The Kanban solution is an advanced solution developed for repetitive manufacturing operations which are looking to take their existing manual Kanban system to the next level.
All component warehouses, raw material warehouse and finished goods warehouses are operated as normal in the “traditional” WMS processes. In other words, PO receipt or Sales order picking is run in a normal WMS environment as described in the Simple DC model above.
The manufacturing process however are managed using RFID tagged Kanban cards. The high level transaction processing is managed in the software as follows:
Kanban Card Creation – The software allows a planning department to create new Kanban cards, assign RFID tags and configure the RFID tag to the specific card. Each Kanban card is actually just another TrackingID in the DATASCOPE WMS solution.
Kanban Board – The software allows the planning department to manage the number of Kanban cards on the various planning boards. By activating and inactivating cards the planners can increase or decrease the manufacture of inventory.
Machine based scanning – At each production machine or within close proximity to production units RFID readers are installed. As each machine produces another Kanban carton full of product, a Kanban card is placed in a sleeve on the Kanban carton and the carton is moved past the RFID reader. In many cases this reader is placed on the side of a slide/gravity conveyer. In other instances the Kanabn cards are taken off the cartons at a logical point and manually swiped at a RFID reader.
Every time a card is read at the RFID station it will process a backflush of product from a WIP warehouse in SYSPRO into a typical inventory controlled warehouse. This transaction also activates the Kanban card and updates its quantity to the standard Kanban pack size.
Picking – The picking of Kanban cards operates in the normal DATASCOPE WMS processes as each Kanban card is actually just another reusable TrackingID in the software.
Back to Planning Board – as soon as the product is picked for a sales order or to be used in the next production process, the card is removed from the product and is scanning in the planning office back to the planning board.
This solution should not be implemented unless the client already has an effective Kanban system in operation.
Click on each module/hardware component listed below to find out more...
|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|
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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.
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.
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.
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:
Numerous picking strategies can be selected. Some of the options are as follows:>> Pick from pickface
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 > CompleteAutomatic 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.
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.
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.
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.
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
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.
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.
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 structures can be agreed and implemented
easily. Bins are catagorised into the following types and
are handled differently in the system depending on the
>> Pick face >> Bulk bin >> Reach truck >> Receipting marshalling bin
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.
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 WMSStatistical 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.
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.