“ Warehousing sorted at long last - Oracle WMS a case study”

By

Jim Garrywww.aflux.com.cn

December 2001

Oracle CustomersOracle Customers

Clinical Trials Services was Clinical Trials Services was set up in 1989, as a set up in 1989, as a

subsidiary of Galen Holdings. subsidiary of Galen Holdings. They undertake all key They undertake all key

Clinical Trial processes from Clinical Trial processes from blinding capsules to blinding capsules to

worldwide distribution to worldwide distribution to investigator sites. investigator sites.

Who are CTS ?Who are CTS ?

CTS provide a wide range of Clinical Trials related services to their customers They work closely with their clients to ensure that all operational procedures comply with Good Manufacturing Practices (GMP) and are accurately and extensively documented. This provides the essential guarantee that ensures the integrity of all products.

What CTS DoWhat CTS Do

CTS WMS RequirementsCTS WMS Requirements•Control of Finished Goods at a Patient Pack (Serial Number) level

•Identification of the storage location within the warehouse

•Status Control at a Lot and Patient Pack Level•Implementation of distribution control workflow processes

•Identification of the Container number (LPN) within the location

•Production of Pick Lists listing products, Lots, Container, and Patient Pack numbers (Rules Based).

•Finished product update/down date at point of dispatch

CTS WMS RequirementsCTS WMS Requirements

•The allocation of stock to Pick Lists•The automatic updating of Inventory quantities using file transfer, barcoding or other suitable means.

•Full traceability of all transactions•Interface with existing and future systems (e.g. IVRS)

•The system to be validated to FDA standards

WMS - WMS - An Implementation Nightmare?An Implementation Nightmare?•Warehouses and Distribution centres are the pivotal points in the Supply Chain that facilitate the balance between supply and demand

•Business Continuity in warehouses is vital and any interruption will cause a ripple effect across the Supply Chain

•The WMS is a key enabler of Supply Chain Execution activity

•WMSs have traditionally proven to be an implementation nightmare

•40% of WMS implementations fail•The success of Oracle WMS is dependent on the success of its implementation and customer satisfaction

ImplementingImplementingOracle Mobile Supply Chain Oracle Mobile Supply Chain

AppsAppsandand

Oracle Warehouse ManagementOracle Warehouse Management

WMS Installed, WMS Organisation

• LPNs• Cost Groups• Rules• Tasks• Cartonisation• Exception Workflows

WMS Installed, Inventory Organisation

• Mobile User Interfaces for• Inventory• Receiving• Shipping• Manufacturing• Quality

• Labeling

• Material Status

• Lot Serial Attributes

What do you get with . . .What do you get with . . .

MSCA• Mobile User Interfaces for

• Inventory• Receiving• Shipping• Manufacturing• Quality

• Labelling

Oracle Mobile Transaction Oracle Mobile Transaction ServerServer

• A “Forms Server” for A “Forms Server” for industrial (barcode) industrial (barcode) devices connected via an devices connected via an RF LANRF LAN

• Standards based - 802.11, Standards based - 802.11, Telnet over TCP/IPTelnet over TCP/IP

• Device independent - Over Device independent - Over 20 devices already 20 devices already certified from Intermec, certified from Intermec, Symbol and LXESymbol and LXE

• Scalable - Multiple serversScalable - Multiple servers• Supportable - Applications Supportable - Applications

may run as Telnet session may run as Telnet session on desktop and may be on desktop and may be “mirrored”“mirrored”

OrOracle Mobile Applications acle Mobile Applications FrameworkFramework

• Java basedJava based• Device independentDevice independent• Intuitive UIIntuitive UI• Field level validationField level validation• DFI’s and 2D barcodesDFI’s and 2D barcodes• Multiple languagesMultiple languages• ExtensibleExtensible

A Development framework designed to create UI’s suitable for these devices

Oracle Mobile Applications Oracle Mobile Applications ArchitectureArchitecture

Application /Application /Data BaseData Base

RF RF Base Base

Station Station (Router(Router

))

