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Carton or Tote Driven Distribution Centre

In many distribution centres the client would like to pick product directly into barcode labelled cartons or totes.

The carton and tote driven model again makes use of all standard DATASCOPE WMS functionality as described in the Simple DC model but during the picking process it differs.

As pick slips are released the software will either ask the user to assign a carton or tote. All items picked are scanning onto this carton or tote. Once full, the picker will simply select “next carton” or “next tote”.

At the checkout stage one of two checkout processes can be implemented. One is a mass based check where each carton or tote is simply mass checked to confirm the content. When the product is of a high value we can implement a SKU based mass check. Here every stock item is unpacked and mass checked. The second option is a key board wedge scanned check. Each carton or tote is placed on a scale and the mass checked. Then the software expects the user to scan every item in this carton as a second check.

Once all cartons or totes linked to this order have been checked the software prompts the checker to complete and invoice the order. The invoicing takes place automatically in SYSPRO and the invoice documentation is printed to the correct checkout station. At this point detailed delivery carton labels and a packing slip is printed.

The completed order is handed over to the LSP (Logistics services provider) and at the same time the DATASCOPE WMS software passes over the orders details in a web service connection.

Click on each module/hardware component listed below to find out more...

WMS Modules
FOUNDATION CUSTOMER RETURNS SUPPLY CHAIN TRANSFERS (SCT/GIT)
SYSTEM ADMINISTRATION STOCK TAKE & CYCLE COUNTS MASS BASED PICKING
MULTI COMPANY WORK IN PROGRESS LABELLING
INBOUND RECEIPTS QUALITY CONTROL FACTORY FLOOR
WAREHOUSE MOVEMENTS CHECKOUT AUDIT ASSET REGISTER
OUTBOUND PICKING LANDED COST TRACKING VOICE PICKING
LOAD PLANNING LOT TRACEABILITY RFID
EDI CUSTOMER TRADING SERIAL TRACKING KPI DASHBOARD & REPORTING

Colour Legend:
M Mandatory O Optional NA Not Applicable

IndustryHardwareWidgetModule

  Recommended Hardware Requirements

CK3 Mobile Handheld

The Intermec CK3 mobile computer has a broad range of data collection and communication features, enabling it to adapt to a variety of in-premise applications. The CK3 assists businesses to improve their operational performance metrics, simplify IT support and control operating costs.


Intermec PD42 Printer

A member of the smartest bar code printer family on the market, the Intermec PD42 is flexible and programmable, enabling customers to optimize their printing operations, streamline deployment, and achieve a quick return on investment

The PD42's graphical display allows users to set up, configure and fine tune printing parameters without having to send commands through the host, saving time. An open design makes media loading quick and easy, and the print head can easily be replaced without tools.


Cisco Wireless Access Points

We make use of the best Cisco wireless hardware to keep your scanners connected. Our standard wireless hardware is a combination of the AiroNet series Cisco Access Points (APs) coupled with Cisco 2.4GHZ high gain antennas


Honeywell Bluetooth Scanner

Honeywell’s Voyager™ hand-held laser barcode scanner incorporates the freedom of Bluetooth® wireless technology and offers a field-replaceable battery that can be quickly and easily exchanged. The 1202g single-line wireless scanner delivers the aggressive linear barcode scanning that users have come to expect from the world-renowned Voyager family of scanners. Read even the poorest quality barcodes with advanced laser scanning technology that only Honeywell can deliver.


RFID Tag and Readers
Our Kanban system utilises the latest RFID technology. Kanban cards have embedded RFID tags. These tags are read and written to by state of the art RFID equipment. Optional integration with LED status indicators provides valuable feedback on reading of cards.

Vocollect Voice TalkMan Devices

The Vocollect Talkman® A500 is an extensible voice-centric mobile computing voice appliance that enables high-performance, hands-free, and eyes-free workflows.
Vocollect’s A730 device contains an integrated short-range scanner, which enables workers to use both voice direction and scanning to fully optimize a process in an ergonomic, wearable form factor that eliminates workers from having to deal with a luggable device.


