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仓库管理系统(_WMS)—外文翻译.doc
Warehouse Management Systems (WMS).
Do You Really Need WMS?
Setup
Other Functionality/Considerations
Implementation Tips
Warehouse Management Systems (WMS).
The evolution of warehouse management systems (WMS) is very similar to that of many
Initially a system to control movement and storage of materials within
other software solutions.
a warehouse, the role of WMS is expanding to including light manufacturing, transportation
management, order management, and complete accounting systems. To use the grandfather of
operations-related software, MRP, as a comparison, material requirements planning (MRP)
started as a system for planning raw material requirements in a manufacturing environment.
Soon MRP evolved into manufacturing resource planning (MRPII), which took the basic MRP
system and added scheduling and capacity planning logic. Eventually MRPII evolved into
enterprise resource planning (ERP), incorporating all the MRPII functionality with full financials
and customer and vendor management functionality. Now, whether WMS evolving into a
warehouse-focused ERP system is a good thing or not is up to debate. What is clear is that the
expansion of the overlap in functionality between Warehouse Management Systems, Enterprise
Resource Planning, Distribution Requirements Planning, Transportation Management Systems,
Supply Chain Planning, Advanced Planning and Scheduling, and Manufacturing Execution
Systems will only increase the level of confusion among companies looking for software
solutions for their operations.
Even though WMS continues to gain added functionality, the initial core functionality of a
WMS has not really changed. The primary purpose of a WMS is to control the movement and
storage of materials within an operation and process the associated transactions. Directed
picking, directed replenishment, and directed put away are the key to WMS. The detailed setup
and processing within a WMS can vary significantly from one software vendor to another,
however the basic logic will use a combination of item, location, quantity, unit of measure, and
order information to determine where to stock, where to pick, and in what sequence to perform
these operations.
At a bare minimum, a WMS should:
Have a flexible location system.
Utilize user-defined parameters to direct warehouse tasks and use live
documents to execute these tasks.
Have some built-in level of integration with data collection devices.
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Do You Really Need WMS?
Not every warehouse needs a WMS. Certainly any warehouse could benefit from some of
the functionality but is the benefit great enough to justify the initial and ongoing costs associated
with WMS? Warehouse Management Systems are big, complex, data intensive, applications.
They tend to require a lot of initial setup, a lot of system resources to run, and a lot of ongoing
data management to continue to run. That’s right, you need to "manage" your warehouse
"management" system. Often times, large operations will end up creating a new IS department
with the sole responsibility of managing the WMS.
The Claims:
WMS will reduce inventory!
WMS will reduce labor costs!
WMS will increase storage capacity!
WMS will increase customer service!
WMS will increase inventory accuracy!
The Reality:
The implementation of a WMS along with automated data collection will likely give you
increases in accuracy, reduction in labor costs (provided the labor required to maintain the
system is less than the labor saved on the warehouse floor), and a greater ability to service the
customer by reducing cycle times. Expectations of inventory reduction and increased storage
capacity are less likely. While increased accuracy and efficiencies in the receiving process may
reduce the level of safety stock required, the impact of this reduction will likely be negligible in
comparison to overall inventory levels. The predominant factors that control inventory levels are
lot sizing, lead times, and demand variability.
It is unlikely that a WMS will have a significant
impact on any of these factors. And while a WMS certainly provides the tools for more
organized storage which may result in increased storage capacity, this improvement will be
relative to just how sloppy your pre-WMS processes were.
Beyond labor efficiencies, the determining factors in deciding to implement a WMS tend to
be more often associated with the need to do something to service your customers that your
current system does not support (or does not support well) such as first-in-first-out,
cross-docking, automated pick replenishment, wave picking, lot tracking, yard management,
automated data collection, automated material handling equipment, etc.
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Setup
The setup requirements of WMS can be extensive. The characteristics of each item and
location must be maintained either at the detail level or by grouping similar items and locations
into categories. An example of item characteristics at the detail level would include exact
dimensions and weight of each item in each unit of measure the item is stocked (each, cases,
pallets, etc) as well as information such as whether it can be mixed with other items in a location,
whether it is rack able, max stack height, max quantity per location, hazard classifications,
finished goods or raw material, fast versus slow mover, etc. Although some operations will
need to set up each item this way, most operations will benefit by creating groups of similar
products. For example, if you are a distributor of music CDs you would create groups for
single CDs, and double CDs, maintaining the detailed dimension and weight information at the
group level and only needing to attach the group code to each item. You would likely need to
maintain detailed information on special items such as boxed sets or CDs in special packaging.
