WMS与库存管理的比较.ppt

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1、SAP IM vs.WM:How to Choose,Use,and Optimize,Gavin KlausCatalyst International,Inc.,What Well Cover,Understanding the difference between WM and IMChoosing between WM and IMOptimizing and overcoming limitations with IM and WM,Inventory Management(IM),Key features/strengthsInventory management by quant

2、ityVisibility of on-hand quantity by storage locationManagement of special stocksEntry and documentation of all material movementsReal-time updates of inventoryDocumentation of all receipts,issues and transfersPhysical inventoryCarry out physical inventory at the material levelPerform inventory adju

3、stments,R/3 Inventory Management(IM)(cont.),Key features/strengths(cont.):Inventory management by valuePostings update account assignments for cost accountingUpdates G/L account for financial accounting Key integration pointsIntegrates directly with MRP,purchasing and invoice verificationProvides in

4、formation for MRP,updates PO;used to check conformity during invoice verificationReal-time updatesWhen transactions are entered,the results the stock updates real time to reflect actual changes,SAP Organizational Structure,Organizational Structure at the IM Level,Challenges with Inventory Management

5、,Lack of detailed visibility to material flow e.g.When the delivery pick list is generated,the deliverys“actual pick quantity”is updated prior to actual pickingRequires manual updates when quantities differInability to assign incoming materials to outbound demand to avoid multiple material handling

6、continued.,Challenges with Inventory Management(cont.),Immediate update of inventory receipts and issues System inventory and status NOT representative of the physical processLimited visibility to locations of materialsOnly possible to assign a single fixed bin location per storage locationBin locat

7、ion is“text”only;no strategies are available,Solution:R/3 Warehouse Management,Initially released with R/2 as an Extension of IMIM-WM integration is real-time and automatic Enables granular traceability and controlAbility to synchronize the system and material flowSimple-to-complex placement and rem

8、oval strategiesAssignment of inbound orders to outbound deliveries Allocation of storage binsProcessing of all stock movements valid for WMReceipts,issues,transfersUtilizes stock placement and removal strategiese.g.Next empty bin,addition to stock,FIFO,LG/SM qtys.,Solution:R/3 Warehouse Management(c

9、ont.),Infancy to maturityFunctionality considerably expanded with 4.6x and higherTwo-step picking,two-step confirmation,managing multiple storage locations with a single warehouseExtension set 2.0 for Enterprise to include Cross Docking,Yard Management,Value Added Services,WM Picks Up Where IM Leave

10、s Off,Typical assignment is one storage location to one warehouseIt is possible to have multiple storage locations managed by a single warehouse,Quant,Bin 1,Quant,Quant,Quant,Bin 2,Stor.Type 2,Stor.Type 3,Warehouse1,Stor.Location1,Stor.Type1,Warehouse 2,Stor.Location2,Plant 1,Location1,Plant 2,Compa

11、ny,IM Level,WM Level,Stor.Type 1,Key WM Features,Management of materialsProvides bin-level trackingInventory management functionsVarious placement and removal strategiesValue-added servicese.g.Special handling requirements(labeling,packaging)Powerful picking controlTwo-step picking,wave pickingFIFO,

12、LIFO,large/small quantity picking strategies,Key WM Features(cont.),Warehouse activity monitorsWAM,RF Monitor,outbound delivery monitor,wave picking monitor,TRM Monitor,Yard Management Cockpit,Cross-Docking MonitorCross-dockingManagement of inbound and outbound movementsYard ManagementAppointment sc

13、heduling,check in and check out,assignment of dock doors,loading/unloading activitiesTask Resource ManagementEnhances WM by breaking work down into distinct task,Fully Integrated with the other SAP ApplicationsFeatures:Flexible Warehouse StructuresGoods MovementsControlInventory,WM Integration With

14、Other Key R/3 Modules(cont.),Source:SAP WM LO530,WM Integration With Other Key R/3 Modules(cont.),IM-WMProcessing of all material movements Automated communication with configurable processingSD-WMTwo-step picking with SD-WM integrationWave picking opportunitiesProcessing individual deliveriesPP-WMP

15、roduction support with PP-WM integrationSupplying materials to the shop floorInternal and external automated replenishment options,WM Integration With Other Key R/3 Modules(cont.),QM-WMHandling of inventory samplesInspection lot is maintained with the material dataHand-held terminals-WMProcessing of

16、 transfer requirementsProcessing of transfer ordersBin and material inquiries,Benefits of WM,BenefitsBetter control of inventory More accurate inventory Able to maintain lower inventory levelsBetter control of information Visibility to picking and put away statusReduced cycle timeGartner:16-25%Picki

