Warehouse Picking Software

Better Inventory Flow with Warehouse Management Systems; Part 6 Replenishment Picking

In this final post, we will discuss Replenishment Picking.  All of these picking strategies are designed to gain warehouse inventory efficiency by selecting the best movement of goods in the most productive manner and part of any good “Best-In-Breed” Warehouse Management System, like AccellosOne WMS.

Replenishment Picking. Replenishment Picking combines the concepts of Batch Picking and the ReserveWarehouse employeeS scans informations from boxes in the warehouse.Storage/Forward Picking best practice. Reserve Storage/Forward Pick is the practice of segregating the warehouse into a storage (Reserve Storage) area and a picking (Forward Pick) area. This approach tends to optimize overall space utilization and pick labor productivity. Space utilization is improved by storing product in bulk (pallets or cases) in dense storage locations. Pick labor productivity is improved by keeping pickers working in smaller forward pick zones that typically hold smaller inventory volumes (days on hand vs. months on hand) with the inventory, eaches, or cases, in more easily accessible and ergonomically friendly locations referred to as the “strike” zones.

When using this approach it is common practice to setup a replenishment strategy to move inventory from the (reserve) storage locations into the forward pick locations. The timing of the replenishment activity is driven by a predetermined reorder point and the amount of inventory to replenish is typically driven by a pre-determined inventory level set at the forward pick location.

The same basic storage and picking principles apply when using Replenishment Picking – Forward Pick with minor variation to reorder point and quantity. With Replenishment Picking, a dedicated forward pick zone is setup to allow operators to work in a smaller area and the inventory is replenished from bulk reserve storage locations. However, replenishment quantity and timing is driven by the projected number of orders over a given time frame (typically a day). Once a group of orders for the day is created, the orders are replenished, in batch, to the forward pick area. At the end of the day, the forward pick area is picked clean and ready for the next pick cycle.

Another form of Replenishment Picking is replenishing to a pack station rather than a dedicated forward pick zone. In this process, all inventory for a group of orders is replenished in batch from reserve storage locations and deposited at a pack station. At the pack station, the inventory is picked to specific orders for shipment processing as outlined in the Batch Picking process.

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Posted by iCepts Technology Group, Inc. An Accellos Highjump WMS ReSeller

Better Inventory Flow with Warehouse Management Systems; Part 5 Picking

From order entry to fulfillment, Accellos One Warehouse works together with your ERP system to provide the end-to-end solution for the materials handling management and real-time inventory visibility throughout the enterprise.  Accellos One integrates with many popular ERP systems including the Microsoft Dynamics Suite of ERP Systems. The following highlights a high-level process flow, derived from a subset of available functionality within Accellos One Warehouse focusing on Picking:

The Accellos One Warehouse picking process needs to remain flexible to accommodate widely differing environments.  No two warehouse operations are exactly the same.  Warehouses come in different shapes and sizes. Some are “wide open” in a square shaped space.  Others are contained in buildings on multiple floorsworker holds package in warehouse of forwarding, utilizing elevators to transport materials.  Warehouses will have varying ceiling heights. Some might have yard space.

Materials handling will differ by product shape and size. As a result, the warehouse racking infrastructure will vary by product size.  Many warehouses keep large products in bulk stacks or pallet racks.  While with small products, picking efficiency may be increased by storing smaller products in flow racking or static shelving.

Product velocity and order types also affect warehouse layout and consequently the picking strategies.  Companies that ship single-sku pallets of product to customers will have significantly different warehouse operations than ones that ship trailer loads of mixed-sku pallets (grocery is a good example of this).

Even subtle differences in customer requirements for consumer products wholesalers will have substantial effects on the materials handling and picking. Operations that ship to retail distribution centers will have different fulfillment requirements than those that ship directly to stores.

Accellos One Warehouse has an abundance of picking styles that will accommodate a warehouse manager’s fulfillment strategy independent of warehouse layout, product size, velocity and order characteristics.

Download the entire White Paper: How Goods Flow Through the Warehouse

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How Does Accellos Warehouse Management (WMS) Work With Your ERP?

Watch the video below to see how Accellos warehouse works with your ERP such as Microsoft Dynamics, Sage ERP, NetSuite, and others.

Warehouse management systems software

ACCELLOSONE WAREHOUSE MANAGEMENT SYSTEM (WMS)

Download Accellos Warehouse Brochure Here

AccellosOne Warehouse consists of three editions designed to meet the demanding needs of customers from small to large.  The Collect Edition is aimed at the company looking to extend their paper processes to the wireless world.  Our Manage Edition is built for the organization that wants to start small, but has plans to expand their warehouse processes over time.  And, the Fulfill Edition is designed for the more sophisticated user that needs more control, automation and flexibility in their warehouse.