Intermec PX4i Printer

A member of the smartest bar code printer family on the market, the PX4i is flexible and programmable, enabling customers to optimize their printing operations, streamline deployment, and achieve quick return on investment. Built to meet the needs of round-the-clock, mission-critical applications, the rugged PX4i delivers advanced connectivity and network protocols, ensuring peace-of-mind today and a reliable, scalable solution for the long haul.

ModuleInfo

DATASCOPE WMS enables businesses to process almost all possible receipting transactions via this module. From scanner based purchase receipting to LCT receipts and job receipts plus many more. Some of the many receipting options are displayed below.

Purchase receipting

A WMS module similar to the standard SYSPRO purchase receipting module allows the receiving department the ability to process all normal purchase receipts for stock items directly into the WMS system. These transactions automatically update SYSPRO, creating the GRN while automatically allocating the product with uniquely numbered bar-coded labels.

Scanner based purchase receipting

Where a level of standardization is achieved on incoming stock barcode labels, the scanner based receipting can be implemented to speed up the capture, posting and label printing. As is the case throughout the system, unique package tracking ID numbering is implemented.

Mass Check

In the case where a company receives raw materials in a mass based unit of measure, there is often a need to weigh off received pallets to ensure that the physical mass corresponds with the delivery note. This software module forces selected products through a mass check before final acceptance into stock.

2D Barcode Receipting

Where stock entering the receipting area is consistently labelled with predefined 2D barcode labels (e.g. from the client’s own manufacturing facility), two types of 2D scanner-based receipting processes can be used to either warehouse transfer or purchase order receipt the stock into WMS. The 2D barcode design is set up in WMS and can be printed directly from the WMS software.

LCT receipting

The system has functionality to process LCT (Landed Cost Tracking) receipts. A variance reporting system ensures that the receipted products and the LCT shipment details match. The GRN process is automatically posted from this module and bar-coded pallet (Track ID) labels printed.

Supply chain transfers

Receipting of supply chain transfers (GITs) from other branches is available. This module controls product leaving one warehouse and entering another. A GIT transfer document accompanies the goods.

Quality module

A new comprehensive quality module now forms part of the WMS software suite. The module works for purchased materials as well as made-in items. Product tests and tolerances can be set. Inspection items will require the correct inspection tests before the batch can be released. All in inspection stock is placed on hold and cannot be used in jobs or sales orders.

DATASCOPE WMS enables businesses to process almost all possible outbound transactions via this module. From job and sales order picking to supply chain transfers and simple warehouse movements. Core to this set of modules is the functionality to pick product for sales orders and jobs using many different picking strategies.

Stock reservation management

The WMS has been designed to manage all stock allocation (reservation) control. This allows the system to prioritise the selection of stock on a FIFO basis while allowing the user to optimise the picking movements through the warehouse. Three main types of pick slip release and stock reservation are offered:

  1. A monitor which automatically releases the picks for sales orders and jobs and reserves stock based on system settings;
  2. Various user sales order and job review and release functions where the user can select optimal package sizes from optimal locations in the warehouse and
  3. Printing of pick slips according to loads and routes via the Load Planning module.

Picking rules

Numerous picking strategies can be selected. Some of the options are as follows:

>> Pick from pickface
>> Pick from bulk then pick face (or vice versa)
>> Pick from reach truck, bulk and pickface and consolidate
>> Pick from bulk, but if less than a setting
percentage of available stock, pick from pickface
>> Picking into boxes with box control
>> Replenish pickface
>> Pick from FIFO (first in first out)
>> Pick from default bin
>> Pick from optimal location
>> Pick from user selections
>> Automated carton cubing algorithms
>> Pick according to lot expiry date
>> Pick according to routes per customer
>> Special packing rules
>> Picking per route
Over and under picking

Over and under picking tolerances can be set at four levels: (1) At the order release and stock reservation stages the software can be configured to allow over and under release of sales orders and jobs; (2) At picking detailed line level, the scanners can be controlled to allow over and under picking as a percentage of the pick instruction; (3) At completed picking level, a percentage tolerance can be set and (4) Over and under picking tolerances can be set by warehouse.

