Radio Frequency and Voice-Activated Picking in a Distribution Center

R

Introductions

Larry Dillender DC Operations Manager

Jim Harnage Functional Systems Manager

Presentation Overview

• Tractor Supply Company

• RF Transactions

• Hardware / Software• WM Functionality

• Pendleton Distribution Center

• Voice-Activated Picking• Intangible / Tangible Gains• Lessons Learned

TSC Overview

“Stores are located in rural communities and in the outlying areas of large cities where the rural lifestyle is a significant factor in the local economy.”

447 Stores in 30 States

6565

66

88

77

66

11 44 44

2525

883232 1919

33

111717

1515

2222

77

6060

171777

1010 3131

44441199

5544

8811

Distribution Center

Store Count

Big Bang Go-Live January 6, 2003

Project Overview

Timeline – Approximately 6 months

Paper Based Environment

Goals - Increase Productivity, Accuracy, and Real Time Inventory

DC Overview

500,00 Square Feet under roof (12 acres)

33,000 Bin Locations

265 Floor Associates

17 Clerical Positions

Pendleton, Indiana – North East of Indy

DC Daily Overview

40-60 Inbound Trailers

50-100 Outbound Loads

315 Stores Serviced

1000 Letdowns

40,000 – 60,000 Pick Lines

1000 Putaways

RF Backbone

Hardware Overview

• 802.11b• Cisco Aironet 350 Access Points

RF Devices• Handhelds – Symbol PDT 6846• Vehicle Mounts – Symbol VRC 6946

Vocollect Hardware

• Proprietary Talkman Units w/Cisco RF Card

Zebra Z6000 Label Printers - Thermal

• SAP Retail Version 4.6c Hotpack 21

Software Overview

• SAPConsole Version 4.6d

• Georgia Softworks Telnet ver. 6.27.0003

• Vocollect Quick Pick

• Veritas Cluster Services ver. 2.0.1

TSC WM Overview

Putaway Strategies Picking Strategies

• Fixed Bins

• Bulk Storage

• Near Picking Bin

• Addition to Stock

• Open Storage

• Fixed Bins

• FIFO

Project RF

• Implementation Partners

• Our RF Transactions

• Some RF extras

RF Transaction Development

Implementation Partners

(215) 579 6191SAPConsole@catalyst-

pa.com

RF Hardware and Installation

Implementation Partners

(215) 579 6191SAPConsole@catalyst-

pa.com

• 8 Physical/Logical Storage Types

TSC WM Overview

• Handling Units (HU) as Shipping Units

• Fixed Bin Auto Replenishment

• 1 Storage Type divided into 2 Sections

Our RF Transactions

• LTL Receiving• Bulk Receiving• Putaway by TO• Manual Letdown• System Letdown• HU Consolidation

Our RF Transactions

• HU Inquiry

• Picking

• Bin/Article Inquiry

• Enter Inventory Counts

• Create Inventory Document

• Master Data Correction

Some RF Extras

• Print Handling Unit Labels from Transaction

• HU Consolidation with Master Label

• Bulk labels – not TO Labels

• Loading by Store rather than Delivery

• LTL TO Labels

Voice Activated• Implementation Partner

• Voice Advantages

• Voice Architecture

• Voice and RF - Cost Differences

• Voice in Action

• Our Interface to Vocollect

Voice-Activated Solution

Implementation Partner

(412) 829-8145www.vocollect.c

om

Voice-Activated Advantages

• Improved accuracy • Increased productivity

• Reduced training time

• Voice communication is natural

• Eliminates paper

• Hands-Free Operation

Gravity Flow Area

Voice-Activated Architecture

Voice-Activated Additional Expense?

Minimum differences:• Server for Pick Manager Database• Additional cost per Unit • Training Devices• Software• SQL License

Vocollect Pick Manager

Vocollect – A Sample

Vocollect – Our WM Interface

• Extract data from SAP

• Record entry in Z table

• Generate .dat file on Server

• Upload file every 10 minutes

The Download from SAP:

Vocollect – Our WM Interface

• Oracle Procedure extracts Completedpicks from SQLServer (2.5

minutes)• Z Program feeds WMTOCO Idoc from

table above (5 minutes)

The Upload to SAP:

Vocollect – Our WM Interface

• Group TO’s by TO number for Idoc processing to avoid Delivery Locking

• Schedule Re-processing Job for Idocs

The Caveats:

• Delivery Locking Fix from SAP

• Purging Strategies for Z tables

• Reduction in Training Time

Intangible Gains

• Real-Time Data

• Better Controls

• Employee Morale

• Overall DC – 8-10% Improvement in Lines/Hr

Tangible Gains

• Receiving – 6% increase in PO’s/Hr

• Put away/Letdown – Elimination of 4 clerical.

• Billing – Went from 7 to 4 clerical

•Gravity Flow – 18% Improvement in Lines/Hr

• Seattle Labs Telnet User Limitations

Lessons Learned

• MASTER DATA, MASTER DATA, MASTER DATA

• End-User Process Training

• SAP Picking Function Modules

• Monitor Table Sizes – HU’s, etc.

QUESTIONS?

Thank you for attending!Please remember to complete and return your evaluation form following this session.

Session Code: Retail - 3305 WM - 4906