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5.6

WAREHOUSE MANAGEMENT SYSTEM 5.6PRODUCTINFORMATION

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Material Handling and Storage Systems

Uses and Benefits Warehouse Manage-ment System (WMS) 5.6The STöcklin WarehouSe ManageMenT

SySTeM coMbineS all funcTionS Which

are neceSSary To operaTe a fully auTo­

MaTed WarehouSe

The Stöcklin Warehouse Management System (WMS) man­

ages articles, quantities and load carriers as well as the ex­

isting warehouse locations. The integrated Material flow

controller (Mfc) controls, monitors and visualizes the different

material flow systems.

The StöcklinWMS® is divided into functional components

comprising a wide range of software modules.

according to the project requirements, the modules can be

used separately or combined. The Stöcklin Warehouse Man­

agement System can be seamlessly integrated into the hier­

archy of the systems used in an automated warehouse. The

operational safety and quality of a software system depends

decisively on its internal structure. So, for the conception and

development of the Stöcklin Warehouse Management System

many different requirements have been taken into account.

Benefits of the Stöcklin WMS 5.6Fast integration• Standardized data acquisition

• Configurable Host (ERP) interface

• Optimized for the Stöcklin Programmable Logic Control (PLC)

Easy to use• Task-focused user interfaces

• Intuitively learnable application

• Visual overview on the entire warehouse systems

Flexible and adaptable to individual needs• Graphic display of working processes

• Parameterizable warehouse strategies

• Configurable user interfaces

• Individually definable reports

The Warehouse Management pyramid

Leading System for storage­ and stock removal orders and the article

administration

Configurable Warehouse Manage-ment System

The different modules can be applied according to

the funcitional requirements of the users

Control Technology operates the warehouse equipment

Order ManageMent SySteM (Ord) in The order ManageMenT SySTeM (ord)

are all funcTionS inTegraTed for The

MoST efficienT operaTion of an auTo­

MaTed WarehouSe

The order Management System (ord) combines all functions

necessary to operate automated warehouses cost­effectively.

Therefore, in the development process the focus was not to

implement as many functions as possible, but rather to design

the relevant features so that they are easy to use and highly

reliable.

basically ord, which interacts closely with loc, the location

Management Module, has been designed to manage articles

and storage quantities. This also includes the handling of lots

(loTcode, Serial number etc.).

for roll­in of goods the quantities of the articles are allocated

to physical or logical load carriers. The nominal quantities of

outgoing orders received from the erp system are reserved

according to e.g. first in, first out from the existing stock.

once the goods have been retrieved from the warehouse, an

acknow ledgement is sent to the erp system.

for rollouts of goods the nominal quantities (retrieval orders)

transmitted by the hoST are reserved from the existing stock

according to first in, first out, first expiry, first out, emptiest

load carrier (pallet or container), or other rules. The actual

retrieval from the warehouse is then reported to the erp system

via the hoST interface.

With the StöcklinWMS®, rollout and picking processes can

easily be adapted and optimized for project-specific require­

ments. Thereby, defined targets like warehouse output or

readiness to deliver and reliability have absolute priority. To

achieve this, in an automated warehouse not only menu­guid­

ed picking workplaces, but also systems like pick by light, pick

by Voice or wireless terminals are used. Printed picking lists

with barcodes for scanning may also be suitable.

Functions of the order management system (ORD)• SKU (Stock Keeping Unit) information and stockkeeping

• Stock receipt orders

• Stock receipt and palletizing process

• Rollin

• Picking orders

• Menu-guided rollout and picking

• System-aided picking

• Inventory

article Masterdata in edit mode

article Master data

Storage processStorage processes may vary strongly because of the differ­

ent types of goods which are to be stored in a warehouse.

accordingly, special workplaces need to be provided for the

stock receipt. Substantial differences exist particularly be­

tween the workplaces of automatic and manual warehouse

sections. it may not be clear in the beginning (by referring

to the article or the order) in which part of the warehouse

the received products are to be stored. in this case, e.g. the

warehouse personnel must decide about the target location

according to the given internal requirements.

for this reason, the Stöcklin Warehouse Management System

is provided with a high flexibility for operating the storage

processes, which may be easy designed individually for each

project.

Stock Receiptusually, stock receipts are transmitted by the erp system

as preliminary notes generated on the basis of supplier or­

ders. Stock receipts can also be created manually, whether

planned or unplanned. The stock receipts are then saved in

the StöcklinWMS® as stock receipt orders waiting for the cor­

responding goods to be delivered. The stock receipt orders

consist of header data and the corresponding position data.