AccellosOne Warehouse integrates seamlessly with many popular accounting/order-entry packages, including Microsoft Dynamics, Sage, SAP and Infor ERP systems,  and shipping systems to provide the warehousing link in your total supply chain solution.  In addition, AccellosOne Warehouse integrates with the rest of the AccellosOne Supply Chain Suite, making sure all of your applications are getting the right information in real time.  Check out some of the white papers and case studies to see how AccellosOne Warehouse performs in the real world.  Each page has several options to connect with a knowledgeable consultant if you have questions.

ACCELLOSONE WAREHOUSE MANAGEMENT SYSTEM (WMS)

ACCELLOSONE WAREHOUSE MANAGEMENT SYSTEM (WMS)

Download Accellos Warehouse Brochure Here

AccellosOne Warehouse Management System acts as the hub of your supply chain solution, integrating accounting/order and shipping software systems, electronic data interchange (EDI) systems, Crystal Reports software, radio frequency and barcode hardware, and warehouse automation equipment. Combining radio frequency and barcode technology with a robust, three-tiered, Internet-based architecture, AccellosOne Warehouse delivers a powerful, scalable and flexible real-time warehouse management system that helps you boost productivity, reduce costs, shorten order fulfillment times, increase customer satisfaction and deliver a rapid return on investment (ROI).

AccellosOne WMS achieves this level of ROI through order accuracy, on time shipping, minimizing inventory carry costs, and decreasing labor costs.  Today’s warehouse managers are consistently finding that 2 to 5% improvement across various performance metrics can mean hundreds of thousands of dollars in bottom-line returns to the business.  Using AccellosOne Warehouse you are able to eliminate manual order checking by automating processes to improve your picking and receiving functions, allowing you to process more orders at a much higher level of accuracy.

AccellosOne Warehouse consists of three editions designed to meet the demanding needs of customers from small to large.  The Collect Edition is aimed at the company looking to extend their paper processes to the wireless world.  Our Manage Edition is built for the organization that wants to start small, but has plans to expand their warehouse processes over time.  And, the Fulfill Edition is designed for the more sophisticated user that needs more control, automation and flexibility in their warehouse.

AccellosOne Warehouse integrates seamlessly with many popular accounting/order-entry packages, including Microsoft Dynamics, Sage, SAP and Infor ERP systems,  and shipping systems to provide the warehousing link in your total supply chain solution.  In addition, AccellosOne Warehouse integrates with the rest of the AccellosOne Supply Chain Suite, making sure all of your applications are getting the right information in real time.  Check out some of the white papers and case studies to see how AccellosOne Warehouse performs in the real world.  Each page has several options to connect with a knowledgeable consultant if you have questions.

AccellosOne Warehouse Features and Benefits:

  • Minimize write-downs and write-offs
  • Integration platform between the warehouse and your ERP, order management, ecommerce or purchasing system(s)
  • Wireless Picking and Receiving
  • Order Management
  • Multi-Zone picking
  • Lots/Serial/Expiry management
  • Kitting
  • Container Receiving
  • License Plates
  • Carton Splitting
  • Putaway/Slotting
  • Multi-Location/Site Transfer
  • RMAs
  • Packaging Carousels/Conveyors
  • Multi-Company/3PL
  • Multi-Carrier Shipping Toolkit
  • RFID Toolkit

Better Inventory Flow with Warehouse Management Systems; Part 1-Receiving

From order entry to fulfillment, Accellos One Warehouse works together with your ERP system to provide the end-to-end solution for the materials handling management and real-time inventory visibility throughout the enterprise.  Accellos One integrates with many popular ERP systems including the Microsoft Dynamics Suite of ERP Systems.

This document highlights a high-level process flow, derived from a subset of available functionality within Accellos One Warehouse:

• Advanced multi-warehouse, multi-zone and multi-bin managementScanner-001Box3

• Automated goods-receipt processing

• Order management including advanced allocation and pick document distribution

• Pick bin replenishment

• Advanced pick and pack strategies for optimal warehouse performance

• Shipping

Once a purchase order has been entered into your ERP system, it is seamlessly transferred to the WWMS (Warehouse Management Software) where receivers await shipment.  They are armed with wireless mobile computers that have integrated bar code scanners.

After an inbound shipment arrives at the warehouse, the receiving team will typically unload the truck and grab the paperwork to identify which purchase orders are being received.

The first job of the WMS software is to receive items accurately into the warehouse and then reconcile the shipment against the original purchase orders entered into your ERP system.

