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Warehouse Management System
www.polarisretail.com | www.polaris.co.in
Introduction
Warehouse management is the art of movement and storage of materials throughout the warehouse.
Warehouse management monitors the progress of products through the warehouse. It involves the
physical warehouse infrastructure, tracking systems, and communication between product stations.
Warehouse management deals with receipt, storage and movement of goods usually finished goods and
includes functions like warehouse master record, item/ warehouse cross-reference lists and such things as
on hand, allocated, transfers in process, transfer in process, and transfer lead time, safety stock, and
fields for accumulating statistics by location.
A warehouse manager needs to perform several crucial functions such as overseeing and recording
deliveries and pickups, loading and unloading materials and supplies, maintaining inventory records and
tracking system, determining appropriate places for storage, rotating stock as needed and adjusting
inventory levels to reflect receipts and disbursements. An individual, who handles the warehouse
management, is required to have knowledge about inventory control and warehousing systems, loading
and unloading procedures, risky and materials storage and mathematical knowledge. For such user, the
Polaris Retail Infotech Ltd. WMS system will be an indispensable tool, for managing warehouses.
A warehouse management system is a critical component of an effective overall supply chain management
systems solution. The proposed Warehouse management system will be the core element to control
movement and storage of materials within a warehouse.
Envisioned for future usage and applicability, it could even incorporate incorporates tasks such as light
manufacturing, transportation management, order management, and entire accounting systems.
Complex warehousing environments usually manage inventory in variety of disparate facilities. Over time,
this would typically evolve into a non – federated structure where each facility employs different
operational processes and disparate system throughout the network. This environment is overwhelmed by
its inherent complexities and unmanaged operations. The fallout is lack of CENTRALIZED VISIBLITY and
INCREASED OWNERSHIP costs because of any or all of these:
i. Non automated environment
ii. Complex Systems Integration
iii. Warehouse processes not defined in system
iv. Entities and subjects of Warehouse are not mapped / recorded in system
To provide industry with as solution that has been dedicatedly created that will automate, streamline and
simplify all the operations of a typical warehouse. The proposed solution will be built according to:
a. functions and an according to processes defined in theory
b. Streamlining processes by extending best practices in industry or within the company to all
storage locations.
c. Stock Keeping Unit (SKU) distribution practices
d. Volumes handled
e. Item velocity
f. Material Storage Policies
g. Material Handling Equipment
Some of the focal areas of the WMS system are depicted by following diagram.
WMS/WCS
A WMS focuses on inventory from the time it arrives at the receiving dock to the time it leaves from the
shipping dock. The software knows where inventory is, orders it when needed and tracks its movement. A
WCS schedules, monitors and commands movement of inventory and tends to include some kind of
automated equipment control.
John T. Phelan* compared a WMS to a symphony’s composer who creates a musical score; the WCS is the
Conductor who directs the orchestral instrument players while performing the symphony in real-time. As
illustrated in the above diagram, WMS and WCS functions often overlap.
* John T. Phelan is COO of TriFactor LLC, a material handling systems integrator based in
Lakeland, FL.
1. Goods In
S. No Activity List Comments / Description
1 Product Received As products enter the warehouse, the Software
system automatically logs the date and time as well
as the supplier details against a unique product
reference. This begins the tracking process which
continues right through until the product leaves the
warehouse and is dispatched.
2 Quality Check and Supplier The software makes this process easy by attributing
any product issues directly with the unique reference
number allowing users to reference supplier and
delivery details.
3 Quarantine Any defective or low quality goods are quarantined to
allow you to manage your quality standards. Any
shed or stack area can be defined as quarantine.
4 Sampling Sampling can be done.
5 Stock Value Generate reports about STOCK VALUE.
2. Put Away
3. Stock Control
S. No Activity List Comments / Description
1 Location Status Access multiple product locations including the put
away and location of individual pallets or boxes
The software also enables to know individual product
at specific location (s).
2 Stock Consignment Software calculates overall stock and gives the ability
to have random and most efficient locations for stock,
offering the most flexible use of the warehouse.
3 Stock Movement Software enables stock to be moved around in the
warehouse providing efficient picking
4 Stock Rotation Software automatically lists the stock along with its
locations according to age, which enables multiple
stock rotation options including oldest product picked
first
4. Order Picking
S. No Activity List Comments / Description
1 Manual Pick The system generates a document that allows the
picker to choose what location to pick the product
from.
2 Pick Routing The software identifies most efficient PICK route and
creates the PICK INSTRUCTION document / Pick
Tickets
3 Batch Picking By running / applying specific PICK – ROUTE pattern,
the software enables the picker to pick multi-part
orders from one location increasing the efficiency and
speed of a pick.
