基本仓库管理概览

存储位置模型 SKU / 产品 物料操作

2
ZONE ALPHANUMERIC
CHARACTERS
听装饮料 电话
2
AISLE ALPHANUMERIC
CHARACTERS O
2 NUMERIC
R
BAY CHARACTERS

芯片
2 NUMERIC 苹果
LEVEL CHARACTERS

2 NUMERIC
SLOT CHARACTERS

Customers
 Warehouse Functions
Receiving Putaway Replenish

Verify Direct Monitor

Locate Locate Initiate

Exceptions Confirm Confirm

Confirm Multi stage Multi stage

Order Pick Consolidate Despatch

Inform Packing Summary

Confirm Accumulate Manifest

Exceptions Identify Shipping

Release Confirm Document

  Discharge Record
 仓库设立过程 (1)
仓库设立过程 (1)

ADD
H
E LOCATION
I WEIGHT SIZE
G
H
TH

T
EP

WIDTH A A A A A
D

I I I I I
S S S S S
L L L L L
RESERVE RESERVE E E E E E

RESERVE RESERVE

ADD
BAY RESERVE RESERVE
ADD AISLE MODEL
MODEL

PICK PICK A
Item Setup Process (1)

SETUP
ASSIGN ADD
MOVEMENT
ZONE ITEM
CLASS

ADD
ADD ADD
STOCK
LOCATION UNITS
UNITS

ADD PICKING STORAGE

PICKFACES UNITS UNIT
Trade
Trade Unit
Unit Identifiers
Identifiers (TUN)
(TUN)

EACH PACK (of 6)

CARTON (of 24)

 Item Attributes
Preferred Zone Group Code Serial Number?
Max Held
Movement Code Cycle Code Batch Number?
Min Held
Lot Number ?
Perishable?
Minimum Life Random/
Expiry Life Normal
Graded Product?
Short Life?

UNIT DEFINITION
Crushable?
- Picking Units
Stacking Factor
- Storage Unit
Security?
Dimension of Units
Weight of Units
Haz-Chem
Inspection? Production
Storage Dated? PICKFACES
Handling
 A Day in the Warehouse

Receiving Putaway Stock Transfer

•Data Entry
Stock Counting •Returns Stock Replenishment
•Sales Order Enquiry
•SKU Maintenance
•Customer Service
Order Despatch •Reporting Load sizing

Sales Order Sc
Order Consolidation Sales Order Picking
heduling

DO A DAY’S WORK IN A DAY

 Receiving & Put-away
Receiving Dock
DELIVERY RECEIVING
TASKS TASKS
•Verify Order •Unload
•Check documentation •Sort and Palletise
•Schedule unload •Check

Warehouse

RECEIPT
STORAGE RELEASE
TASKS •Check SKU details
•Putaway to Crossdock •Schedule SKU for putaway
•Putaway to Pick location
•Putaway to Reserve
•Putaway to Bulk
 Put-away Processing

Print Paper
Device
worksheet

Data entry and releas Place SKU into storage

e lines to workpool location

Device available for

new putaway list

Device Worksheet Return Device

lines confirmed worksheet to data
processing
Orders via Host Transfer

PURCASE ORDER
SALESORDER

HOST
HOST SYSTEM
TO
BUSINESS SYSTEM WMS
INTERFACE

PURCHASE ORDER
SALES ORDER

WMS
WAREHOUSE
MANAGEMENT
SYSTEM
 Sales Order Data Processing

Phone

Fax WMS SALES

ORDER ENTRY
CUSTOMER
ORDERS
Letter

WMS
WAREHOUSE
MANAGEMENT
SYSTEM

EDI
Gateway
 Sales Order Picking

Pick SKU
From
Location
Print Device
Worksheets
Select & Release Sales
Order For Picking

A LABELS

Print
Label picked Package Confirm Device
packages Labels Worksheet
 Multiple
Multiple Customers
Customers Orders
Orders Consolidation
Consolidation
Process
Process
Orders from multiple customers

Consolidate Customer
orders in delivery
destinations Routes
11.00 AM:
Order consolidation cut of

At any Time Left over

Consolidate Customer
Direct process Small orders in delivery
FTL Orders orders destinations Routes
2.00 PM:
Consolidated Order consolidation cut of
FTL Order
Consolidate Customer
Left over orders in delivery
Small destinations Routes,
Delivery to Multiple customers orders including Small orders
5.00 PM:
Order consolidation cut
Consolidated
FTL Order all LTL Order
 Consolidation
Consolidation Process
Process
Generate and apply to picked
Receipt of Multiple Goods dispatch and delivery Labels
customers orders, from TCL
and other customers Assign dispatch grid
and Loading dock/ delivery route
Place goods
Scheduling of Generate Picking Batch picking of In nominated
Consolidate orders documentation products in WH dispatch
in destination Routes By delivery Route By delivery Route grids area

Generate Check goods

If FTL load transport against paperwor
Yes documentation
Waite until next No
consolidation
process cutoff time Determine Move goods to
transport Order Trucks Truck arrive at docks Dispatch docks
Requirements and Notify Dock No
availabilities
Loading
trucks
Daily accumulated LTL orders

Critical Order Lead Time ( LTFTL)

