2015 promat wms vs. wcs
- 1. Presented by: Jim Barnes Senior Managing Partner WMS vs. WCS: Where and When to Apply Warehouse Management Systems and Warehouse Control Systems for Optimal Results Sponsored by: © 2015 MHI® Copyright claimed for audiovisual works and sound recordings of seminar sessions. All rights reserved.
- 2. Today’s Agenda: WMS and WCS Defined Day in the Life of an Order Standard Interface Architecture Case Studies Questions
- 3. What Is a WMS? • A highly specialized business application whose purpose is to control the flow of inventory into, within and out of a company’s distribution center (DC) – Four Walls – Between Multiple DCs • WMS knows where all products are at all times
- 4. A Real-Time Environment Verify Receipts Track/Control Inventory Balance On Hand Amounts Allocate Orders Ship to Customers
- 5. Supporting a Real-Time Environment • Most WMSs incorporate – Wireless Data Terminals (RF Devices) – Bar-Coded Pallets, Cases and Item Labels – Radio Frequency Identification Tags (RFID) – Conveyor Systems / Material Handling Equipment – Voice Enabled RF Devices
- 6. What Is a WCS? • A Warehouse Control System (WCS) is a real-time integrated control solution that manages many types of automated equipment: conveyor, sorters, ASRS, Pick to Light, Carrousels, Print and Apply • WCS exchange real-time communications (milliseconds), command processing, discrete equipment signals, and the optimization of material (multiple UOML: units, cartons and pallets)
- 7. WMS vs. WCS Analogy Tilt Tray Sorter (Bones) Conveyor (Bones) WMS (Brain) WCS (Central Nervous System) 5 Senses: Sight Sound Touch Taste Smell Machine Control Input & Output ASRS (Bones)
- 8. Warehouse Management Systems WMS Do Not control Put Light, Sorters, Conveyors, Print and Apply and ASRS WMS Do Not track carton level LPNs on automation equipment WMS Do Not provide a GUI (ACAD) layout of your automation system WMS Do Not control machine control (starters and motors) WMS Do Not control machine language (ladder logic and PLCs)
- 9. Warehouse Control Systems WCS Do not support wave management strategies WCS Do not hard allocate inventory in reserve or forward pick locations WCS Do Not interface with your ERP (typically, there are exceptions) WCS are not your inventory of record (4-walls inventory) WCS Do not support extensive cycle counting and physical inventory processes WCS Do not support labor management and allocation WCS Do not support Transportation Planning and Shipping Execution
- 11. WMS and WCS Convergence Host Interface WMS WCS User Interface Reports Alerts Host Interface Manage Inbound POs & Receiving Manage Outbound Orders & Shipping Inventory, Storage & Location Management User Interface Reports Alerts Equipment Communication & Control Activity Execution Receiving, PutAway, Replenishment, Picking, Packing, Shipping
- 12. Today’s Agenda: WMS and WCS Defined Day in the Life of an Order Standard Interface Architecture Case Studies Questions
- 13. Day in the Life of an Order ERP| OMS Soft Allocation WMS WCS CON SPL SPL CON SPL SPL CON SPL SPL CON SPL SPL CON SPL SPL CON SPL SPL CON SPL SPL CON SPL SPL CON SPL SPL SPLSPLSPLSPLSPLSPLSPLSPLSPL CON SPL SPL CON SPL SPL CON SPL SPL CON SPL SPL CON SPL SPL SPLSPLSPLSPLSPL CONCONCONCONCONCONCONCON SPLSPLSPLSPLSPLSPLSPLSPL CONCONCONCONCON SPLSPLSPLSPLSPL CONCONCON SPLSPLSPL KD KD KD KD KD KD KD KD KD KD KD KD KD KD KD KD KD KD KD KD KD KD KD KD PRPRPRPRPRPRPRPRPRPRPR PRPRPRPRPRPRPRPRPRPRPR PRPR PRPR PRPRPRPRPRPRPRPRPRPRPRPR PRPRPRPRPRPRPRPRPRPRPRPR PR PR PRPRPRPRPRPRPRPRPRPRPR PRPRPRPRPRPRPRPRPRPRPR PRPR PRPR PRPRPRPRPRPRPRPRPRPRPRPR PRPRPRPRPRPRPRPRPRPRPRPR PR PR PRPRPRPRPR PRPRPRPRPR PR PR PRPRPRPRPR PRPRPRPRPR PR PR PRPRPRPRPRPRPRPRPRPRPRPRPRPRPRPRPRPRPRPRPRPRPRPRPRPRPRPRPRPRPRPR PRPRPRPRPRPRPRPRPRPRPR PRPRPRPRPRPRPRPRPRPRPR PRPR PRPR PRPRPRPRPRPRPRPRPRPRPRPR PRPRPRPRPRPRPRPRPRPRPRPR PR PR PRPRPRPRPR PRPRPRPRPR PR PR Hard Allocation 4 - Walls
- 14. Today’s Agenda: WMS and WCS Defined Day in the Life of an Order Standard Interface Architecture Case Studies Questions
- 15. Standard Interface Architecture ERP/HOST WMS SO Header Detail PO Header Detail Receipt Detail Item Master Shipment Detail Inventory Adjustments Interface Layer (Point to Point) or (ESB) WCS Shipping Execution
- 16. Today’s Agenda: WMS and WCS Defined Day in the Life of an Order Standard Interface Architecture Case Studies Questions
- 17. Case Study 1 • $800M Fashion Apparel Company • Tier 1 WMS • WCS Required for Put to Light and Conveyor • However the WCS was used for discrete order picking…… • WCS assumed inventory was always in the forward pick location and did not manage, allocate or control the inventory
- 18. Case Study 2 • $4B Shoe Retailer (Highly Automated) – Tier 1 WMS • Managed IB Receipts • Inventory Control • Replenishment to the Tilt Tray • Forward picking for accessory items • Allocation – WCS for Conveyor and Print and Apply • 8 inbound lanes with 2 to 1 merge • Put-away loop with sortation • 17 outbound lanes for pool point shipment – Separate Controls for the Tilt Tray
- 19. Lessons Learned • Understand who (WMS vs. WCS) does best for your business…..lines are getting blurred • Understand how the physical movement of inventory (UOM) moves through your facility • Use a solutions architect that knows both technologies…. – Happy Path work flows but more importantly….. – Exception Management
- 20. Today’s Agenda: WMS and WCS Defined Day in the Life of an Order Standard Interface Architecture Case Studies Questions
- 21. For More Information: Jim Barnes jbarnes@envistacorp.com www.envistacorp.com