LAN or LAN or WANWAN

Mobile Mobile Transaction Transaction

ServerServer

SQL NetSQL NetTelnet over TCP/IPTelnet over TCP/IP

RF RF DeviceDevice

Mobile Transaction ServerMobile Transaction Server– Standards based, Device Standards based, Device

independent, Scalable, independent, Scalable, SupportableSupportable

Mobile Applications FrameworkMobile Applications Framework– Java based, Extensible, Device Java based, Extensible, Device

independent, Intuitive UI, independent, Intuitive UI, Field level validation, DI’s and Field level validation, DI’s and 2D barcodes, Multiple 2D barcodes, Multiple languageslanguages

Oracle Mobile Supply Chain Oracle Mobile Supply Chain ApplicationsApplications

• Mobile Manufacturing -Mobile Manufacturing - Issues, Moves, Issues, Moves, Completions, Scrap, ...Completions, Scrap, ...

• Mobile Quality - Quality collections, View Mobile Quality - Quality collections, View specifications, …specifications, …

• Mobile Receiving - PO’s, transfers & returns, Mobile Receiving - PO’s, transfers & returns, cross-dockong, ...cross-dockong, ...

• Mobile Inventory - Transfers, misc issues & Mobile Inventory - Transfers, misc issues & receipts, counts, ...receipts, counts, ...

• Mobile Shipping - Ship confirm, Print shipping Mobile Shipping - Ship confirm, Print shipping documents, ... documents, ...

Mobile support for existing desktop applications

Oracle MSCA is best for Customer who:– Want RF support and are satisfied with the

current 11i inventory functionality – Need Mobile Manufacturing or Mobile Quality

Warehouse execution systems, bolted on to existing legacy or ERP systems

Traditional Bolt-on WMS Traditional Bolt-on WMS SolutionsSolutions

ERP ERP SystemSystem

• ERP Schema• ERP Techstack• ERP Hardware• ERP Vendor • EPG Support• ERP Release

Bolt-on WMSBolt-on WMS(EXE, Swisslog, LIS, …)(EXE, Swisslog, LIS, …)

• WMS Schema• WMS Techstack• WMS Hardware• WMS Vendor• WMS Support• WMS Release

• Huge and ongoing integration costsHuge and ongoing integration costs• Operational complexityOperational complexity• Business process limitationsBusiness process limitations

Items, Customer, Vendors, ...Items, Customer, Vendors, ...

PO’s, Orders, Deliveries, ...PO’s, Orders, Deliveries, ...

Receipts, Shipments, Adjustments, ...Receipts, Shipments, Adjustments, ...

Complex integration

Physical, Replenishment, ...Physical, Replenishment, ...€€

Oracle Warehouse ManagementOracle Warehouse Management

A full-function, Warehouse Management application delivered as an integral part of the Oracle E-Business Suite•Built-in, not Bolt-onBuilt-in, not Bolt-on•Faster, Easier ImplementationFaster, Easier Implementation•Lower Ongoing Cost of OwnershipLower Ongoing Cost of Ownership•Strong WMS & Logistics Strong WMS & Logistics

FunctionalityFunctionality

• Where do we pick this order line from?Where do we pick this order line from?• Where do we put this receipt away to?Where do we put this receipt away to?• What is the best way to organise our picking What is the best way to organise our picking

wave?wave?• Who is best qualified to perform activities?Who is best qualified to perform activities?• What container should we use to pack this What container should we use to pack this

delivery?delivery?• What labels do customers want on their deliveries?What labels do customers want on their deliveries?• How can we automatically adjust these How can we automatically adjust these

requirements day-to-day, warehouse-to-requirements day-to-day, warehouse-to-warehouse, customer-to-customer, …?warehouse, customer-to-customer, …?

… and we want to do this without customisation ?