Dispatch instructions

Dispatch instructions
5pm

Dispatch instructions

Receiving instructions
7pm

7.00 am
8pm

Internal

Dispatch instructions

Customer received goods

Order
processing

Order

8.00am
Customer order received

Picking/

Untill 5.00pm
Consolidation
Transport
booking
Long Distance Transportation
Transfer
to Transport
Hub,
Load- consolidation Hub
De-
consolidation Local
Delivery
Overall 24 Hours
 Internal
Internal Consolidation
Consolidation Physical
Physical Work
Work Flow
Flow
Traffic Flow Receiving
Consolidate multiple customers
orders in Truck loads

Consolidate multiple customer

order Pick from Pick area
Consolidated Dispatch

Replenishment from Bulk to Pick area

Consolidation area

Customer order point

Bulk storage
Picking Area
Dispatch,

Receiving
Traffic Flow
 Order Picking Operations

• By carefully selecting the optimal approach to order

picking and achieving goals such as the lowest cost per
pick and the highest accuracy rate, you can almost
guarantee efficiency, productivity and a return on capital
invested.

• Simple improvements such as segmenting stock

according to popularity, or printing picking list in operator
travel sequence, or picking several orders in one circuit
are effective methods of reducing picking operating
costs.
 Customer Order Preparations

• Objectives
– Maximize efficiencies
– Accessible locations
– Balanced picking
– Batch orders
– Sequence picking with documents
– Use appropriate and efficient equipment
One of the Major Warehouse Functions

Customer Order delivered Order

places order to customer shipped

Order Order Order picked

Received processed and packed

Key:
1.order preparation and transmittal 1 day
2.order received and entered into system 1 day
3.order processing 1 day
4.warehouse picking and packing 1 day
5.transit time 3 days
6.warehouse receiving and placing into storage 1 day
Total order cycle time 8 days
 Analysis of Picking Operation

.get new order

.refer to order
25% .check location
.tick order
.query order
45%

14% Travel

Paperwork

.walk with order Pick

.search for goods 16% Check &
.walk with goods Pack
 Three Popular Types of Picking
Strategies,

Strict Order picking

A picker completes one order at the time. This
introduces long travelling times when there are many
line items per order, but it maintain strict order
integrity.
Batch picking
A picker select items for several orders
simultaneously, and completes multiple orders in one
run. Sortation downstream is required. Bar-code
labels facilitate automated sortation.
 Three Popular Types of Picking
Strategies, cont.
Zone picking
Similar as batch picking, but each picker is assigned
to a particular zone. Travel distances are greatly
reduced. Additional sortation is required.
Sequencing can improve pick rates and maintain
integrity
Comparison of the Most Common
Case Picking Methods.
Method Application notes

Bin shelving, pick to Trolley Ideal for slow to medium moving SKU’s
Can be used for split case picking.

Carton flow rack, pick to Belt Ideal for fast moving SKU’s. Provide high
number of pick faces over small area. Can
achieve up to 350 picks/ hr. Can be used for
split case picking.
Pallet flow rack, pick to belt Medium moving SKU’s. Used for full case
picking.

Pallet rack, order picking truck Ideal for slow moving SKU’s. Used for full
case and full pallet picking. High storage
density.

Automated storage and retrieval, Used for slow, medium, and fast picking of
stackers cranes full pallets and loose SKU’s.
Best trade off between storage density and
pick rates.
 Picking Options = Productivity
•DISCRETE PICK
S •MULTI ORDER PICK PICKFACES D
L •BATCH PICK (LARGE ITEMS) E
O S G
W P R
Batch Pick Consolidation
A I
REPLENISH / PICK CONSOLIDATION T D
C S
BULK / H
RESERVE F PICK / PACK
A (SMALL ITEMS) X-
S DOCK
T
RECEIVING
 Despatch
Despatch

A
GRID 01 GRID 02
Palletise pack
Place pallet in ass ages on pallet
igned Despatch G
rid
GRID 03 GRID 04

Load Truck

Select Sales orders for loa

Print Load out documentation ding. Release sales orders
•Route Manifest for despatch
Hand load out
•Load Manifiest
documents to driver
•Consignment note
 Replenishment
Replenishment

MAX

MIN

Print Replenish
Initiate stock move to fill Device
Worksheet
to maximum level
PICKFACE stock at or
below minimum level

Top up
PICKFACE
stock

Assign new job Confirm Replenish

Device Worksheet
 Transfer
Transfer
FUNCTION
FUNCTIONSUPERVISOR
SUPERVISORACTIVATED
ACTIVATEDHOUSEKEEPING
HOUSEKEEPING

Print Transfer
Device
Supervisor identifies hou worksheet
skeeping, top up part fill Initialise Transfer combine
ed locations stock in part filled location
s

Move stock
from
location to
location as
directed
Assign new job Confirm Transfer Device
Worksheet
 Stock Take and Cyclic Count Options
• SKU / Client / Warehouse / Aisle / Location

S PICKFACES
L (LARGE ITEMS)
O
W

REPLENISH / PICK CONSOLIDATION

BULK /
RESERVE F PICK / PACK
A (SMALL ITEMS)
S
T
CROSS-
DOCK