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1、 Warehouse Management Systems (WMS). The evolution of warehouse management systems (WMS) is very similar to that of many other software solutions. Initially a system to control movement and storage of materials within a warehouse, the role of WMS is expanding to including light manufacturing, tr

2、ansportation 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

3、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 function

4、ality. 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 Ma

5、nagement 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 func

6、tionality 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 proce

7、ssing 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

8、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. Do You Really Need WMS? Not every warehouse needs a WMS.

9、 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 sy

10、stem 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 r

11、educe 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

12、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 accura

13、cy 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

14、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 effi

15、ciencies, 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

16、 picking, lot tracking, yard management, automated data collection, automated material handling equipment, etc. 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 locati

17、ons 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 i

18、t 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 yo

19、u 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

20、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

21、 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 gro

22、up. 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

23、 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”

24、 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 defi

25、ne 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 dow

26、n your storage locations into zones you can direct picking, 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.

27、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

28、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-o

29、ut (FIFO). Directs picking from the oldest inventory first. Last-in-first-out (LIFO). Opposite of FIFO. I didnt 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. T

30、hey 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 yo

31、u 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. Maximiz

32、e 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

33、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 ca

34、pacity. 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

35、 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 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 pro

36、ductivity 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. In high-volume fulfillment operations, picking logic can

37、 be a critical factor in WMS selection. See my article on Order Picking for more info on these methods. 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 operati

38、ons, task interleaving will direct a lift truck operator to put away a pallet on his/her way to the next pick. In large warehouses this can greatly reduce travel time, not only increasing productivity, but also reducing wear on the lift trucks and saving on energy costs by reducing lift truck fuel

39、consumption. Task interleaving is also used with cycle counting programs to coordinate a cycle count with a picking or put away task. Integration with Automated Material Handling Equipment. If you are planning on using automated material handling equipment such as carousels, ASRS units, AGNS, pi

40、ck-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 automa

41、ted 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

42、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 con

43、tents (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. Labor Tracking/Capacity Planning. Some WMS systems provide fu

44、nctionality 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

45、 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 ag

46、ainst 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 report

47、ing. 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 interfa

48、ce 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 standardized interface, we isn’t there yet. Ideally

49、 you’ll want an integrator that has already 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 a

50、rticle, 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. I don’t see this as a unilateral move of WMS from an add-on module to a core system, but rather an optional ap

51、proach 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. If warehousing/distribution is your core business function and

52、 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. Implementation Tips Outside of the standard “don’t underestimate”, “thoroughly test”, “train, train, train” imple

53、mentation tips that apply to any business software installation ,it’s important to 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 o

54、perate 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 Sy

55、stems. 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 ha

56、ving 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. 倉庫管理系統(tǒng)（ WMS ） 倉庫管理系統(tǒng)（ WMS ）的演變與許多其他軟件解決方案是非常相似的。最初的系統(tǒng)用來控制物料在倉庫內(nèi)的流動和貯存，倉庫的作用正在延伸到包括輕型制造業(yè)，交通運輸管理，訂單管理，和完整的會計制度中。利用與先前的業(yè)務

57、有關(guān)的軟件，制造資源計劃，作為一個比較，材料需求計劃（ MRP ）開始作為一個規(guī)劃要求，原材料的生產(chǎn)環(huán)境的系統(tǒng)。 物料需求計劃很快演變成以MRP系統(tǒng)，補充調(diào)度和容量規(guī)劃為基礎(chǔ)的邏輯制造資源計劃（ MRPII系統(tǒng)）。最終MRPII系統(tǒng)演變成企業(yè)資源規(guī)劃（ ERP ），吸收所有的MRPII系統(tǒng)的功能包括充分的財務與客戶和供應商管理功能?，F(xiàn)在，無論倉庫管理系統(tǒng)演變成一個以倉庫為中心的ERP系統(tǒng)是一件好事或不可達的辯論。清楚的是，在倉庫管理系統(tǒng)，企業(yè)資源規(guī)劃，布局規(guī)劃要求，交通運輸管理系統(tǒng)，供應鏈計劃，高級計劃與排程，以及制造執(zhí)行系統(tǒng)之間擴大重疊功能性只會增加那些尋找軟件解決方案業(yè)務的公司混亂水平。