The header contains data like the date of creation and de­

livery. The positions contain the individual articles with batch

number as well as ordered and delivered quantities.

Palletizingin the goods receiving area, the delivered items are checked

and the quantities assigned to physical or logical load car­

rier (pallet, bin, tray, carton etc.) by the warehouse staff. if

there are several warehouses, the goods may be registered

in a common receiving area and then stored according to the

accompanying documents into the corresponding warehouse.

Order pickingin automated warehouse sections palletizing or depalletizing

robots or dedicated picking systems, may also be integrated.

according to the individual requirements, delivery/packing or

accompanying documents can be used.

extensive business rules and the common retrieval strategies

fifo, fefo and lifo can be applied according to the indi­

vidual requirements.

The picking orders consist of header data and the corre­

sponding position data. The header contains data like the

date of creation and delivery, the current order status and

order­related data of the customer. The positions contain the

individual articles with lot number as well as ordered and de­

livered quantities.

Menu-Guided Order Picking in the auto-mated warehouseThe load carrier is displayed with its partitions, if any. an ar­

row shows the operator the location of the load carrier from

which the articles have to be picked.

afterwards, the picking screen is cleared and waits for the

next load carrier to reach the picking station.

example: picking user interface for automated warehouses

example: roll­in user interface

LOcatiOn ManageMent (LOc) in order To Manage The differenT TypeS

of WarehouSeS and carrierS opTiMally,

STRaTEGIES HaVE bEEn IMPLEMEnTEd fOR

roll­in (STorage poSiTion Search) and

roll­ouT (rouTe opTiMizaTion) ThaT enable

an efficienT operaTion of The enTire Ware­

houSe:

To achieve an enhanced performance for roll­in and roll­out

smart rules and algorithms have been implemented. Multiple­

deep storage is supported, too.

loc optimizes the performance of total warehouse system so

that, for instance, load carriers that belong together are stored

on the same shelf while those which are to be retrieved earlier

than others are placed in front. another example: based on

how full the warehouse is overall, the search for a location for

the first load carrier of a group is carried out in such a way

that a rear rack location is assigned within a suitable aisle.

Methods of storage location management• fixed location system (static storage position allocation). a

fixed storage location is assigned to the article master data

• Chaotic or dynamic storage. Unlike the fixed location sys­

tem, with this method the system determines and allocates

the best location for all incoming goods „on the fly“. This

decision is based both on item-specific criteria (quantity,

size, transfer frequency, compatibility etc.) and warehouse­

related data (available space, free locations).

Storage strategiesThe storage strategy is assigned as an attribute to each ar­

ticle. different articles may have different strategies:

• fixed-location storage

• fIfO/Chaotic storage

• Incremental storage strategy

• Replenishment strategy

Capacity checkThe capacity checks can be defined according to the follow­

ing aspects:

• quantity

• weight

• volume

• size

The capacity check may be carried out for various locations

together (e.g. a rack section with a determined cumulated

load capacity).

Carriers and storage locationsThe related information can be searched and displayed in

detail both for carriers and storage locations. navigation ac­

cesses to the articles stored on the carriers is available. The

creation and modification of carrier types is easy by using the

carrier configuration option.

Other storage allocation strategiesThe StöcklinWMS® permits the implementation of individual­

ized allocation strategies within the system. These strategies

comprise for instance:

• customized storage allocation

• article and warehouse area-related strategies for an opti­

mized utilization of space and short distances for storage

and retrieval

• Short transportation ways for roll-ins and roll-outs

• optimization by means of warehouse consolidation pro-

cesses

information about carriers

Double/Multiple depth storage for large amounts of identical articlesStacker cranes may pick up several load carriers simultane­

ously in order to store or retrieve them from double/multiple­

deep racks. This requires rules and algorithms for a high­per­

formance storage and retrieval.

The type of storage decides on the performance level of the

posterior retrieval. The critical issue is: e.g. how many rear

containers are to be retrieved before retrieving one front con­

tainer. if no boundary conditions are known, the „randoM“

strategy can be implemented. This strategy is implementing,

that there is no dependence between the carriers. relocations

are the result.

To achieve an optimized double/multiple­deep storage, the

load carriers have to be grouped (e.g. by articles, lots, goods

receipt, etc.) or sorted by a clearly defined value, e.g. the stor­

age date whereby also the retrieval strategy must be taken

into account to ensure an optimum performance of the entire

system.