Hard Questions asked by CTSHard Questions asked by CTS

WMS Rules EngineWMS Rules Engine

• ““Customisation without coding”Customisation without coding”• Any data combination may be used Any data combination may be used • Designed for business users, not programmersDesigned for business users, not programmers• Visible, UpgradableVisible, Upgradable• Seeded examples, Testing and debug modesSeeded examples, Testing and debug modes• Used throughout Oracle WMSUsed throughout Oracle WMS

Allows you to control Oracle WMS operations via flexible, user defined business rules

Directed Picking and PutawayDirected Picking and Putaway

ReceiptReceiptRulesRules

EngineEnginePickPick

LocatorLocator

• Optimises the use of storage locationsOptimises the use of storage locations• Minimises inventory fragmentationMinimises inventory fragmentation• Controls hazmat and co-mingling restrictionsControls hazmat and co-mingling restrictions• Reduces obsolescenceReduces obsolescence

Suggest optimal locators for picking & putaway via user defined business rules in Rules Engine

Automated Task DispatchingAutomated Task Dispatching

Task Task QueueQueue Task 1Task 1 Task 2Task 2 Task 3Task 3 ......

Move Move OrdersOrders Line 1Line 1 Line 2Line 2 Line 3Line 3 ......

• Eliminates manual, parallel systemsEliminates manual, parallel systems• Correctly matches skills and equipment Correctly matches skills and equipment

to tasksto tasks• Minimises picking travel timeMinimises picking travel time

Assign tasks to the optimal, qualified resource and send them directly to that users RF device

Task Sorting and SequencingTask Sorting and Sequencing

• Cluster pick, by Order, by Zone, Bulk, Paper-Cluster pick, by Order, by Zone, Bulk, Paper-based, Pick and Pass/Label Picking, User definedbased, Pick and Pass/Label Picking, User defined

• Will merge tasks for Bulk, Split tasks for capacityWill merge tasks for Bulk, Split tasks for capacity• Minimises picking pathMinimises picking path

Grouping/Splitting of tasks by a variety of Pick Methodologies to optimise overall process

Task ExceptionsTask Exceptions

•Trigger corrective actions (counts, Trigger corrective actions (counts, inspection, …)inspection, …)

•Increases inventory accuracyIncreases inventory accuracy•Assist in user performance trackingAssist in user performance tracking

Launch corrective action workflow for any task not completed as expected

LPN’s - License Plate NumbersLPN’s - License Plate Numbers

Inventory

== A23595P

|| || | ||| ||| ||

• Supports infinite levels of nesting Supports infinite levels of nesting • Perform mass, complex operations with a Perform mass, complex operations with a

single scansingle scan• Improves efficiency, accuracy and trackingImproves efficiency, accuracy and tracking• Fully integrated with ASN’s Fully integrated with ASN’s

A “mobile locator” used to identify and transact against any set of inventory

CartoniCartonissationation

• Define content types - solid, liquid, frozen, Define content types - solid, liquid, frozen, etc.etc.

• Assign those types to items and to Assign those types to items and to containerscontainers

• e.g. Drum “A” is for liquids up to 100 litrese.g. Drum “A” is for liquids up to 100 litres• Match the container to the item based on Match the container to the item based on

the content type and the item dimensionsthe content type and the item dimensions• Automates picking the correct containerAutomates picking the correct container• Minimises the number of containers usedMinimises the number of containers used

Automate packing container selection based on the characteristics of the item and shipment

Cost GroupsCost Groups

• Permits and controls co-mingling of Permits and controls co-mingling of inventoryinventory

• Reduces inventory fragmentationReduces inventory fragmentation• Automatic assignment via the Rules EngineAutomatic assignment via the Rules Engine

Represents accounting / ownership of an inventory balance, independently from location

Old Old Sub-Sub-

InventoryInventory

New Sub-Inventory New Sub-Inventory (Physical Zone)(Physical Zone)

Cost Group Cost Group (Financial)(Financial)

Advanced Materials Advanced Materials ManagementManagement

• Material StatusMaterial Status– Status of an Item instance or Item lotStatus of an Item instance or Item lot

• e.g. Raw, Immature, Rework, Refurbished, e.g. Raw, Immature, Rework, Refurbished, Used, ...Used, ...