You would also create groups for the different types of locations within your warehouse. An
example would be to create three different groups (P1, P2, P3) for the three different sized
forward picking locations you use for your CD picking. You then set up the quantity of single
CDs that will fit in a P1, P2, and P3 location, quantity of double CDs that fit in a P1, P2, P3
location etc. You would likely also be setting up case quantities, and pallet quantities of each
CD group and quantities of cases and pallets per each reserve storage location group.
If this sounds simple, it is…well… sort of. In reality most operations have a much more
diverse product mix and will require much more system setup. And setting up the physical
characteristics of the product and locations is only part of the picture. You have set up enough
so that the system knows where a product can fit and how many will fit in that location. You
now need to set up the information needed to let the system decide exactly which location to pick
from, replenish from/to, and put away to, and in what sequence these events should occur
(remember WMS is all about “directed” movement). You do this by assigning specific logic to
the various combinations of item/order/quantity/location information that will occur.
Below I have listed some of the logic used in determining actual locations and sequences.
Location Sequence. This is the simplest logic; you simply define a flow through your
warehouse and assign a sequence number to each location.
In order picking this is used to
sequence your picks to flow through the warehouse, in put away the logic would look for the
first location in the sequence in which the product would fit.
Zone Logic. By breaking down your storage locations into zones you can direct picking,
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put away, or replenishment to or from specific areas of your warehouse. Since zone logic only
designates an area, you will need to combine this with some other type of logic to determine
exact location within the zone.
Fixed Location. Logic uses predetermined fixed locations per item in picking, put away,
and replenishment. Fixed locations are most often used as the primary picking location in piece
pick and case-pick operations, however, they can also be used for secondary storage.
Random Location. Since computers cannot be truly random (nor would you want them
to be) the term random location is a little misleading. Random locations generally refer to areas
where products are not stored in designated fixed locations. Like zone logic, you will need
some additional logic to determine exact locations.
First-in-first-out (FIFO). Directs picking from the oldest inventory first.
Last-in-first-out (LIFO). Opposite of FIFO. I didn't think there were any real
applications for this logic until a visitor to my site sent an email describing their operation that
distributes perishable goods domestically and overseas. They use LIFO for their overseas
customers (because of longer in-transit times) and FIFO for their domestic customers.
Pick-to-clear. Logic directs picking to the locations with the smallest quantities on hand.
This logic is great for space utilization.
Reserved Locations. This is used when you want to predetermine specific locations to
put away to or pick from. An application for reserved locations would be cross-docking, where
you may specify certain quantities of an inbound shipment be moved to specific outbound
staging locations or directly to an awaiting outbound trailer.
Maximize Cube. Cube logic is found in most WMS systems however it is seldom used.
Cube logic basically uses unit dimensions to calculate cube (cubic inches per unit) and then
compares this to the cube capacity of the location to determine how much will fit. Now if the
units are capable of being stacked into the location in a manner that fills every cubic inch of
space in the location, cube logic will work. Since this rarely happens in the real world, cube
logic tends to be impractical.
Consolidate. Looks to see if there is already a location with the same product stored in it
with available capacity. May also create additional moves to consolidate like product stored in
multiple locations.
Lot Sequence. Used for picking or replenishment, this will use the lot number or lot date
to determine locations to pick from or replenish from.
It’s very common to combine multiple logic methods to determine the best location. For
example you may chose to use pick-to-clear logic within first-in-first-out logic when there are
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multiple locations with the same receipt date. You also may change the logic based upon
current workload. During busy periods you may chose logic that optimizes productivity while
during slower periods you switch to logic that optimizes space utilization.
Other Functionality/Considerations
Wave Picking/Batch Picking/Zone Picking. Support for various picking methods varies
from one system to another.
critical factor in WMS selection. See my article on Order Picking for more info on these
methods.
