Oracle R12 dWMS Implementation

Success Story for Implementing Oracle R12 Distributed WMS

Dale Welsh, Ron Wind August, 2010

Agenda
        Introduction Evaluation Process to define and deliver dWMS Implementation Infrastructure Implementation Implementation Road Map Benefits of dWMS Questions

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MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. All other product or service names are the property of their respective owners. © 2010 Motorola, Inc. All rights reserved.

Malaysia. two-way radios. and Israel. barcode scanning and wireless network infrastructure to enterprises and governments. secure public safety systems. 3 MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. it makes the concept of a distributed WMS all the more relevant. Motorola has a global footprint with manufacturing and fulfillment facilities in the United States. A few products in our portfolio include. As we are trying to rebuild our supply chain systems footprint and because our operations footprint is global. Central Europe.Introduction Motorola Solutions is a global communications leader providing next-generation mobile communication solutions. Brazil. All other product or service names are the property of their respective owners. Inc. mobile computers. Mexico. © 2010 Motorola. . All rights reserved.

Since 2005 the warehousing operations that support the Schaumburg. Replenishment. the need for a WMS system became evident. IL manufacturing site had been outsourced to a 3PL. With the decision to no longer outsource warehousing operations.8 ERP  Decision to in source operations based in internal cost savings • Focus on top tier WMS solution versus custom one off • Fit within the long term strategic design and architecture . • Integrated with Motorola 11.Project Background • In 2009 Motorola decided to cease the outsourcing of the Schaumburg warehousing operations and return it back to in house.5. Picking and Cycle Counting in proprietary warehouse management system.  Outsourced operations to Third Party Logistics provider • Performed Receiving. Putaway.

5.8 ERP to 11.5. . © 2010 Motorola.5.8 instance • Several point releases old • Significant patching required and impact to other schemas • Reduced functionality as compared to R12. Inc. All rights reserved.10 11.5.2 Implement 3rd party WMS package • Step away in long term strategic direction • Software and licensing costs • Increase support costs 5 MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.10 EBS Other regions had already upgraded to 11.1.5.5.10 • • • • Use WMS module in the 11. All other product or service names are the property of their respective owners.8 had many extensions and enhancements to consider in regression testing Concern upgrade would take longer than original project timeline Configure WMS module in the 11.Evaluation Upgrade Oracle 11.

© 2010 Motorola. Inc. .5. the selection of Oracle dWMS was the right choice for Motorola.8 patching and maintenance • Quick to deploy with full WMS functionality Weighing all the aforementioned key points.5.10 WMS implementation in EMEA • Decoupled from ERP.Evaluation Implement Oracle R12.2 Distributed Warehouse Management System (dWMS) After evaluating all four options the decision to implement dWMS was best based on the following key points: • • • • • Host ERP will still be on 11. All rights reserved.1. 6 MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. All other product or service names are the property of their respective owners. no dependency on 11.5.8 dWMS fits into long term strategy Ability to leveraged existing internal and external resources familiar with Oracle WMS Licensing costs covered with existing 11.

setup and configuration. All rights reserved.Process to Define and Delivery R12 dWMS  Leverage EMEA Oracle WMS Implementation Although EMEA WMS was considerably different the team analyzed what could be leveraged from EMEA in terms of design. and conversion code reuse. Inc. All other product or service names are the property of their respective owners. • • • • Fully defined customer requirements Conducted several structured workshops Very experienced in warehousing operations Bring in lessons learned from EMEA 7 MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. . © 2010 Motorola.

Inc. . All other product or service names are the property of their respective owners. © 2010 Motorola.1.Process to Define and Delivery R12 dWMS  Stay Standard Oracle • • • • Standard Oracle met requirements Understand new features in R12. All rights reserved.2 ODI provides advantages with pre-built maps Understand how dWMS is different than WMS using Oracle standard interfaces dWMS white papers from Oracle were valuable aids • 8 MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.

. Inc. no Financial) in11i Warehouse Locators Locator max capacity from 3PL Min/Max values from 3PL for home slot items On hand values from 3PL Sub inventory creation 9 MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. • • • • • • • • • • Open PO’s in 11i All Suppliers in 11i All Items in 11i (excluding phantoms.Process to Define and Delivery R12 dWMS  Conversion The section will list the conversion data that was required from 11i and from the former 3PL legacy WMS. option class) Item Categories 11i Item costs (for cycle count ABC only. © 2010 Motorola. All other product or service names are the property of their respective owners. All rights reserved. options.

includes an inspection DFF flag (11i to R12) PO Receipts (R12 to 11i) Item New. • • • • • • • • PO new. All rights reserved.Process to Define and Delivery R12 dWMS  Interfaces This section will list the interfaces that were created between 11i and the dWMS system. Change (11i to R12) Subinventory Transfers WIP picks in 11i (11i to R12) Ship Confirm (R12 to 11i) Return to Stock (R12 to 11i) New Suppliers (11i to R12) 10 MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. © 2010 Motorola. . All other product or service names are the property of their respective owners. Inc. change. Informatica Power Center was the approved ETL tool and therefore new maps where required for this project.

but Skilled Resources • Oracle Data Integrator (ODI) evaluation • Recommend approach by Oracle. All rights reserved. All other product or service names are the property of their respective owners. .Implementation  Aggressive Schedule. © 2010 Motorola. with provided “Maps” for integration • No in house expertise • Resistance • Informatica Power Center selected Existing Integration Challenges • Previous Integration between 3PL WMS and Oracle 11i • Custom application acting as part ETL-forced to retain • Retain file format • Used open interfaces with staging table approach Five month implementation • Tight schedule. Inc.condensed system integration testing and UAT • Skilled resources leveraged • Functionality that met all business requirements • • 11 MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.