With regard to the retrieval strategy, the goods may be

grouped or sorted by a determined value.

When applying above strategies it is convenient to place

matching carriers in the same storage location. The carriers

which are to be retrieved first should be stored in front.

Taking into account the above, different search strategies are

the result.

Warehouse visualization for an optimum overview on the current warehouse occu-pationThe warehouse visualization offers a view on the storage

racks so its occupation with carriers (pallets or boxes) can be

observed. Users can see at first glance the degree of occupa­

tion of a storage rack and the situation of the free storage

locations. The color of the storage positions may represent the

storage location type or the storage zone affiliation.

by clicking on the storage location its detailed information is

shown in the lower part of the visualization screen. in order to

obtain an optimal view on the storage rack, it can be zoomed

or scrolled, if too large.

Single/double (as shown in the picture) or multiple­deep stor­

age racks can be visualized.

Warehouse Visualization

MateriaL FLOW cOntrOLLer (MFc) uSer of inTralogiSTic SySTeMS are

focuSing More and More on iTS logiSTic

proceSSeS in order To gain long laSTing

COMPETITIVE adVanTaGES, aS WELL aS TO

increaSe reTurnS.

along the whole value chain of production, intelligent logistics

solutions are needed in order to speed up significantly the

flow of goods, and enhance the availability on time while still

reducing costs.

The main task of warehouse logistics is to maintain and

smoothly process the different flows of information and ma­

terials. existing cost saving potentials can be realized only

through permanent optimization of the logistics processes.

Stöcklin took this essential requirement as a commitment to

integrate an innovative solution into the Warehouse Manage­

ment System in order to ensure an efficient control of the com­

plex material flow processes any time.

each operation has its own characteristics, and therefore it

must map the warehouse users business processes 1:1 and

fully support them.

Thus, the system architecture is designed to visualize precisely

these specific processes and characteristics without any pro­

gramming.

The project practice would look like this: With the Workflow-

Explorer, a component of the StöcklinWMS®, the Stöcklin pro­

ject team can customize the system directly and efficiently for

the customer‘s needs without loosing time for writing software

codes. The graphic user interface of the Workflow explorer

also enables to recover previously used processes and sto­

rage strategies immediately. This helps for quick adaptations

on a current business situation.

Stöcklin logistik is focusing on this technology and procedure

for many reasons. for the customer they have positive effects

on the project duration and costs. another advantage is the

fact that the future software versions can be installed without

relevant effort because the strategies and procedures are not

written directly into the software code.

Control desk with 2d-Visualization

the SySteM aLWayS Under cOntrOL With the cOntrOL deSkThe conTrol deSk alloWS The coMprehen­

SIVE OPERaTIOn Of THE STöCKLIn WaREHOUSE

ManageMenT SySTeM 5.6:

Functions of the control desk• Information on the material flow (visualization 2d and 3d),

on load carriers, articles, storage locations, picking orders,

orders and picking lists

• Control of the material flow (manual load carrier roll-out, roll-

out of unknown load carriers)

• Manual operation of automated sections

• Correction of material flow and transport orders as well as

changes of priorities

• Information necessary for the operation of the system (used

by Stöcklin personnel for system maintenance and support)

• Comprehensive information on the master data

• administration of the identity management

• Creation of system queries (Quick Queries) and reports

Control desk with 3d-Visualization

in times of steadily rising energy costs, Stöcklin logistik has

focused its development projects more and more on active

energy saving. The features already available allow to save a

total of up to 20% of energy.

nevertheless, the actually achievable power savings depend

substantially on the applied storing strategy and the required

warehouse output as a function of time. furthermore, in this

context the optimum deployment of the used erp system is

crucial. a large part of the energy saving potentials must

be implemented already in these systems. Thus, it is very im­

portant to synchronize all important subsystems (erp system,

warehouse management system, control and drives) optimally

to achieve the desired energy saving goal.

in the end, active energy saving cannot be reduced to the

technical aspects of warehousing only. if the operator of the

warehouse does not share this attitude, the systems will only

profit of a part of its energy saving potential.

for that reason Stöcklin logistik gives great importance to the

training of warehouse staff in order to achieve that all involved

persons get the right feeling for an energy­saving warehouse

operation.

The warehouse users will be able to control the subsystems

and take operative decisions in a way that really important

energy savings will be achieved.