Picking review

A comprehensive picking slip review screen is available to monitor the progress of picks in each warehouse. Various time settings can be applied to highlight overdue picks and drive warehouse efficiencies.

Every picking slip maintains a date and time history of the following statuses:

> Created > Printed > Assigned > Started > Picked > Checked> Invoiced > Loaded > Dispatched > Complete

Automatic Invoicing

If the automatic invoicing option is switched on within the WMS, at a pre-defined point in the picking or checkout process, the WMS software will automatically ship the picked or checked stock in SYSPRO and initiate an invoice print, using the company’s standard invoicing stationery. Yet another system option to streamline and automate the distribution process. Certificates Of Analysis (COAs) can also be automatically printed along with the invoice.

Material Handling Equipment (MHE) Control

Different MHE Types can be defined in WMS (e.g. Forklift or Man-Up) and these MHE’s can be allocated to certain zones or areas in the warehouse. A predefined allocation rule exists which will reserve cartons against the different MHE Types so multiple pickers can pick the same pickslip for different areas of the warehouse. This is useful when planning warehouse resource.

Conveyor Integration

DATASCOPE WMS can be integrated into certain conveyor systems to assist in automated warehouse stock control. Induction of cartons into the conveyor system is managed by the WMS and in-line scanners on the conveyor use the carton’s 2D barcodes to direct and manage the flow of picking through the warehouse. Coupled with voice-directed work, this option can dramatically increase the efficiency of picking.

EDI trading

A full customer trading solution allows for electronic trading with high volume customers. This module manages all EDI incoming sales orders into SYSPRO with stock code and customer verification. New orders are shown in a summary view before being released as picking slips. Price and stock availability issues are automatically highlighted. Only invoicing the order the EDI module automatically generates the required invoice XML file which is sent to the customer.

Checkout audit

The Checkout audit module is used in environments where a high level of dispatch verification is required. There are two modes of check out audit available. (1) A company will implement a standard picking strategy and then force all completed picks through a set of check out stations or “tills”. With product moving through these checkout stations, it ensures that every picked item is scanned a second time to ensure a 100% delivery accuracy. At the end of this mode, a Packing List and box labels can be automatically printed. (2) Alternatively, all completed picks can be rescanned using the scanner-based checkout audit module. This requires each and every stockcode and quantity to be double-checked. Only a 100% checkout audit passes through to the invoicing stage. Individual carton checkout is also available.

Load Planning

A colour-coded route and load planning module allows for distribution orders to be assigned to a route with truck and driver details. Based on the system setting, created pick slips can either first be load-planned and then released to the floor for consolidated route picking when the routes are optimised.

Truck Loading

Once the invoices are printed from SYSPRO, these can be scanned onto the truck. Should the truck return in the evening without completing all deliveries, the software allows the invoices to be scanned back off the truck and these immediately re-appear on the load planning schedule for the following day. Uniquely-numbered Actual Trip Sheets can be generated from the Load Planning module after Truck Loading.

Unloading & Credit Note Control

Should goods be returned for redelivery, a scanner-based Unload transaction can be done. This ensures the pickslip is returned to the original route for re-loading. Functionality exists to process Credit Notes into SYSPRO for goods that are returned by customers.

DATASCOPE WMS includes detailed functionality to process all typical warehouse transactions such as bin transfers, stock adjustments, cycle counts and general stock takes.

General scanner movements

The scanner application holds functionality to process all of the following stock transactions:

>> Bin to bin transfers
>> Warehouse transfers
>> Product pack away transactions
>> Backflushing for jobs
>> Inventory adjustments
>> Alternate stock replacements
>> General stock queries by bin, pallet or stock code
>> GIT (Goods In Transit)
>> Palletization and depalletization transactions
>> Ad hoc expense Issues to specific GL accounts
Stock take & cycle count module

The stock take module is comprehensive and improves accuracy and speed. Typical stock take time reductions from manual counts are between 75% and 85%. Companies traditionally taking entire weekends to count their warehouse now stock take in a single afternoon.

