Warehouse Management System Implementation scope/flow in GINESYS

WMS = Stock point in GINESYS WMS will be a system stock point. One organization site can only have one WMS. Assumption: If more than one WMS needs to be maintained at a single location, then multiple organization sites needs to be implemented in such cases. For example, if Merchandiser wise racks/bins or Channel wise stock is maintained, then multiple organization sites needs to be prepared in such cases. Note: Channel wise stock practice is followed by Being Human.

WMS Structure - Bins Organization site wise BINs will be allowed to be created. Following information shall be captured at BIN level: BIN No. (unique at site level) Sequence No. (this shall help in pick list generation to reduce travel path) Allow Reservation (if enabled, this BIN shall be considered for reservation/pick list generation, else not.) UDF shall be enabled. Assumptions: Not linking Item with racks/bins. This will allow user to use any BIN for any Item. Not maintaining BIN Capacity. Thus system won’t be able to provide put-away list. User will have to manually understand put-away BINS using BIN stock reports and input the same in the system as per actual.

Bin Master - Prototype

Stock Inward Process - WMS Applicable for all stock inward transactions like goods receive, sales return, miscellaneous in, production receipt, etc. Goods Received at QC Stock point (for ad-hoc delivery without reservation or preserving stock) Cross Dock Put Away from QC Stock point to Bins @ WMS Stock point (for item storage & reservation)

Put Away - Prototype

Stock Outward Process (non-reservation) - WMS Applicable for all stock outward transactions like goods return, delivery challan (without reservation), miscellaneous out, production issue, etc. Reverse Put Away, i.e., Stock to be moved from Bins @ WMS Stock point to any out stock point. (manual process using Bin stock report - no pick list in this case) Select out stock point in aforesaid transactions.

Reverse Put Away - Prototype

Bin Consolidation - Prototype There are certain scenarios where bin consolidation or inter-bin transactions needs to be done. For example, making space for new products by consolidating same items in a single bin from multi scattered bins or may be due to wrong put away entry bin stock showing wrong, etc.

Assumption on Outward Transactions - WMS WMS Stock point’s negative stock method = Stop Irrespective of user’s profile setting, we won’t allow negative stock for this stock point. This is to safeguard the process of reservation (reserved & free/available stock). If we enable negative stock in this stock point, then the purpose of reservation (details in later slides) gets defeated. No Pick list for non-reservation movement: Since there won’t be any reservation, system won’t be able to provide any pick list for the same. User can use BIN stock report for available stock of any Item in bins. No manual date concept: Server date shall be considered as transaction date. We won’t be allowing user to input date manually in any bin related transactions. Reason: No financial impact, only inventory postings and negative stock maintenance at Bin level.

Stock Reservation - Functional Flow Order Marked as “Reservation Required” and authorized Reservation needs to be done once stock available (multi time reservation allowed against single order) Pick list needs to be generated against reservation (one or many reservations = one picklist) Once pick up gets completed, user will have to confirm picking task at Item level. (for short pick, user can cancel the pick list and then cancel reservation as well) Once Delivery Challan is prepared, stock is deducted from respective bin & moved to package stock point.

Stock Reservation - Entry Flow Since we have provided reverse mechanism in every stage, so there can be multiple transactions for each stage, like multi reservation, pick list & packets.

Stock Reservation appl. in Sales/Transfer Order Applicability as per site profile, i.e., optional, mandatory or not required. In case of optional, If reservation is required for any order, user will have to mark the order as “Reservation required”. Dispatch for such orders can only take place via WMS stock point and against reservation, i.e., these orders won’t be available in existing delivery challan (against order) module.

Stock Reservation for Sales/Transfer Order A separate module shall be provided for reservation. Reservation will be done at Item level of the order (manual/full selection option available to user) & Bin level of WMS (automatic by system). Reservation shall take place as per the Pick List rule selected at the time of reservation: Max fit bin first: The bin having the maximum quantity required for an order shall be reserved first. Note: This should be used when you want the picking operation to be efficient. Min fit bin first: The bin having the minimum quantity required for an order shall be reserved first. Note: This should be used when you want to clear the less occupied bins. Bin Sequence: The stock shall be reserved as per the sequence defined in the bin master.

Stock Reservation for Sales/Transfer Order One reservation can contain only single order’s item details. If multiple orders are selected and reserved at one go, multiple reservation entries shall get created. On reserving the stock, the stock at Bin & WMS stock point level shall get segregated to “free” & “reserved stock”. Free Stock: Available for Bin movements or reverse put away. Reserved Stock: Can only be picked for delivery of the orders against which it is reserved. Assumption: We are not providing Item wise reservation view for reserving stock as of now, only order wise view shall be provided. This shall be provided in 2nd phase.

Stock Reservation (Multi Order) - Prototype

Stock Reservation (Order wise) - Prototype

Pick Lists against Reservations There are multiple business practices for pick lists: Individual pick: Pick list shall be generated against single reservation. Commonly used by EBO chains. Cluster pick: Pick list shall be generated against multiple reservations (irrespective of customer as well). The picker picks the stocks from respective bins and keeps on throwing in respective destination’s carton. Commonly used for E-commerce delivery (fulfilled by seller process). Batch pick: The picker picks the stocks from respective bins and keeps on throwing in a common carton / package. On pick completion, takes the packages to the batch processing area where the products are segregated as per destination. Commonly used by MBOs. Note: For us both cluster pick & batch pick are same.

Pick Lists against Reservations On generation of pick list, an entry shall be passed to mark the reserved stock status from “Pick pending” to “Pick initiated”. Pick process can be completed by either of the ways: Paper based picking: In this process, the pick list printout is taken and picking gets initiated. On completion of the process, the user manually marks the picking complete in the system (with shortage information, if any). Handheld device integrated picking: In this process, the picker is guided on-the-go by the handheld device for first/next Bin to visit, which Item to pick and how much qty. to pick. Bin wise pick confirmation is done as soon as he moves to the next Bin.

Pick Lists against Reservations On marking the pick list confirm/complete, the picked qty. shall be allowed to be packed. The short qty.’s pick list needs to be cancelled manually and thereafter cancellation of reservation for that quantity needs to be done. Assumptions: We are not considering handheld device integration in the current phase as responsive UI needs to be developed for the same. Selective picklist generation from a reservation won’t be allowed.

Pick List Generation - Prototype

Pick List Confirmation - Prototype

Reservation & Pick List cancellation There can be various scenarios due to which pick list or reservation needs to be cancelled. Cancellation reasons: Item physically short in the reserved BIN. Dispatch stopped due to any reason at any stage like reserved or pick pending or pick completed or packed. Cancellation for both shall be provided at Item level, i.e., for any reservation or pick list, partial cancellation is possible. Assumption: Once cancelled, there is no way to revert the changes. The user will have to again generate pick list and/or do reservation.

Pick List Cancellation - Prototype

Reservation Cancellation - Prototype

Packing Process - For reserved orders User can start the packing process in either ways by selecting the order or reservation no. or pick list no. While packing, We shall set-off the pick list (reason: to ensure that the pick list is not cancelled since the items are already packed) We shall update the reservation’s pack qty. (reason: to get the reservation’s status) On saving the delivery challan, the stock will get deducted from respective bins and move to another stock point, i.e., normal package stock point. In case delivery challan is cancelled, then, Stock shall move back to respective bins (from where it was picked). Status of pick list & reservation will get updated.

Thank you For further queries mail me at siddharth.bh@gsl.in