In high-volume fulfillment operations, picking logic can be a
Task Interleaving. Task interleaving describes functionality that mixes dissimilar tasks
such as picking and put away to obtain maximum productivity. Used primarily in
full-pallet-load operations, task interleaving will direct a lift truck operator to put away a pallet
on his/her way to the next pick.
only increasing productivity, but also reducing wear on the lift trucks and saving on energy costs
by reducing lift truck fuel consumption. Task interleaving is also used with cycle counting
programs to coordinate a cycle count with a picking or put away task.
In large warehouses this can greatly reduce travel time, not
Integration with Automated Material Handling Equipment.
If you are planning on
using automated material handling equipment such as carousels, ASRS units, AGNS,
pick-to-light systems, or separation systems, you’ll want to consider this during the software
selection process. Since these types of automation are very expensive and are usually a core
component of your warehouse, you may find that the equipment will drive the selection of the
WMS. As with automated data collection, you should be working closely with the equipment
manufacturers during the software selection process.
Advanced Shipment Notifications (ASN).
If your vendors are capable of sending
advanced shipment notifications (preferably electronically) and attaching compliance labels to
the shipments you will want to make sure that the WMS can use this to automate your receiving
process. In addition, if you have requirements to provide ASNs for customers, you will also want
to verify this functionality.
Yard Management. Yard management describes the function of managing the contents
(inventory) of trailers parked outside the warehouse, or the empty trailers themselves. Yard
management is generally associated with cross docking operations and may include the
management of both inbound and outbound trailers.
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Labor Tracking/Capacity Planning. Some WMS systems provide functionality related
to labor reporting and capacity planning. Anyone that has worked in manufacturing should be
familiar with this type of logic. Basically, you set up standard labor hours and machine
(usually lift trucks) hours per task and set the available labor and machine hours per shift. The
WMS system will use this info to determine capacity and load. Manufacturing has been using
capacity planning for decades with mixed results. The need to factor in efficiency and
utilization to determine rated capacity is an example of the shortcomings of this process. Not
that I’m necessarily against capacity planning in warehousing, I just think most operations don’t
really need it and can avoid the disappointment of trying to make it work.
I am, however, a big
advocate of labor tracking for individual productivity measurement. Most WMS maintain
enough data to create productivity reporting. Since productivity is measured differently from
one operation to another you can assume you will have to do some minor modifications here
(usually in the form of custom reporting).
Integration with existing accounting/ERP systems. Unless the WMS vendor has
already created a specific interface with your accounting/ERP system (such as those provided by
an approved business partner) you can expect to spend some significant programming dollars
here. While we are all hoping that integration issues will be magically resolved someday by a
Ideally you’ll want an integrator that has already
standardized interface, we isn’t there yet.
integrated the WMS you chose with the business software you are using. Since this is not
always possible you at least want an integrator that is very familiar with one of the systems.
WMS + everything else = ?
As I mentioned at the beginning of this article, a lot of
other modules are being added to WMS packages. These would include full financials, light
manufacturing, transportation management, purchasing, and sales order management.
see this as a unilateral move of WMS from an add-on module to a core system, but rather an
optional approach that has applications in specific industries such as 3PLs. Using ERP systems
as a point of reference, it is unlikely that this add-on functionality will match the functionality of
best-of-breed applications available separately.
business function and you don’t want to have to deal with the integration issues of incorporating
separate financials, order processing, etc. you may find these WMS based business systems are a
good fit.
If warehousing/distribution is your core
I don’t
Implementation Tips
Outside of the standard “don’t underestimate”, “thoroughly test”, “train, train, train”
tips that apply to any business software installation ,it’s important to
implementation
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emphasize that WMS are very data dependent and restrictive by design. That is, you need to
have all of the various data elements in place for the system to function properly. And, when
they are in place, you must operate within the set parameters.
When implementing a WMS, you are adding an additional layer of technology onto your
system. And with each layer of technology there is additional overhead and additional sources
of potential problems. Now don’t take this as a condemnation of Warehouse Management
Systems. Coming from a warehousing background I definitely appreciate the functionality
WMS have to offer, and, in many warehouses, this functionality is essential to their ability to
serve their customers and remain competitive.
It’s just important to note that every solution has
its downsides and having a good understanding of the potential implications will allow managers
to make better decisions related to the levels of technology that best suits their unique
environment.
