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Warehouse
Control System
The Warehouse Control System (WCS) is
designed to help in the automation of five operations commonly found in most
warehouses:
Radio Frequency Data Collection
Terminals Most of the operations utilize portable
terminals which use radio frequency to collect data (RF/DC) from warehouse
personnel. The portable terminals
can be handheld or mounted to a piece of equipment such as a forklift.
The terminals have a display used by the computer programs to give
instructions to the operator. A
keyboard is located on the terminal to allow the operator to enter data expected
by the computer programs. Most
terminals also have some type of scanning device to help with data entry.
A scanning device helps the operator with entry by reading and
interpreting bar codes located in various places within the warehouse.
A variety of scanning devices can be used such as a wand or a laser gun. Receiving The WCS electronically obtains
notification of shipments in advance of their arrival.
Reports are provided that help plan staging space within the receiving
area of the warehouse. The reports
indicate items needed to fill current orders or transfers.
These items can be set aside as they are unloaded so they will not be put
away in storage. If storage zones are being used, the reports show items by
zone so they can be placed in zone staging areas as they are unloaded.
This data is also used to "check off" items as they are stored
in the warehouse. The result is a report of receiving discrepancies. Storing As the operator moves items from the
receiving staging area to the storage systems of the warehouse, the computer
advises locations that can be used. The
operator can easily override the system if he desires to use a different
location. Multiple products can be
stored in the same location to facilitate a wide variety of storage systems
including open bay. Picking Two types of picks are possible from a
distribution center. A
replenishment pick groups all transfers for a destination warehouse that have
been placed for the purpose of restocking items that may have dropped below
their low stock level. An order
pick is concerned only with items on a specific sales order.
The sales order can involve either drop shipping to the customer or a
transfer of the items to another warehouse. In either case, when the operator has
identified the destination warehouse or the order number being picked, the
computer calculates the most efficient travel path leading to all items.
The operator is asked to indicate his current location so the computer
can pick the first location closest to him and continue the path from that
point. If zones are used in the
distribution center, only items from a particular zone are referenced on the
pick to the operator. Shipping Two types of shipping exist:
will call and transfer. Will
call pallets are usually packing into boxes for shipping.
Pallets or boxes are processed through the freight manifest system (UPS
approved). This system produces a
manifest for the common carrier or customer.
A transfer is shipped by placing its pallets on a truck destined for a
specific warehouse. As pallets are
loaded the destination id is accepted from the RF terminal. The operator can load the pallets in any desired order.
When the truck is filled, a manifest is produced showing pallet and
product detail. Each day a report
is produced showing all shipments leaving the warehouse as well as all receipts. Counting In cycle counting, the warehouse
manager can specify the cycles per year and the count sessions per year.
Whether by location or product, the cycle count process tracks the last
one counted. When preparing to do
cycle count, the computer reports the next location or product range to be
counted. If the quantity count
differs from the computer's quantity, a recount is necessary.
If a discrepancy still exists, a product count alert is passed to the
warehouse supervisor. The
supervisor counts all locations of the product and allows the computer to make
necessary adjustments. Accuracy
reports are generated for audit and management purposes.
Counting inventory by location insures the data's integrity.
Accurate computer data benefits all facets of the system, as well as, the
goal of the locator system in knowing what is on hand and where it is stored at
all times. |