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© 2016 HighJump. All Rights Reserved. © 2016 HighJump. All Rights Reserved.

Leveraging Configurability to Drive Operational Efficiency

From Quick Hits to Complex SolutionsPresented by Jon Gustafson of 4SIGHT Supply Chain Group

© 2016 HighJump. All Rights Reserved.

Introduction

• Jon Gustafson– Director, HighJump WMS Practice– 14 years experience designing and implementing HighJump Solutions

– 24 years Supply Chain Industry experience– Experience within a vast array of industry verticals– Pioneered the Operational Assessment Offering at HighJump


• This presentation reviews several recent examples of how HighJump customers have leveraged the unique configurability of the Warehouse Advantage product to increase efficiencies in their operations.

• The presentation will look at some unique solutions that customers have implemented to tackle both basic and complex situations. Some of the solutions represent highly customized logic put in place to raise efficiency levels to their highest degree. Other solutions are examples of simple solutions to common issues faced by HighJump customers.

• Lastly, the presentation will touch on leveraging the HighJump App Station Applications as an approach to reducing implementation costs while realizing savings by implementing solutions addressing common efficiency opportunities.

Presentation Overview


Agenda

• Introduction• Overview• Efficiency Topics

– Double pallet scanning– RF picking for eCommerce– “Super Charging” Cycle Counting– Integrating Yard Advantage– Leveraging App Stations– Coming functionality

• Q&A


Double Pallet Scanning –Scenario

• A large manufacturing client with a warehouse that uses license plate control and double wide fork trucks for moving product.

• The base WA solution calls for each LP to be scanned individually one at a time, and then loops the user back through the process to identify the second LP.– This setup caused two areas of inefficiency for the warehouse:

1. The fork truck driver would have to physically move around to scan around the fork lift mast while trying to scan the LP on the pallet.

2. After going through a series of screens to indicate that they were taking the entire pallet, they would need to go through the entire cycle again to pick up the second pallet.


Double Pallet Scanning –Solution

• Two scan heads were fixed mounted to the backstop of the forks.• LP’s were consistently placed in the lower left of the pallet during

all label application.• The scanners were configured to receive input from both scanners.

The left prefixed with the letter L, the right with the letter R, and the two were concatenated together with a pipe ‘|’separating the scanned values.– Input string sample “L_LP12345|R_LP98765”


Double Pallet Scanning –Solution

• When this data is passed back into the WA application, the user is presented with the two LP’s that were scanned, and has the option of accepting both, choosing right, choosing left, or repeating the scan.

• The WA application processes were configured to accept both LP scans, assuming the full pallet was being taken, with an option to take less than the full LP via a function key.

• Additionally, the process to drop off the pallets was enhanced with an F2:Drop All function key.


Double Pallet Scanning –Improvement Calculations

Old Process New Process ChangeNumber of Scans 7 2 -‐71.43%Seconds per scan 5 2 -‐60.00%Total pickup time 35 4 -‐88.57%Travel Time per move 120 120 UnchangedSeconds per Move 155 124 -‐20.00%Pallets per move 2 2 UnchangedCapacity per associate per hour 46 58 25.00%Associates in process per shift 5 5Shifts per day 2 2Total pallet capacity with current workforce 465 581 116

Workers required 10 8 -‐2Note: Numbers presented are approximations based on one specific scenario. The model allows what if analysis to support other scenarios


RF Picking for eCommerce –Scenario

• One of the challenges for eCommerce is that orders tend to be for very small quantities (1.4 lines per order average).

• Some operations try to use order picking to fulfill these order requests:– In one case, even while picking multiple orders to a cart, the customer

was using order picking.– This leads to multiple pick tours for the associate and exponentially

increases their travel time.


RF Picking for eCommerce –Simple Solution

• Let Advantage Fulfillment Application (AFA) help group orders for picking– Split out single line orders and bulk pick them using a simple sort process

that sorts and ships in one step.– Split out multiple line orders and batch pick them.

• Batch picking either by order or by container allows the user to pick several orders at a time while discretely separating them on their equipment.

– Using cartonization allows further efficiency gains by allowing the user to know in advance how many containers they will need and allowing for a very specific cart batch to be built for the user.


RF Picking for eCommerce –More Complex Solution

• An alternative approach to picking single line orders:– Pick single line orders in bulk as described earlier.– Pick multi-‐line orders in several bulk “Sortation POD Batches” where each batch represents a

sortation pod

• A “Sortation POD Batch” is defined by the number of orders that a POD can physically hold. Orders are further defined by the size of the order using Container Advantage. This is the key to getting the right orders to the right POD.– This approach allows better pick density but requires a secondary “Put to Store” type of sort

or “Put to Light” setup.