Stöcklin Energy Concept works in two directions, not only to

save energy but also to reduce and avoid energy costs and

total energy delivery costs:

­ reduction of energy consumption in kW/h

­ avoidance and reduction of current peaks

StöckLin energy ManageMent (SeM)The „STöcklin energy concepT“ coMpriSeS

a SerieS of feaTureS and acTionS WiThin

The STöcklin WarehouSe ManageMenT

SySTeM and The STöcklin conTrol SyS­

TEM, WHICH aRE dEPLOyEd TO aCTIVELy SaVE

energy.

Easy operation and overview with 2D and 3D

visualization

To render the 3d visualization of the Stöcklin Warehouse Man­

agement System, the positioning data of the individual ma­

terial flow objects like pallets or containers are recorded at

regular intervals by the system and converted into a dynamic

animation. The warehouse section selected via the zoom func­

tion can be turned and tilted in any direction by means of

sliders to allow an optimum view. The selected sections may

be stored in the system and re­used if necessary.

especially customers with wide spread material flow systems,

which are difficult to overlook, benefit from the high visual in­

formation content of a control desk equipped with 3d visual­

ization. The great advantage of the 3d visualization compared

to the 2d visualization system, which can be used additionally,

is the better perceptibility of the events in the plant, as they are

very similar to the real appearance.

furthermore, the information content of the 3d visualization

is considerably higher. The status information of the material

flow objects and stations is provided through color changes.

The colors allow a quick identification of faulty system parts

which are displayed in red on the screen. Thus, the person­

nel at the control desk are able to make the correct decisions

in critical situations quickly, in order to recover an error­free

operation promptly.

a clear overview on vast or complex warehouses is made pos­

sible with 3d visualization. It offers also additional advantages

for servicing, plant maintenance and repair. The 3d visualiza­

tion guarantees a comfortable, reliable and cost­effective op­

eration of the Stöcklin Warehouse Management System from

the control desk.

Control desk with 2d-Visualization

graphical display of the energy consumption

report of Stöcklin enegery concept

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Material Handling and Storage Systems

for more than 80 years, the Swiss Stöcklin group has

been providing worldwide innovative logistics solutions

to the highest standards.

We provide a successful completion of turnkey systems,

professional project management, clearly defined sys­

tems interfaces and closely coordinated partnerships.

Stöcklin stands for long­term, ongoing development of

propriety systems and products, high­quality and pre­

dominantly Swiss manufacture, and the highest stan­

dard of customer service.

our range includes:

· manually and automatically controlled warehousing

for pallets and small parts

· conveying and order picking systems

· control systems, warehouse management and

material flow systems

· Refurbishment and retrofitting of existing installations

· 24 hours support service

STOCKLIN LOGISTICSyour general conTracTor for

ToTal SoluTionS — Turnkey

MaTerialS handling and STorage

SySTeMS — cloSe To you

Stocklin SidusMaterial handling and Storage SystemsRUS-445032 Samarskaya oblastoffice@sidus.ruwww.sidus.ru

Stöcklin Logistik agförder– und lagertechnikCH-4143 Dornachinfo@stoecklin.comwww.stoecklin.com

Stöcklin Logistik agförder– und lagertechnikbüro JonaCH-8645 Jonainfo@stoecklin.comwww.stoecklin.com

Stöcklin Logistik gmbhförder– und lagertechnikDE-57250 Netpheninfo-dE@stoecklin.comwww.stoecklin­logistik.de

Stocklin Logistics Sarl.Technique de manutentionet de stockageF-93350 Le Bourgetslf@stocklin-logistics.frwww.stoecklin.com

Stocklin c.a.S.Material handling andStorage SystemsGB-Aston Oxon OX18 2DQas@stocklin.co.ukwww.stocklin.co.uk

Stöcklin spol s r.o.flurfördermittel undkomponentenCZ-76001 Zlínstoecklin@zln.czwww.stoecklin.cz

Stöcklin Logistics de MéxicoMaterial handling and Storage SystemsMX-54090 Tlalnepantlaestado de Méxicoinfo@stoecklin.com.mxwww.stoecklin.com

Stöcklin Logistica do Brasil Ltda.Material handling and Storage SystemsBR-Moema-São Paulo-SPernesto.grassl@stocklin.com.brwww.stocklin.com.br

Stöcklin BVMaterial handling and Storage SystemsNL-5835 AC Beugeninfo@stoecklin.nlwww.stoecklin.nl

Stoecklin Logistics inc.Material handling and Storage SystemsGA-30318 Atlantainfo-us@stoecklin.comwww.stoecklin.com