58、 盡管倉庫繼續(xù)獲得額外的功能，最初的倉庫管理系統(tǒng)的核心功能還沒有真正改變。其主要目的是控制管理系統(tǒng)在工藝操作相關(guān)聯(lián)的交易中的流動和材料儲存。定向采摘，定向補充，定向收集是倉庫的關(guān)鍵。從一個軟件供應商到另一個在一個管理系統(tǒng)中詳細的安裝和處理可以有一個很大的差別，但是其基本邏輯將使用相結(jié)合的項目，地點，數(shù)量，度量單位，并以收集信息以確定在哪里儲存，在哪里挑選，以及以何種順序執(zhí)行這些操作。 一 最低限度，一個倉庫管理系統(tǒng)應采取下列措施 有一個靈活的定位系統(tǒng)。 利用用戶定義的參數(shù)，指導倉庫任務和使用Live文件來執(zhí)行這些任務。 有一些內(nèi)置的一體化和數(shù)據(jù)收集

59、設備結(jié)合體。 您是否真的需要倉庫管理系統(tǒng)？ 并非每一個倉庫需要一個倉庫管理系統(tǒng)。當然，任何倉庫可受益于其中一些功能，但這些受益是否足以證明管理系統(tǒng)最初的和正在進行的相關(guān)費用是正確的？倉庫管理系統(tǒng)是大的，復雜的，數(shù)據(jù)密集型的應用。他們往往需要大量的初始安裝，很多系統(tǒng)資源的運行，很多正在進行的數(shù)據(jù)管理為繼續(xù)運行。沒錯，你需要“管理”你的倉庫“管理”制度。一般情況下，大規(guī)模的行動最終將建立一個新的IS部門用來唯一負責管理倉庫管理系統(tǒng)。 二 聲明 1) 倉庫管理系統(tǒng)將減少庫存！ 2) 倉庫管理系統(tǒng)將減少勞動力成本! 3) 倉庫管理系統(tǒng)將增加存儲容量！ 4) 倉庫管理系統(tǒng)將提高客戶

60、服務！ 5) 倉庫管理系統(tǒng)將增加庫存的準確性 ！ 三 現(xiàn)實 實施一個倉庫管理系統(tǒng)用來自動的數(shù)據(jù)收集將可能使你的準確性增加，減少勞動力成本（提供需要維持系統(tǒng)的勞動力少于物品保存在倉庫樓需要的勞動力）和更好地來服務客戶以降低周期。預期庫存減少和增加存儲容量的可能性較小。雖然在接收過程中增加了準確性和效率可能降低庫存安全水平，但這種降低產(chǎn)生的影響與整體庫存水平相比可以忽略不計。控制庫存水平批量最主要的因素是多種尺寸，交貨時間和需求的變化，倉庫管理系統(tǒng)將對任何因素有重大影響是不可能。而且同時倉庫管理系統(tǒng)確實的為更多的有組織的存儲提供工具，因為這種存儲可能會導致更多的存儲容量，相對于這種改善您

61、之前的倉庫管理系統(tǒng)是多么草率啊。除了勞動效率，決定實施倉庫管理系統(tǒng)的決定因素，往往與一些能滿足您的客戶的需求有更多關(guān)聯(lián)，比如您目前的系統(tǒng)不支持（或不太支持）像先進先出，交叉對接，自動挑選補充，波采摘，多種跟蹤，停車場管理，自動數(shù)據(jù)采集，自動材料處理設備等 。 四 設置 倉庫管理系統(tǒng)的設置需求是廣泛的，每個項目和地點都必須保持在詳細或分組類似項目和地點分類。一個例子，項目詳細程度的特點將包括確切尺寸和重量，每個項目在每個單位的項目儲備（項目，案件，托盤等），以及信息，如是否可以與其他物品混在一個位置，無論是的最高層次，最大堆疊高度，最高量的位置，危險性分類，半成品或原材料，快與慢動，等。盡

62、管一些行動將需要用這種方式設立每個項目，但大多數(shù)業(yè)務將有利于創(chuàng)造群體的類似產(chǎn)品。例如，如果你是一個音樂CD分銷商，您將創(chuàng)建集團單一CD和雙張CD ，保持詳細的尺寸和重量的資料在組一級，只需要對每個項目附上組代碼。您可能會需要對特殊物品保持詳細的資料，如盒裝套或CD的特別包裝。您也可以為地域的不同類型在您的倉庫里創(chuàng)造群組。一個例子是，為您用于CD采摘的三種不同大小前瞻性采摘地點建立3個不同群體（小一，二，三）。然后，您可以建立單一的光盤數(shù)量，將適合P1，P2和P3的位置，多種雙張CD適合在小一，二，小三的位置等。您可能還設立案件的數(shù)量，每個CD組光盤數(shù)量,貨箱的數(shù)量和光盤的每個后備存儲位置組。

