Transcript WMS Sorted at last

“Warehousing sorted at
long last - Oracle WMS a
case study”
By
Jim Garry
www.aflux.com.cn
December 2001
Oracle Customers
Who are CTS ?
Clinical Trials Services was set up
in 1989, as a subsidiary of Galen
Holdings. They undertake all key
Clinical Trial processes from
blinding capsules to worldwide
distribution to investigator sites.
What CTS Do
CTS provide a wide range of
Clinical Trials related services
to their customers
They work closely with their
clients to ensure that all
operational procedures
comply with Good
Manufacturing Practices
(GMP) and are accurately and
extensively documented. This
provides the essential
guarantee that ensures the
integrity of all products.
CTS WMS Requirements
• Control of Finished Goods at a Patient Pack (Serial
Number) level
• Identification of the storage location within the
warehouse
• Status Control at a Lot and Patient Pack Level
• Implementation of distribution control workflow
processes
• Identification of the Container number (LPN) within
the location
• Production of Pick Lists listing products, Lots,
Container, and Patient Pack numbers (Rules Based).
• Finished product update/down date at point of
dispatch
CTS WMS Requirements
• The allocation of stock to Pick Lists
• The automatic updating of Inventory
quantities using file transfer, barcoding or
other suitable means.
• Full traceability of all transactions
• Interface with existing and future systems
(e.g. IVRS)
• The system to be validated to FDA standards
WMS - An Implementation Nightmare?
• Warehouses and Distribution centres are the pivotal points
in the Supply Chain that facilitate the balance between
supply and demand
• Business Continuity in warehouses is vital and any
interruption will cause a ripple effect across the Supply
Chain
• The WMS is a key enabler of Supply Chain Execution activity
• WMSs have traditionally proven to be an implementation
nightmare
• 40% of WMS implementations fail
• The success of Oracle WMS is dependent on the success of
its implementation and customer satisfaction
Implementing
Oracle Mobile Supply Chain Apps
and
Oracle Warehouse Management
What do you get with . . .
WMS Installed, WMS Organisation
WMS Installed, Inventory Organisation
• MSCA
Mobile User Interfaces for
• Inventory
• Mobile
User Interfaces for • Material
• Receiving
Inventory
Status
• •Shipping
Receiving
• Lot Serial
• •Manufacturing
Shipping
Attributes
• •Quality
• Manufacturing
• Labeling
• Quality
• Labelling
• LPNs
• Cost Groups
• Rules
• Tasks
• Cartonisation
• Exception
Workflows
Oracle Mobile Transaction Server
•
•
•
•
•
A “Forms Server” for
industrial (barcode)
devices connected via an
RF LAN
Standards based - 802.11,
Telnet over TCP/IP
Device independent - Over
20 devices already certified
from Intermec, Symbol and
LXE
Scalable - Multiple servers
Supportable - Applications
may run as Telnet session
on desktop and may be
“mirrored”
Oracle Mobile Applications Framework
A Development framework designed to
create UI’s suitable for these devices
• Java based
• Device independent
• Intuitive UI
• Field level validation
• DFI’s and 2D barcodes
• Multiple languages
• Extensible
Oracle Mobile Applications Architecture


