A Northeastern Ohio manufacturing company contacted the Dowling Consulting Group to solve several problems in their warehouse distribution system.
Major concerns were correcting inaccurate inventories with a real-time process versus an existing batch system, shortening the long, labor-intensive pick procedure, and insuring the correct items were picked for each customer invoice.
Proposed solution was an RF inventory system utilizing Telxon (subsequently updated to Symbol) equipment.
System Architecture:
IBM mainframe running business ERP system
34 - Symbol PDT 6800 hand held terminals
3270 emulation
CICS session allowing communication with the ERP system on the mainframe
Hand held terminals inter-active with the mainframe
Terminals need to pass data to the mainframe, then wait for a response for verification, retrieval of information, and updating of production files
Redundancy for backup if mainframe is down
Decipher different bar code symbologies: UPC, Code 3 of 9, and Code 128
Verify scanned data is for proper field input
Application:
Track everything done in the warehouse
Track everything through the hand held terminal
Putway – tells users where to place pallets based on available locations
Replenishment – picking bin
Tells users location of oldest pallet in the warehouse to replenish the picking bin
Picking
User scans pick list and items picked; information is sent to ERP
Scan verified that it is on the pick list and quantity picked is accurate
Interactive messages sent to user if something was not picked, under-picked or over-picked
ERP directs full pallet pick for FIFO
Result:
Customer now has real time inventory information versus outdated, incorrect data
Pickers directed to pick location, save considerable time locating and picking inventory
Oldest inventory shipped first
Orders picked accurately and more quickly resulting in improved customer satisfaction