17、ng Productivity ImprovementBetter manage work and workforce to gain efficienciesTools to balance and optimize resources Increased picking/shipping accuracy11-25%Reduction in Customer Returns,Benefits of WM(cont.),Measurable benefits16-25%Picking Productivity Improvement11-25%Reduction in Customer Re

18、turns10-25%Savings in Material Handling Labor10-40%Space Utilization Improvement13-30%Reduction in Scrap8-15%Reduction in Carrying Costs Source:Gartner Report,What Well Cover,Understanding the difference between WM and IMChoosing between WM and IMOptimizing and overcoming limitations with IM and WM,

19、When Is Inventory Management the Answer?,IM is great when.Small facility Lower levels of inventory on handSimplistic material handling processesLower volume of activityOutsourced warehouse operationsOnly need storage location or bucket of inventory visibility,Key Elements With IM,Required data for I

20、MPlant,valuation and storage location dataRelevant data for IMWork scheduling,accounting,materials planning,purchasing,classification,storage and quality managementIM menuGoods movementsMaterial documentsReservationsEnvironmentFocused on reporting,lists and LIS,When is Warehouse Management the Answe

21、r?,WM is great whenLarger facilitiesLarge number of materials on handHigher volume or flow throughTraceability and visibility is criticalTrack material flow,status,inventory levels Complex processesAutomated systems,wide spread site,Key Elements With WM,Extend material masterWarehouse management vie

22、wNo required dataDefine warehouse structureMinimize the number of storage types Define based on similar and different rules for storing materialsMixed stock,Storage or Handling Unit ManagementDefine the WM ProcessesAutomatic,semi-automatic and manual processingTransfer order creation,confirmation,po

23、sting changes,Evaluating IM vs.WM,1 Define business processes2 Evaluate ROI of a WMS solution3 Consider RF functionality4 Training resources and schedule5 Focus on optimization opportunities,Step 1-Define Business Processes,Start with receiving,inventory and pick/ship firstCreate and evaluate proces

24、s flow chartsLook at process improvement opportunitiesScore the level of complexityTarget areas for improvementReduce travel timeInventory accuracyReduce material handlingMap improvements to IM and WM functionality,1-Define Business Processes(cont.),“The level of functionality that customers need in

25、 a WMS is completely dependent upon their environment.Customers have to define their needs before they can realistically look for a WMS.”Source:Integrated Solutions,Step 2-Evaluate ROI of a WMS Solution,Measure productivity and accuracy before and after the WMS installationReview and analyze picking

26、 operationsKey area of improvementReview and analyze inventory accuracyWhen supported with RF,accuracy can reach 98%,2-Evaluate ROI of a WMS Solution(cont.),“There is no right time for paying back a WMS,but typical paybacks are within six to 18 months,depending on the inefficiencies of the current o

27、peration and how much safety stock was needed to cover daily operations.”Source:Total Supply Chain,Step 3-Consider RF Functionality,RF supports improves warehouse bin accuracyBin accuracy 98%is possibleReduces order fill process cycle time RF projects often have a 1 year or less payback period Sourc

28、e:Intermec,Compare current receipt process to the time saved when the task is aided by automatic data collection(ADC),3-Consider RF Functionality:Example,As-is1,000 pallets at five minutes/pallet=5,000 minutesWith two minutes saved per pallet2 minutes*1,000 pallets=2,000 minutes 2,000/480 minutes wo

29、rked by each receiver per day=4.16 receivers saved from the pallet receiving process,Step 4-Training Resources and Schedule,Resources to evaluate,guide and support a WM solutionA full-time,dedicated WM resource is critical This may or may not be the same IM resourceTraining scheduleA WM solution wil

30、l require a certain level of IM trainingWM training will vary based on the degree of functionalitySupport resourcesConsider a single resource for IM and WM if possible,5-Optimization Opportunities,Picking operations and inventory accuracyWhat are your baseline requirementsWhat is the volume of activ

31、ityEvaluate picking paths and demandLook at your accuracy numbers over a period of timePerhaps monthly,quarterly,annuallyMaterial handling labor costsSpace utilization improvementsPacking tasksCan you benefit from packing while picking,What is the BEST Stock Management Solution?,1-Inventory Manageme

32、nt2-Lean Warehouse Management3-Full Warehouse Management4-Decentralized Warehouse Management,Option#1-Inventory Management,ProsSimplisticKey receipt,issue or transfer in a single step transactionImmediate update of inventoryRequires less training commitmentFewer transactions to document and presentT

33、race-ability of all material postings into SAP R/3Date,user,material,quantity,storage locationReal-time update of accounting information,1-Inventory Management(cont.),ConsDoes not handle complex warehouses operations wellUnable to monitor activitiesLacks tools to manage resources and tasksLacks func