63、 如果這聽起來很簡單，但在現(xiàn)實中很多業(yè)務有更多元化的產(chǎn)品組合，將需要更多的系統(tǒng)設置。而且建立產(chǎn)品的物理特性和產(chǎn)品的位置只是藍圖的部分。你設定的使系統(tǒng)知道產(chǎn)品可以適合哪里并且多少產(chǎn)品將滿足這個地方已經(jīng)足夠了。您現(xiàn)在需要建立必要的信息，以讓系統(tǒng)決定從哪些位置選擇，補充，并采集，并在這些事件應該出現(xiàn)這些序列中（記得倉庫管理就是“指示”流動）。你分配具體邏輯的的做法使各種組合項目/訂單/數(shù)量/位置信息將出現(xiàn)。 下面我列出一些用于確定實際位置和序列的邏輯 1) 位置順序。這是最簡單的邏輯;您只需確定流經(jīng)你的倉庫和為每一個地點分配序列編號。 為了挑選這是把您選擇的在流經(jīng)的倉庫排序，在采集邏輯將尋求

64、在第一位置的順序適合的產(chǎn)品。 2) 區(qū)邏輯 。由于把你的儲存地點分到區(qū)，您可以直接采摘，收集，或補充或特定地區(qū)的倉庫。自區(qū)邏輯唯一指定的一個地區(qū)，則需要再加上一些其他類型的邏輯，以確定確切位置在禁區(qū)內(nèi)。 3) 固定的位置。 邏輯使用預先確定的固定地點，每一項目中分揀，采集 ，和補充。固定地點是一塊采摘挑選和個案選擇的行動最常用的首要位置，但是，它們也可用于二級存儲。 4) 隨機地點。由于電腦不能真正隨機（也不想要他們）的任期隨機位置有點誤導。 隨機地點一般指的是產(chǎn)品不會儲存在指定的固定地點的地方。如Zone邏輯，您將需要一些額外的邏輯，以確定確切位置。 5) 先入先出（ FIFO的

65、）。首先指示挑選最古老的庫存。 6) 最后，先出（ LIFO ）。我不認為這種邏輯有任何實際應用，直到我的網(wǎng)站訪問者發(fā)送一封電子郵件，說明自己在國內(nèi)和海外銷售易腐貨物的行動。他們?yōu)楹Ｍ饪蛻羰褂肔IFO（因為長期在途中）和為國內(nèi)客戶使用FIFO。 7) 挑選到清楚。用最少的人手挑選邏輯指示的地點。這種邏輯是巨大的空間利用率。 8) 預留位置。這個是在預約具體地點采集時使用。從申請預留位置將交叉對接，在那里你可以指定一定數(shù)量的入境貨物轉(zhuǎn)移到具體的舉辦地點外，或直接到等待出境拖車。 9) 最大限度地立方。立方體邏輯中是在WMS系統(tǒng)發(fā)現(xiàn)最多的，盡管它很少使用。立方體邏輯基本上使用單位面積計算立

66、方體（立方英寸每單位）。然后比較這個位置的立方體能力，以確定有多少適合。現(xiàn)在，如果這些單位能堆疊成的位置，以填補每立方英寸的空間中的位置，立方體邏輯將工作。由于這很少發(fā)生在現(xiàn)實世界，立方體的邏輯往往是不切實際的。 10) 鞏固。查詢看是否有一個以現(xiàn)有性質(zhì)存放相同產(chǎn)品的位置。還可以創(chuàng)造更多的行動，以鞏固同類產(chǎn)品存放在多個位置。 11) 很多序列。用于采摘或補充，這將使用大量批號或日期，以確定位置，以選擇或補充。這是非常常見的邏輯結(jié)合多種方法，以確定最佳的位置。例如您可以選擇使用挑選到清晰的邏輯內(nèi)先入先出邏輯當有多個地點以同樣的收據(jù)的日期。您也可能會根據(jù)目前的工作量改變的邏輯。在繁忙時段內(nèi)您可以選擇的邏輯，優(yōu)化生產(chǎn)力，同時在速度較慢時期您切換到邏輯，優(yōu)化空間利用率。 五 其他功能/思考 1) 波拾取/批次揀貨/區(qū)揀貨。支持各種不同選擇方法從一個系統(tǒng)到另一個。 在高銷量的完成作業(yè)，可采摘邏輯中的一個關(guān)鍵因素韋氏選擇。見我的文章的訂單欲知有關(guān)這些方法。 2) 任務交織 。工作交織介紹混合不同的功能，任務，如挑選和采集獲得最大的生產(chǎn)力。主要用于全貨負荷運作，任務交織