4 Order Fulfillments The software assigns orders to picking zones for
efficient picking operation and consignment
5. Dispatch
S. No Activity List Comments / Description
1 Dispatching Automatic log profile of individual items to be
despatched. Allows full management of the despatch
process.
2 Dispatch Manifest System generates hard copy of items despatched
including amongst other things that despatched them
and the date and time they were despatched.
3 Weight and Volumetric Software stores and logs individual item weights and
Considerations therefore offer an indication of consignment weight.
Useful when working on a combined weight basis
4 Dispatch Note and delivery labeling System offers the facility to print despatch notes and
consignment labels and an option for automatic print
WMS
1. Warehouse Setup
1 Warehouse Define Warehouse
Define Floor Area
Define Volumetric and Tonnage capacity
2 Warehouse Structure Define physical structure of warehouse
Create Multi-blocs
Set Volumetric capacity and maximum cargo-hold capacity.
Create Special Blocs – Refrigerated, Fire protect, Hazardous
material storage, Temperature & Environment controlled
storage, Secure storage and many more standard types
Cost of storage
Minimum Cargo hold area / capacity
Minimum cost of storage
Optimum cost of storage
3 Storage Bins Create Storage Racks of various sizes and volumetric
specifications ; set dimensions
Create Multi- Level Racks
Create Rack Clusters
Create Palletized Storage Bins
4 Aisles and Storage Plan Create Aisles for traversals by order handlers
Map Aisles with Racks
Create Layout Plan
Replicate Aisles & Racks setup
Apply Standardized Numbering pattern on Aisle – Rack maps
5 Occupancy & Vacancy Know collateral occupancy and vacancies in terms of Volume
status and Weight
6 Staging Areas Define Staging Areas
Set STAGING capacity – Volume, and Weight
Set STAGING area floor space
7 Dock Doors Create Dock Doors
Link with Staging Areas and STORAGE areas
Realize ASN document at Dock Doors
Govern Entry of Inbound products to storages by routing
through specific Dock Doors.
Govern Exit of Outbound products from storages through
specific Dock Doors.
Automatic routing and shipper managed through dock door
according to shipment cargo type
WMS
2. Product Setup
1 Physical Characteristics Define Product specific to Warehouse storage
Define Volume, Dimensions, and Weight
Set as Volumetric Measurement or Weight Measurement or
both
Set storage, requisition Unit of Measures
Containerized Product creation
2 Special Attributes Palletized Product
FMCG product
Set to a standard type in industry – Metals, Apparels, Food
Grains, High Value and many more.
Special characteristics – Hazardous, Rain Protect
WMS – Inbound
3. PUT AWAY
1 PUTAWAY based on Conduct PUTAWAY based on Advance Shipment Notice
ASN Document On GRN
2 PUTAWAY Validation Automatically validate the Inward cargo with the vacant
capacity in storages
Automatically set products to PUTAWAY locations according to
matching done by:
– Product Type
– Product dimension
– Product Weight and Volume
WMS – Outbound
4. Requisition Management and Stock Release
1 Requisition Documents Handle Requisition from multiple sources :
– Customer
– Another Warehouse sites
– Shippers / Vendors
2 Requisition Consolidate multiple requisitions from same source
Consolidation Consolidate multiple requisitions from different sources
Auto- convert to Warehouse types – Products and Unit of
Measure
3 Validations for Automatically validate the requisitioned products and their
Fulfillment quantities for fulfillment.
Option to Reject, Modify or Accept with Shortfall in fulfillment.
4 Release orders Generate Release Orders for validated requisition.
Generate Release Orders for multiple customers in one go.
For a single requisition, conduct partial fulfillment by making
multiple Release Orders.
Set priority for products and create Priority Based Release
Orders
5 Batch Picking Create multiple Release Orders :
– Clustered by Product Type
– Clustered by Vendor’s Inventory
WMS – Outbound
5. PICK
1 Pick Area Selection Select locations to conduct PICK
Automatic guidance to select location according to
– Product Type
– Vendor Inventory
– Pick Area
2 Consolidate Pick Consolidate Pick Tickets
3 Generate Equipment Manage pick by associating Warehouse equipments – trolley,
Handlers instruction fork lifts, cranes etc.
4 Pick Tickets Print PICK Tickets
WMS – Inventory
6. PICK
1 Vacant – Occupancy Space Check
status – Vacant positions
– Occupied Positions
– On Threshold
2 Cross Docking Do cross docking
Space optimization
3 Inter Warehouse Inventory movement to internal locations
transfers (Pick and Put)
4 Container Containerized product creation
WMS – Reports
9. Some of the reports
1 Inventory Dispersal Inventory
Report – Vendor wise
– Storage Block Wise
– On Threshold
2 Occupancy / Vacancy Do cross docking
Space optimization
3 Scheduled Tasks Report Scheduled PICK report
Fig 1-a, 1-b --- The Login screen & Home Page of WMS system