RF
Device
RF Base
Station
(Router)
Mobile Transaction Server
– Standards based, Device
independent, Scalable,
Supportable
Mobile Applications Framework
– Java based, Extensible, Device
independent, Intuitive UI, Field
level validation, DI’s and 2D
barcodes, Multiple languages
LAN or WAN
Telnet over TCP/IP
Mobile
Transaction
Server
Application /
Data Base
SQL Net
Oracle Mobile Supply Chain Applications
Mobile support for existing desktop
•applications
Mobile Manufacturing - Issues, Moves, Completions,
•
•
•
•
Scrap, ...
Mobile Quality - Quality collections, View
specifications, …
Mobile Receiving - PO’s, transfers & returns, crossdockong, ...
Mobile Inventory - Transfers, misc issues & receipts,
counts, ...
Mobile Shipping - Ship confirm, Print shipping
documents, ...
 Oracle MSCA is best for Customer who:
–
–
Want RF support and are satisfied with the current 11i
inventory functionality
Need Mobile Manufacturing or Mobile Quality
Traditional Bolt-on WMS Solutions
Warehouse execution systems, bolted on
to existing legacy or ERP systems
ERP
System
• ERP Schema
• ERP Techstack
• ERP Hardware
• ERP Vendor
• EPG Support
• ERP Release
•
•
•
€
Complex integration
Items, Customer, Vendors, ...
Bolt-on WMS
(EXE, Swisslog, LIS, …)
PO’s, Orders, Deliveries, ...
Receipts, Shipments, Adjustments, ...
Physical, Replenishment, ...
Huge and ongoing integration costs
Operational complexity
Business process limitations
• WMS Schema
• WMS Techstack
• WMS Hardware
• WMS Vendor
• WMS Support
• WMS Release
Oracle Warehouse Management
A full-function, Warehouse Management
application delivered as an integral part
of the Oracle E-Business Suite
• Built-in, not Bolt-on
• Faster, Easier Implementation
• Lower Ongoing Cost of Ownership
• Strong WMS & Logistics Functionality
Hard Questions asked by CTS
•
•
•
•
•
•
•
Where do we pick this order line from?
Where do we put this receipt away to?
What is the best way to organise our picking
wave?
Who is best qualified to perform activities?
What container should we use to pack this
delivery?
What labels do customers want on their
deliveries?
How can we automatically adjust these
requirements day-to-day, warehouse-towarehouse, customer-to-customer, …?
… and we want to do this without
customisation ?
WMS Rules Engine
•
•
•
•
•
•
Allows you to control Oracle WMS
operations via flexible, user defined
business rules
“Customisation without coding”
Any data combination may be used
Designed for business users, not programmers
Visible, Upgradable
Seeded examples, Testing and debug modes
Used throughout Oracle WMS
Directed Picking and Putaway
Suggest optimal locators for picking &
putaway via user defined business rules
in Rules Engine
Receipt
Rules
Engine
Locator
Pick
•
•
•
•
Optimises the use of storage locations
Minimises inventory fragmentation
Controls hazmat and co-mingling restrictions
Reduces obsolescence
Automated Task Dispatching
Assign tasks to the optimal, qualified
resource and send them directly to that
users RF device
Move
Orders
Line 1
Line 2
Line 3
...
Task
Queue
Task 1
Task 2
Task 3
...
• Eliminates manual, parallel systems
• Correctly matches skills and equipment to
tasks
• Minimises picking travel time
Task Sorting and Sequencing
Grouping/Splitting of tasks by a variety of
Pick Methodologies to optimise overall
• process
Cluster pick, by Order, by Zone, Bulk, Paper-
•
•
based, Pick and Pass/Label Picking, User
defined
Will merge tasks for Bulk, Split tasks for
capacity
Minimises picking path
Task Exceptions
Launch corrective action workflow for
any task not completed as expected
• Trigger corrective actions (counts,
inspection, …)
• Increases inventory accuracy
• Assist in user performance tracking
LPN’s - License Plate Numbers
A “mobile locator” used to identify and
transact against any set of inventory
=
|| || | ||| ||| ||
A23595P
Inventory
• Supports infinite levels of nesting
• Perform mass, complex operations with a single
•
•
scan
Improves efficiency, accuracy and tracking
Fully integrated with ASN’s
Cartonisation
Automate packing container selection
based on the characteristics of the item
and shipment
• Define content types - solid, liquid, frozen,
etc.
• Assign those types to items and to
containers
• e.g. Drum “A” is for liquids up to 100 litres
• Match the container to the item based on the
content type and the item dimensions
• Automates picking the correct container
• Minimises the number of containers used
Cost Groups
Represents accounting / ownership of an
inventory balance, independently from
location
Old
New SubInventory
(Physical Zone)
Sub-Inventory
Cost Group
(Financial)
• Permits and controls co-mingling of
•
•
inventory
Reduces inventory fragmentation
Automatic assignment via the Rules Engine
Advanced Materials Management
Additional features designed to support
complex inventory needs
• Material Status
– Status of an Item instance or Item lot
• e.g. Raw, Immature, Rework, Refurbished,
Used, ...
– Can control which transactions are valid
– Additional to “Item Type” which is for whole
“product”
• Sub-lot support (split and merge)
• Lot and Serial Genealogy
• Lot and Serial Attributes
– User definable, updateable, searchable, ...
WMS Control Board
A general purpose workbench for
managing Oracle WMS status and
activity
• View pending workload across the
•
•
•
•
•
organisation
Manage exceptions
Review, reassign and reprioritise queued
tasks
Create new tasks
Perform mass updates
Display in tabular or graphical
representation
WMS Control Board Task Detail
WMS Control Board Status by Employee
CTS Issues and resolution
• 11i
Upgrade needed
– Server Capacity
– TARs
– Functionality training
– Upgrade timing
•
Pharmaceutical Validation (FDA)
– CFR Part 11
CTS Issues and resolution
• U.I. Development
– No release procedure – initially
– Defaulting Data
– Drop down menus
– Change prompt order (e.g. S/Ns first)
– Quantity always 1
– Logic Changes
CTS Issues and resolution
• Labelling
– Label design
– Labelling of warehouse
– Labelling of existing stock
• Picking changes
– Untampered and tampered
CTS Issues and resolution
• Barcode Placement
• Transacting non-sequential Serial Numbers
• Making “suggest” Serial number pick mandatory
• Moving full and partial cartons
• Moving ranges of serial numbers
• Making existing stock serial controlled
• Procedural changes
• Training
• Contingency planning
Top 7 impediments to a successful WMS
Implementation
1) Installing a WMS in a broken warehouse
2) Poor Project Mgmt/Change Management
3) Equipment Integration pitfalls
4) Overselling the Product
5) Inadequate end-user training
6) Lack of a Contingency Plan
7) Failure to audit results
Being in a “Pharms” environment
helped all of these
Implementation Considerations
1) 11i Upgrade Requirement
2) Barcoding Strategy
3) Warehouse Re-engineering/Layout
4) Hardware Considerations
5) Operational Processes
6) Testing/Training
7) Go-Live Strategy
8) Miscellaneous


Custom Reports
Document Changes (ASNs, Labels etc.)
Q U E S T I O N S
&
A N S W E R S
Want to talk to me ?
Mail me at [email protected]
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