Rather than using pen and paper to reconcile physical receipts, the receiver will bring up the purchase orders on a handheld computer. Once this is done, the receiver only needs to start identifying the product that is being unloaded (in no particular sequence).

With Accellos One Warehouse Management Systems, the receiver counts down against items being received right off of the container. It validates items against multiple purchase orders in the background, and then seamlessly updates your ERP system. No more paperwork!

Because a receipt is recorded as soon as items are entered into the handheld, stock may be immediately put away to a bin location.

Bin location assignment following receipt may be automatic; stock can be transferred to a temporary receiving location if receipts are to be staged prior to put-away.

Most of the time, stock will be put-away following goods receipt.  If there are backorders waiting for product (standard or non-stock) or there is a “low stock alert,” stock may be put away directly to pick locations. Otherwise, stock handlers will move pallets into bulk locations (typically up in the pallet racks or on floor stacks).

Whether you receive floor loaded containers from overseas or small shipments by common courier, Accellos One Warehouse has tools to enable accurate, efficient receiving:

• Receive multiple orders simultaneously in no sequence, without paperwork

• Scan product bar code or use quick lookup functions to identify products as they are being received

• Print carton or pallet-ID labels as product is being received

• Receive multiple pack-sizes on the fly.

• Cross-dock non-stock items to forward pick locations

• Immediately put product away without staging

Request the entire document at:

How Goods Move through a Warehouse Correctly 

Making Room In Your Warehouse

Space management is a big deal!  Your warehouse (or vault as I like to refer to it) has only so many square feet.  You need to utilize the space to its fullest potential.  In part 5 of my series of blogs on the 4 simple ways to pay for a warehouse management system I will discuss how a WMS (warehouse management system) can help you use your space and save you money.large warehouse

A WMS should improve space usage through improved inventory placement and tracking.  Because the WMS gives you a full view of your warehouse and where your items are, which ones are moving and which ones aren’t you can manipulate your stock with ease.  Putting the fast items in locations that are readily available for picking and replenishment.  You will have full visibility of where empty slots or bins are in order to put products away.  You can mix pallets and use pallet license plates to identify with one scan what is stored on the pallet in the slot it is assigned to.  This can be a big space saving technique.  Here are some other areas where savings can be derived

  • Eliminate existing overflow space  (this is usually a second location used solely to store items that won’t fit in your main location)
  • Reduced transport costs with elimination of overflow space
  • Avoid or greatly delay new construction of additional space or move to bigger space

When you can use the space you have more efficiently this allows you to reduce the space used for existing inventory.  Because a WMS allows you to reduce your on hand inventory levels this saves you money in carrying costs and purchases.

We had one customer put off the need to build on to their distribution center by nearly 4 years.  And when they did it was in order to do more fulfillment work which had a very positive impact on their profits.  Warehouse space is expensive so use what you have in the best possible way.  A WMS will certainly help you do this.

It a Matter of Time

Over the last 5 posts I have reviewed the 4 simple ways a WMS can be paid for.  The time for achieving a return on investment (ROI) of an investment in a warehouse management solution should be very short.  Many companies find that the system can pay for itself in as little as 6 to nine months.  A good average to plan on is 12 to 18 months.  Once you have reached the break even point all the found money flows directly to your bottom line and it can be thousands of dollars each month.  What could you do to grow your business with an extra 5 or 10 or 20,000 dollars each and every month.

Wouldn’t You Like to Know

As you can see a warehouse management solution reduces labor costs, improves space utilization and reduces inventory cost.  The big question to ask yourself is “By how much”.  Each business is different, you should investigate how a WMS would fit into you business.  We recommend that you work with a company with a great deal of experience in how a WMS works and how a warehouse operations functions.  We suggest engaging with a organization that will collect, compile and total all the information and provide you with a sound useful and believable ROI.  Once you have done this the decision to purchase and implement a WMS should be very clear.

Find out more about Warehouse Management Systems by contacting us here:

 

Improve Shipping Accuracy! (Part 4 of Four Simple Ways to Pay For a WMS)

Shipping accuracy to some companies is an oxymoron and to others a solid part of their business.  So what causes some to struggle and others to excel?  The accuracy of their pick and verification process.  Lets look a little closer.

I was talking with a prospect recently who shared with me that they shipped an average of 600 orders per day and 800 boxes.  He was very proud to tell me that they were 98.6% accurate on their shipping.  Now 98.6% sounds pretty good (especially in a busy disorganized paper driven warehouse) when you think of the fact that they ship 600 orders per day right.  I pointed out to him that means that about 8 orders go out wrong every day.  Industry statistics show it costs $200.00  to fix each mis-shipped order.  So if you do the math that’s $1600.00 per day for this prospect to cover the cost of their mistakes.  If you look at that over the course of one year the total is $83,200.  That’s a Problem.