– Can control which transactions are validCan control which transactions are valid– Additional to “Item Type” which is for Additional to “Item Type” which is for

whole “product”whole “product”• Sub-lot support (split and merge)Sub-lot support (split and merge)• Lot and Serial GenealogyLot and Serial Genealogy• Lot and Serial AttributesLot and Serial Attributes

– User definable, updateable, searchable, ... User definable, updateable, searchable, ...

Additional features designed to support complex inventory needs

WMS Control BoardWMS Control Board

• View pending workload across the View pending workload across the organiorganissationation

• Manage exceptionsManage exceptions• Review, reassign and reprioritiReview, reassign and reprioritisse queued e queued

taskstasks• Create new tasksCreate new tasks• Perform mass updatesPerform mass updates• Display in tabular or graphical representationDisplay in tabular or graphical representation

A general purpose workbench for managing Oracle WMS status and activity

WMS Control BoardWMS Control Board Task DetailTask Detail

WMS Control BoardWMS Control Board Status by Status by EmployeeEmployee

CTS Issues and resolutionCTS Issues and resolution

• 1111i i Upgrade neededUpgrade needed– Server CapacityServer Capacity– TARsTARs– Functionality trainingFunctionality training– Upgrade timingUpgrade timing

• Pharmaceutical Validation (FDA)Pharmaceutical Validation (FDA)– CFR Part 11CFR Part 11

CTS Issues and resolutionCTS Issues and resolution

• U.I. DevelopmentU.I. Development– No release procedure – initiallyNo release procedure – initially– Defaulting DataDefaulting Data– Drop down menusDrop down menus– Change prompt order (e.g. S/Ns first)Change prompt order (e.g. S/Ns first)– Quantity always 1Quantity always 1– Logic Changes Logic Changes

CTS Issues and resolutionCTS Issues and resolution

• LabellingLabelling– Label designLabel design– Labelling of warehouseLabelling of warehouse– Labelling of existing stockLabelling of existing stock

• Picking changesPicking changes– Untampered and tamperedUntampered and tampered

CTS Issues and resolutionCTS Issues and resolution• Barcode PlacementBarcode Placement• Transacting non-sequential Serial NumbersTransacting non-sequential Serial Numbers• Making “suggest” Serial number pick mandatoryMaking “suggest” Serial number pick mandatory• Moving full and partial cartonsMoving full and partial cartons• Moving ranges of serial numbersMoving ranges of serial numbers• Making existing stock serial controlledMaking existing stock serial controlled• Procedural changesProcedural changes• TrainingTraining• Contingency planning Contingency planning

Top 7 impediments to a successful Top 7 impediments to a successful WMS ImplementationWMS Implementation

1)1) Installing a WMS in a broken warehouseInstalling a WMS in a broken warehouse2)2) Poor Project Mgmt/Change Poor Project Mgmt/Change ManagementManagement3)3) Equipment Integration pitfallsEquipment Integration pitfalls4)4) Overselling the ProductOverselling the Product5)5) Inadequate end-user trainingInadequate end-user training6)6) Lack of a Contingency PlanLack of a Contingency Plan7)7) Failure to audit resultsFailure to audit results

Being in a “Pharms” environment helped all of these

Implementation ConsiderationsImplementation Considerations

1)11i Upgrade Requirement2)Barcoding Strategy3)Warehouse Re-engineering/Layout4)Hardware Considerations5)Operational Processes6)Testing/Training7)Go-Live Strategy8)Miscellaneous

Custom Reports Document Changes (ASNs, Labels etc.)

AQ&Q U E S T I O N SQ U E S T I O N S&&

A N S W E R SA N S W E R S

Want to talk to me ?Want to talk to me ?

Mail me at info@aflux.com.cn

更多案例：http://www.aflux.com.cn/anli.html