Various settings to count open and closed pallets and product in remote “off-line” warehouses are available.

A comprehensive cycle counting module can be used to complete regular cycle counts at bin level. An approval process is in place to control the acceptance of variances and all count details, accepted and reject, are held in a history table.

The cycle counting and stock counting modules both support 2D barcode scanning.

Job Labelling

Bar-code labelling of job cards, pallets on the factory floor, general product and box labelling have all been catered for.

Job release

In many high-volume manufacturing environments the planning department releases jobs to the floor for picking when in fact some components are not available. This causes untold “wheel spin” in the warehouse. The DATASCOPE WMS job releasing module ensures that every job is reviewed and allocated correctly before the picking slip can be released. This review screen also allows planners to see on hold stock in receiving or Inspection. A “component replace” function allows the planner to substitute components with recognized alternatives when stock is not available.

Job picking

The standard WMS system’s picking functionality includes the management of job picking with a number of picking strategies. Options allow for effective control of the picking process to ensure a pre-set level of accuracy. A number of levels of tolerance management is available from ‘issue anything you want’ to a 100% accurate pick. Split warehouse picking is also available in the job picking module - allowing you to pick two warehouses simultaneously and marry the picked products in the marshaling area (e.g. bulk bags from one warehouse and part bags from a pickface warehouse).

Massed-based picking

The massed-based picking module can be used in conjunction with integrated scales to accurately pick small quantities of stock. Tolerances can be set up and the associated reports are available for this module.

Job receipting

PC-based and scanner-based job receipting applications allow for efficient product receipting at any level of the bill of material. Kit issue, bulk stock and floor stock items are managed throughout. Kit issuing at the time of receipt is a setting option and can be activated at any time. Some advances cost comparison and cost override options are available.

Factory floor labour posting

The factory floor module has been developed to capture labour postings into SYSPRO directly from the factory floor. This module is deployed to touch screen PC’s at key capture points on the factory floor. Typical installation areas are at constraint machines, at the start and finish of each BOM operation, at existing weigh-off points and at logical stocking areas.

The module is particularly effective at enforcing WIP tracking data accuracy and process control. Companies looking to implement advanced planning systems which use real time job operation data will benefit from this module.

Bin labelling

Bin labelling structures can be agreed and implemented easily. Bins are catagorised into the following types and are handled differently in the system depending on the settings selected:
>> Pick face >> Bulk bin >> Reach truck >> Receipting marshalling bin

General labelling

Bin labeling, box labelling, job card labelling, general stock labelling etc are all available in the software. Each label format is created in Crystal Reports from a set of standard labels. Changes to these label designs are simple and can be administered by the on-site IT department.

Management dashboard

A detailed management KPI efficiency dashboard is available, graphically displaying progress on the floor.

DATASCOPE WMS – QUERIES & REPORTS

There are a growing number of standard DATASCOPE WMS reports and queries, used to identify efficiencies within the warehouse. These reports are very versatile and user-friendly, allowing users to access information, sort in various forms, and distribute the information in a number of different output types. Furthermore, a comprehensive Notification System assists with instant messaging within the warehouse.

Grid formats

All WMS queries and reports are professionally displayed in versatile grid formats with drag and drop functionality. The column headings are very customisable, can be sized and moved to suit the user and arranged to filter and pivot the information. A number of run-time parameters are available for each report to filter the required data easily. The reports are refreshable, ensuring that accurate, up-to-date information is available to the user at the click of a button. All the WMS data grids are able to be exported to MS Excel, exported and saved as a PDF document or printed directly to the user’s default Windows printer.