• Building pick batches by class or zone leads to more efficiency


RF Picking for eCommerce –Improvement Calculations

Muti -‐ Line Orders Order Picking Batch Picking ChangeTypical Pick Tour in seconds 240 420 75.00%Number of tours 10 1 -‐90.00%Total pick time 2400 420 -‐82.50%

Single Line Orders Batch Picking Bulk Picking ChangeTypical Pick Tour in seconds 420 360 -‐14.29%Number or tours 1 1 0.00%Orders per tour 10 40 300.00%Seconds per order 42 9 -‐78.57%


“Super Charging” Cycle Counting

• Inefficiencies in base cycle counting1. Cycle Count Check

• Executes counts by priority, due date, due time• User is forced to continue counting after finding a problem

2. Cycle Count by Item is a problem in large warehouses3. Cycle Counting LP controlled block stack locations means

tearing apart the entire location


Cycle Count Check –Solution

• Execute counts by pick flow sequence within a priority for a given due date or date range.– This allows an efficient travel path for the counter, yet ensures the counts are

executed in a timely manner.– Using a date range gives more count density and further increases efficiency.

• Configure the Count Check process to move to the next location as soon as an error is encountered.– The only result of a bad count check is to schedule a location count. Once the

location is found to be in error, schedule the count and move on to the next location.


Cycle Count by Item –Problem further Defined

• Cycle Count by Item is controlled by one work queue entry.– One person executes the counts for all locations containing the item.– If the user backs out of the count, the count is not complete and

counting starts over.– Counting by item and location are mixed under one menu option so

the user doesn’t know which type of count they are executing.


Cycle Count by Item –Solution

• Instead of creating a work queue entry for an item count:– Create separate location counts for all locations containing the item

that have not been counted in the last ‘n’ seconds, minutes, hours.– This allows multiple users to execute the counts and does not have

one user covering the entire warehouse.– Counts for all locations do not need to be completed in full to avoid

resetting the work queue. Each location is counted on it’s separate work queue entry.

– All counts are location counts, so there is no need to try to split them out on the menu for different users.


Cycle Count LP Block Stack –Solution

• Warehouses that have block stack locations that are LP controlled face a challenge using base counting.

• Instead of having the user identify each specific LP in a location, configure the cycle counting processes to only count the number of LP’s in a location.

• If there is an error in the number of LP’s, then drive the user down to the base process for counting LP’s where the location will be thoroughly interrogated.


Cycle Count LP Block Stack –Solution


Integrating Yard Advantage -Challenge

• Yard Advantage (YA) is not integrated with WA. YA uses its own data model and activity is not communicated to WA.

• YA does not use logic for door planning -‐ it counts on the user to make the decision.

• YA does not use actual or anticipated demand to get the right trailer to the right door.


Integrating Yard Advantage –Simple Solution

• The first level of integrating YA to WA is to simply allow them to communicate.– When an inbound trailer is staged at a door in YA, this can insert an unload work request into the work queue.

– When a load or door is shipped in WA, this can insert a yard move task to have a shunter remove the trailer from the door.


Integrating Yard Advantage –Next Level Integration

• The next level of integration typically calls for ASN and/or production schedule data.– By knowing what is on a trailer, YA can be configured to make

intelligent decisions on what is needed next in the warehouse.• Customer example, Direct Loading and Unloading:

– Based on the ASN and the production schedule, the customer’s application runs a door planning algorithm to select which trailer is needed next for inbound or outbound.

– Inbound trailers are scheduled to the door closest to the production line feed, or put away location using XY coordinates.

– The reverse logic is used for outbound trailers. The trailer of the required type is scheduled to an available door nearest to the end of the production line.


Integrating Yard Advantage –Taking it all the way

• Customer Example– Based on ASN data and scheduled ship time, the door scheduling

algorithm schedules an inbound trailer to the door.– Pick plan logic is extended to include anticipated receipts, and the

entire inbound load is planned either for cross dock or for put away.– In this scenario, the merchandise is serialized, but is not pegged to an

outbound order. In turn, the receipt scan of the serialized item selects the best outbound order and a door-‐to-‐door transfer is performed.


• Cancel Order• Create Counts• Create Pickup• Cycle Count Approval• Demand Replenishments• Email Notification

• Equipment Audit• Format Validation• On Demand Cycle Count• Quick View• Trailer Inspection• WA Appointment

Useful App Stations

A full listing of App Stations available can be found on the HJ Customer Portal


New Functionality on the Way

• Scheduled functionality for March release– 4 Wall Serial Tracking

• Full trace for serialized items from receipt to ship– Pick Plan

• Minimizes replans (problematic if you have a pick module)• Allows cool things like the planned cross dock explained earlier

• Coming App Stations– Returns Manager– Trailering Loading Suspend/Resume


Questions

© 2016 HighJump. All Rights Reserved. © 2016 HighJump. All Rights Reserved.

Please feel free to contact me with any follow up questions regarding your situation

Jon Gustafson – 4SIGHT Supply Chain [email protected]

Visit us on-‐line at www.go4sight.com

Follow us on:LinkedIn and Google+

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