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Infrastructure May 07 Businessexcellence 31 In any warehousing or manufacturing operation, errors can creep in at all stages of the process, the most common cause being human error. Whether in putting a product away in the wrong location, or picking the wrong product or an inaccurate quantity of the right product, the root cause of problems in the warehouse can almost always be traced back to something involving an error on the part of an individual. Short of having a fully automated receipt, movement, pick and ship warehouse, no system will ever completely eliminate the human component of warehouse operations. However, systems can help to significantly reduce the opportunity for human error and, at the same time, improve overall productivity throughout the warehouse. One of the most common warehouse problems is a large scale write-on or write-off of inventory at year-end. This occurs because of three factors. First, the control of the movement of inventory within the warehouse is not adequate to insure that material movement of any kind in the facility is accurately tracked. Second, there are inadequate controls over the receipt of material to insure that the quantity received is accurately recorded. Finally, the controls over the shipping process are similarly inadequate, resulting in shipping of either the incorrect product or the correct product in incorrect quantities. Material in the warehouse is often not located where the system thinks it is. This is a common problem which, unfortunately, results in a significant loss of productivity. When product cannot be found where it is supposed to be, the individual needing the material must spend An integrated warehouse management system is essential to an efficient manufacturing facility, says Thomas R. Cutler warehousing Joined up

Businessexcellence May 07 32 “The system must be part of the core package and fully interconnected to all other modules. From order management through production, the user must have complete access to strong WMS functionality” numerous other warehouse related problems, lies in the implementation of the Enterprise Warehouse Management System. The system is a complete warehouse management system that includes receiving, put away, locating, order pool management, picking, replenishment, and shipping. In addition, physical and cycle counts as well as vendor returns, license plating, warehouse labor allocation, and product specific multiple storage types provide the tools necessary to truly manage your inventory. Moreover, each of these time searching for it. Non-productive time like this is waste. Another warehouse issue arises where items are not stored in the most appropriate areas to maximize productivity opportunities. This takes several common forms. Firstly, high volume items are not located to minimize the transit time required to both put them away from receiving and pick them for shipping. The second common problem is that high volume items are often stored in areas of the warehouse not readily accessible from the floor. Both of these situations result in significant loss of productivity. Hand written tags help workers put away received goods, move product from one location in the warehouse to another, and, later, pick them for shipment or use in a manufacturing operation. Inevitably, there will be mishaps which require restocking of the wrong items and picking and redelivery of the correct ones. This creates additional labor and shipping costs for processing or returns and replacements, as well as testing the continuing good will of the customer. The solution to these, and