仓库管理系统（ WMS ）
仓库管理系统（ WMS ）的演变与许多其他软件解决方案是非常相似的。最初的系统
用来控制物料在仓库内的流动和贮存，仓库的作用正在延伸到包括轻型制造业，交通运输
管理，订单管理，和完整的会计制度中。利用与先前的业务有关的软件，制造资源计划，
作为一个比较，材料需求计划（ MRP ）开始作为一个规划要求，原材料的生产环境的系
统。 物料需求计划很快演变成以 MRP 系统，补充调度和容量规划为基础的逻辑制造资源
计划（ MRPII 系统）。最终 MRPII 系统演变成企业资源规划（ ERP ），吸收所有的 MRPII
系统的功能包括充分的财务与客户和供应商管理功能。现在，无论仓库管理系统演变成一
个以仓库为中心的 ERP 系统是一件好事或不可达的辩论。清楚的是，在仓库管理系统，企
业资源规划，布局规划要求，交通运输管理系统，供应链计划，高级计划与排程，以及制
造执行系统之间扩大重叠功能性只会增加那些寻找软件解决方案业务的公司混乱水平。
尽管仓库继续获得额外的功能，最初的仓库管理系统的核心功能还没有真正改变。其
主要目的是控制管理系统在工艺操作相关联的交易中的流动和材料储存。定向采摘，定向
补充，定向收集是仓库的关键。从一个软件供应商到另一个在一个管理系统中详细的安装
和处理可以有一个很大的差别，但是其基本逻辑将使用相结合的项目，地点，数量，度量
单位，并以收集信息以确定在哪里储存，在哪里挑选，以及以何种顺序执行这些操作。
一 最低限度，一个仓库管理系统应采取下列措施
有一个灵活的定位系统。
利用用户定义的参数，指导仓库任务和使用 Live 文件来执行这些任务。
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有一些内置的一体化和数据收集设备结合体。
您是否真的需要仓库管理系统？
并非每一个仓库需要一个仓库管理系统。当然，任何仓库可受益于其中一些功能，但
这些受益是否足以证明管理系统最初的和正在进行的相关费用是正确的？仓库管理系统
是大的，复杂的，数据密集型的应用。他们往往需要大量的初始安装，很多系统资源的运
行，很多正在进行的数据管理为继续运行。没错，你需要“管理”你的仓库“管理”制度。
一般情况下，大规模的行动最终将建立一个新的 IS 部门用来唯一负责管理仓库管理系统。
二 声明
1) 仓库管理系统将减少库存！
2) 仓库管理系统将减少劳动力成本!
3) 仓库管理系统将增加存储容量！
4) 仓库管理系统将提高客户服务！
5) 仓库管理系统将增加库存的准确性 ！
三 现实
实施一个仓库管理系统用来自动的数据收集将可能使你的准确性增加，减少劳动力成
本（提供需要维持系统的劳动力少于物品保存在仓库楼需要的劳动力）和更好地来服务客
户以降低周期。预期库存减少和增加存储容量的可能性较小。虽然在接收过程中增加了准
确性和效率可能降低库存安全水平，但这种降低产生的影响与整体库存水平相比可以忽略
不计。控制库存水平批量最主要的因素是多种尺寸，交货时间和需求的变化，仓库管理系
统将对任何因素有重大影响是不可能。而且同时仓库管理系统确实的为更多的有组织的存
储提供工具，因为这种存储可能会导致更多的存储容量，相对于这种改善您之前的仓库管
理系统是多么草率啊。除了劳动效率，决定实施仓库管理系统的决定因素，往往与一些能
满足您的客户的需求有更多关联，比如您目前的系统不支持（或不太支持）像先进先出，
交叉对接，自动挑选补充，波采摘，多种跟踪，停车场管理，自动数据采集，自动材料处
理设备等 。
四 设置
仓库管理系统的设置需求是广泛的，每个项目和地点都必须保持在详细或分组类似项
目和地点分类。一个例子，项目详细程度的特点将包括确切尺寸和重量，每个项目在每个
单位的项目储备（项目，案件，托盘等），以及信息，如是否可以与其他物品混在一个位
置，无论是的最高层次，最大堆叠高度，最高量的位置，危险性分类，半成品或原材料，
快与慢动，等。尽管一些行动将需要用这种方式设立每个项目，但大多数业务将有利于创
造群体的类似产品。例如，如果你是一个音乐 CD 分销商，您将创建集团单一 CD 和双张 CD ，
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