging and shipping
Sealed orders are conveyed to an in-motion scale and
scanner. The order is weighed and its LPN is scanned.
Using the weight, FastTrak generates the appropriate
shipping label and the order is conveyed to a shipping
label printer applicator where the proper label is applied.
FastTrak scans the label to verify the integrity of its content
TM

and the order is conveyed to a shipping sorter.

18
Contact us for more information:
610-397-1050
solutions@grsinc.com

FastTrak WM+
®

Warehouse management and control plus (WM+)

Integration made easy TM

Glen Road Systems, Inc.

401 East Elm Street, Suite 100
Conshohocken, PA 19428 www.grsinc.com
610-397-1050
© 2010 Glen Road Systems, Inc. All rights reserved.