34、tionality to optimize key processes(picking)Inaccurate system inventoryInventory updated before the physical movementRequires additional work if there are discrepanciesLimited trace-abilityOnly visibility is when the system posting took placeNo visibility to the follow on physical activities,Option#

35、2-“Lean”Warehouse Management,Use of very small portion of WM capabilitiesYou do not process goods receipts or issues as a subsequent process in WM,No storage bins are managed in the WM applicationEvolved from SD pick listPut-away and pick from 1 or more fixed binsBin is hard assigned on material mas

36、terTOs are created for picks and put away,and pick list is created from TOs,2-“Lean”Warehouse Management(cont.),ProsRequires less configuration than full WMReduced number of steps in the processUse of transfer orders as pick listsConfirmation is not requiredAdditional processing optionsConfirm put-a

37、way,picking,over-deliveries,shortages,batchesPrint transfer ordersIntegration to HRAdditional picking functionalityWave picking is possible with Lean WM,2-“Lean”Warehouse Management(cont.),ConsMust have a fixed bin assigned for all materialsRandom storage is not possibleInventory is still under IM f

38、unctionality onlyInventory options are at the storage location Stock differences can only be processed in MM-IMLacks additional optimization opportunitiesPicking,packing,bin accuracyNo strategies are usedLack of picking and put away strategies,Option#3-Full Warehouse Management,ProsOptimization oppo

39、rtunitiesPicking-Two step pickingPacking-Pick and pack in a single stepCross-docking-Inbound,outbound,prod.materialsMonitoring and real time visibility to process statusVisual queues at the detailed stepsOpen tasks,completed tasksAdditional inventory methods(annual,zero stock)The module is FREE with

40、 the purchase of SAP,3-Full Warehouse Management(cont.),ConsInventory counting interferes with operations without RFPrior to 4.7 extension set 2.0Initial overhead to set up depending on designMaster dataCapacity checking,control cyclesConfiguration requirementsDesigning the warehouse layout and set

41、upPotential for additional steps to support processingConfirmationsClearing differencesProcessing posting changes,Option#4-Decentralized Warehouse Management,Use of SAP as a standalone WMSWith SAP or other ERP/host as the core systemCore system and decentralized WM run on separate machinesCommunicat

42、ion is through BAPIs for transactions and IDOCs for master dataGoods movements done through delivery notes to the stand-alone SAP WM system,4-Decentralized Warehouse Management(cont.),ProsOn a separate machineDecreases criticality of down time24x7 operationCan leverage newer SAP R/3 releasesEven if

43、core system is on an older releaseCan add additional warehouses without impact to the core systemCan communicate to multiple core ERP systems,4-Decentralized Warehouse Management(cont.),ConsCore system is not 24x7 operationIDOC and/or BAPI errorsIDOC failuresHuman intervention is required to work th

44、e error queueIDOC overheadIDOCs do not offer all of the available field options that a user may or may not use with the PC transactionMust modify the IDOCSAPConsole has to be set up in the decentralized system and in the core system,Scaling the Solution,Operational Complexity,Transaction Volume,IM O

45、nly,Lean WM,WM,DecentralizedWM,TRM,What Well Cover,Understanding the difference between WM and IMChoosing between WM and IMOptimizing and overcoming limitations with IM and WM,Optimizing and Overcoming Limitations With IM and WM,1-Physical Inventory tips2-Enhance visibility of material flow and loca

46、tions3-Automate picking and put-away4-Automatically replenish fixed bins5-Consolidate your picking activities6-Overcome bottlenecks with RF,1-Physical Inventory Tips(IM),Only possible if the storage location data has been maintainedSolution:Activate automatic storage location for movement types that

47、 receive material into the plantAvoids the need to create storage data manually For materials with multiple storage location reqmts.Use the mass creation option for entering all valid storage locations at one time into a single entry screenTransaction code=MMSC,2-Enhance Visibility of Material Flow

48、and Locations(IM),Use fixed bin assignment to gain additional visibilityMaterial master storage location viewTwo-step transfers vs.one-step movementsStorage location-to-storage location(movements 313,315)Plant-to-plant(movements 303,305,351,352)Outbound delivery monitorUse to view outbound deliverie

49、s,shipments and loading activities,3-Automate Picking and Put-away(WM),Define a picking strategy per storage typeA-Partial quantity managementIf picking results in partial quantities,pick from here first to avoid breaking new palletsM-Large/small quantities includedUse to facilitate larger quantity

50、picks from bulk areas and smaller quantity picks from rack areasP-Fixed bin from material masterFor fast moving items,assign a dedication location toward the front of the warehouseUse replenishment to enough maintain stock for demand,3-Automate Picking and Put-away(WM)(cont.),Define a put away strat