 

A WMS will virtually eliminate the potential for making these mistakes.  By providing an accurate way to pick orders by scanning the barcodes and verifying the product  being picked is correct you gain tremendous accuracy.  By using a WMS to consolidate orders you can send fewer boxes and save shipping costs. By creating efficient pick paths and picking processes accuracy is increased dramatically.  Many companies find they can eliminate costly, time stealing check processes once a WMS has been implementing without increasing mistakes.  If the shipping process is integrated into the WMS shipping accuracy is improved and much more efficient.

Eliminating mistakes that go out the door to your customers will offset a large portion of the initial investment in a warehouse Management system like Accellos One Warehouse.  To learn more about how A1W can help a business be more profitable check out our dedicated website http://www.warehouse-management-systems-us.com/wp-admin/post-new.php.

Managing Your Labor Costs Pays Off

This is part 3 of my 5 part series on the four simple ways to pay for a warehouse management system. In the first part I listed the four ways and outlined each one.  In part two I covered how better control and accuracy of the inventory can save money and help pay for a WMS.  In part three I will discuss what is arguably your most important asset, your employees.

Here are a few points for you to consider; effectively managing labor costs in most businesses is difficult.  Labor costs account for a huge portion of your cost of doing business.  Arguably your staff in the warehouse can/will make or break your business.

Reducing or reallocating labor is the primary driver for finding the money to pay for a warehouse management solution.   A properly implemented WMS like Accellos One Warehouse can reduce your labor needs, help you reallocate staff and or keep you from needing to bring on more staff to meet growing sales or seasonal fluctuations.  More people mean more problems most of the time.  There is a long list of labor areas  that are strongly impacted by the implementation and use of best practices while deploying a WMS.

From the moment product hits your receiving dock until the invoice is sent for the shipped out items people are involved.  By using a WMS you increase the efficiency and accuracy of the work they do while eliminating the mistakes they will make.  A best of breed WMS should provide useful labor reports that can help you determine who your best people are and who needs help.  When the WMS is integrated tightly to your ERP/accounting/business management software  you can eliminate the costly clerical work.  This allows the people doing this manual data entry to be re-positioned  into areas that will help the company make money not just spend it.  Another plus here is the accuracy factor a WMS provides.  You can also speed up the invoices process which gets you paid in a more timely manner.

Here is an overview of areas of improvement;Workers In Warehouse Preparing Goods For Dispatch

  • Lines picked per shift are improved
  • Fill rates increase
  • Inventory accuracy is dramatically improved
  • Reduced staff and increased work volume
  • Higher pick/pack rates
  • Reduced shipping department needs
  • Shift elimination and or hour reductions
  • Transportation cost are optimized

It is not unusual for a WMS to reduce labor costs by 20 to 30 percent.   Lets look at a simple example.  If your annual labor cost for a staff of 15 warehouse employees including clerical support is $561,000.00 (18.00 per hour loaded, X 2080 per year, X 15 employees) and you save 20% with the implementation of a WMS you would save $112,000.00.  That is huge!  Of course every business is different but I have seen this kind of savings by many of our customers.  Maybe its time you took a good look at what you could save.

My next post will how cover how a WMS saves money by improving shipping accuracy.

Learn more about iCepts Technology Group and the many ways we work daily to help our customers improve their businesses.

Four Simple Ways To Pay For A WMS (Part 2)

In my last post (which I admit was a while ago) I outlined four simple ways a WMS solution can be paid for.  In this post I will discuss the first way, reduced stock.

It may seem obvious that if you reduce your stock levels you would probably save money.  But how to do this without causing disruption to fill rates and customer service is a key issue. With real-time and online data collection that a WMS like Accellos One Warehouse provides, inventory accuracy can be drastically improved.  This leads to a significant improvement in stock location, quantity and lot/serial number accuracy, as well as reduced “buffer” or “safety stock” levels.  If you reduce your inventory value while maintaining adequate stock levels to meet order demand you can save a tremendous amount of money and in addition reduce carrying costs as well.

Lets take a look at a simple example.  Let’s say you carry 5,000,000 dollars of inventory.  And you find a way to reduce that by 4% to 6% Industry average range when implementing a WMS) you could save $200,00 to $300,000.  Carrying cost range from 15% to 25% so if yours is say 20% you will pocket $40,000 to $60,000 dollars.  This will go a very long way in helping you invest in a system that will produce for you these kind of results.

In my next post I will discuss how reducing or reallocating labor will help you pay for a WMS solution.  stay tuned!!