Queries & Reports

A host of varying reports exist within the core software. A few examples: >> Track ID History - a history of all movements on a pallet >> Balance Report - a validation between SYSPRO and WMS stock quantities >> Pickface Replenishment Review - a list of all pickface replenishments and their status >> Information Check - used to query pallets, bins or stockcodes >> Cycle Count History - a history of cycle counts within a date range >> SYSPRO Inventory Movement Report - a list of transactions processed directly through SYSPRO, bypassing WMS

Statistical Reporting

A key benefit of implementing DATASCOPE WMS is the immediate access to accurate on-the-floor information. The statistical reports within WMS provide valuable insight to the activity on the floor. Two key reports exist: (1) Picking Statistics Report, giving picker efficiencies, fill rate, lines picked for date ranges and (2) Replenishment Statistics Report, giving replenishment efficiencies. The data from these reports can be graphically represented for display in the warehouse.

DATASCOPE WMS – ADMINISTRATION

The DATASCOPE WMS is highly parameter driven to allow for successful operation in many different environments. These environments may be different companies or industries or may be different warehouses on a single site.

System settings

All key settings are parameter driven on two levels namely: system wide and at warehouse level. Printer setup and configuration is administered centrally.

System deployment

The software comprises of four main components: the server core-install, various server services, the client install and the scanner install.

Version upgrades are free for all clients paying annual license fees and these are released quarterly. The upgrade process is simple, as ClickOnce technology automatically upgrades the client PC’s when a new version is released onto the server. Scanners then auto-heal too.

System securities

As each user in the WMS is a named user in SYSPRO, all standard security functionality in SYSPRO immediately applies. For instance, if an operator is prevented from transacting in a certain warehouse in SYSPRO, the WMS system will not allow a transaction in this warehouse. Every transaction posted to SYSPRO holds the correct user’s name and therefore gives a detailed audit trail. Additional to the SYSPRO security settings, many security over-ride settings are available in the WMS system.

System documentation

The WMS has a comprehensive on-line help function. All system setting options, functionality and technical specifications are detailed. Almost all frequently asked questions can be answered in the on-line help.

Manufacture of automotive components is a fast-paced process that requires a high level of accuracy, simultaneously giving the speed required for the large volumes of transactions. The DATASCOPE WMS RFID (radio frequency identification) module can be implemented to assist with this. At strategic positions in the facility, RFID readers are placed and Kanban-type production cards are used to backflush the manufactured automotive parts into SYSPRO quickly and easily. Using Kanban stock management with WMS and RFID will greatly enhance your facility and will provide valuable tools to the client to control stock accurately (with the speed required).

The DATASCOPE warehousing solution (WMS) has been built specifically for operation with SYSPRO ERP and therefore is highly integrated into SYSPRO via the standard SYSPRO E.NET object layer. Although the WMS has its own MS SQL database, it holds the bulk of its data in the standard SYSPRO tables. The software therefore acts as an intelligent layer between the warehouse factory floor operations (mobile devices) and core SYSPRO.

Over the past seven years DATASCOPE has invested heavily into this software suite thus building a plug and play solution for almost all SYSPRO distribution and manufacturing companies. The software is completely settings driven and can therefore easily be configured to operate in many environments.

All transactions within the WMS are posted live into SYSPRO and are security controlled based on named users. Each transaction requires an operator login which authenticates all standard SYSPRO securities and logs the user name against every transaction posted to SYSPRO. Further, the system maintains a detailed operator log file of key security overrides. The software has been developed in the latest .Net development tools. All grid screens can be dynamically filtered and exported to MS Excel, converted to PDF or printed directly. ClickOnce deployment technology is used for deployment and upgrades and all software is strictly version controlled. Updates to the software are covered in the standard annual license fee structure.

NOTIFICATION SYSTEM

A detailed Notification System is built into the WMS, which allows instant messages to be sent from PC clients to a single or multiple list of scanner users. Notifications have three areas: (1) Template management, allowing the creation and modification of generic notification templates, (2) Inbox on the PC clients and scanners, displaying all new messages and (3) Outbox, displaying all sent items. Notifications can be created as “actionable” or as information messages only. Uses of these notifications include bins to cycle count, pallets to put away or move, etc.