All other product or service names are the property of their respective owners. . Inc. operations were just slightly below the target MFG picking goal. Within 3 full days of application use. © 2010 Motorola. All rights reserved. The following graph illustrates the ramp up for sales order picks.Deployment Ramp Once deployed operations quickly began to realize the systems capabilities and rapidly began to ramp to normal operating transactional volumes. 12 MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.

Daily WMS Activity GMT Day Completed Pick/Rcpt 4000 3500 3000 2500 2000 1500 1000 500 0 /2 6/ 010 1/ 2 6/ 010 3/ 2 6/ 010 5/ 2 6/ 010 7/ 2 6/ 010 9/ 6/ 201 11 0 / 6/ 201 13 0 / 6/ 201 15 0 / 6/ 201 17 0 / 6/ 201 19 0 / 6/ 201 21 0 / 6/ 201 23 0 / 6/ 201 25 0 / 6/ 201 27 0 / 6/ 201 29 0 /2 7/ 010 1/ 20 10 Pick/drop MFG Warehouse/Rcpt Total Sch MFG Goal 5/ 30 Date 13 MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. All other product or service names are the property of their respective owners. © 2010 Motorola. . Ramping to this volume with the previous 3PL and WMS system took over a month to accomplish.Post Deployment Ramp The next graph illustrates how operations were to ramp to the target pick volumes in just 7 days from actually go live. Inc. All rights reserved.

Deployment Ramp This last graph illustrates how operations ramped with Oracle WMS compared to a previous experience with a custom WMS application utilizing an outsourced 3PL Operation's comments: Daily WMS Activity vs 3PL Logistic ramp . All other product or service names are the property of their respective owners. /2 0 6/ 10 1/ 20 6/ 10 3/ 20 6/ 10 5/ 20 6/ 10 7/ 20 6/ 10 9/ 2 6/ 01 11 0 /2 6/ 01 13 0 /2 6/ 01 15 0 /2 6/ 01 17 0 /2 6/ 01 19 0 /2 6/ 01 21 0 /2 6/ 01 23 0 /2 6/ 01 25 0 /2 6/ 01 27 0 /2 6/ 01 29 0 /2 0 7/ 10 1/ 20 10 Date 5/ 30 . Inc.3PL used a lot of OT to keep up (historically) Operations doesnt use much OT even now. All rights reserved. nearly zero week 1. . © 2010 Motorola. .R12 dWMS in the first week = 3PL first month. 4000 3500 3000 2500 2000 1500 1000 500 0 Completed Pick/Rcpt Total Sch f MFG Goal 3PL Ramp 14 MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.3PL startup was difficult.

Infrastructure Design and Implementation  The Schaumburg. provide high availability. Inc. • 2 x 2 architecture design. • Load balancing for application and using hardware load balancer and database server using Oracle RAC. The advantage of this architecture solution is providing for high availability (no single point of failure). and fit within the Motorola architecture framework  Selected low cost Sun solution using Oracle Enterprise Linux on x86-64 servers  First implementation for Motorola in using a smaller. IL warehouse . © 2010 Motorola. . yet robust Linux solution. All other product or service names are the property of their respective owners. • Sun Green Server X4170. • Linux x86-64 OS platform. All rights reserved. • Oracle 11g RAC with 11g Grid (ASM and Oracle Clusterware) • Warm standby DR site with Oracle data guard and Rsync for DB and file replication respectively. 15 MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. and internal disks for OS binary and temp files. • SAN Raid 5 for business data. both application and database layers are load balanced to fully utilize the hardware and incremental capacity can be added with no downtime.24 x 5 operation  Need solution that would be scalable.

Inc. . All other product or service names are the property of their respective owners. © 2010 Motorola.Infrastructure Design and Implementation 16 MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. All rights reserved.

home grown.  Motorola’s Alsdorf. © 2010 Motorola. . Germany facility running Oracle 11. The implementation of the R12 dWMS in Schaumburg.10 with integrated Oracle WMS. Inc. All rights reserved. or 3rd party solutions  Prior implementation of Oracle WMS in EMEA provided the Motorola IT staff the necessary experience to implement R12 Oracle dWMS under an aggressive time line.  Other regions using 3PL WMS solutions. as well as provided the initial footprint of an implementation road map to get all other regions on R12 dWMS. All other product or service names are the property of their respective owners. IL has provided Motorola the first successful install of a distributed Oracle Warehouse Management System.Implementation Road Map Prior to the dWMS Implementation there was only one region leveraging the capabilities of Oracle WMS.5. 17 MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.

8 ERP McAllen. Malaysia SAP 18 MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. Isreal 11. Germany Alsdorf.5. © 2010 Motorola. . IL Berlin. Inc.5.5. All other product or service names are the property of their respective owners.10 ERP Penang. TX 11.EBS and WMS Architecture Prior to dWMS Implementation Schaumburg. Germany 11.5. All rights reserved.10 ERP Tel Aviv.10 ERP/wWMS 11.

10 ERP Tel Aviv.5.10 ERP Penang.8 ERP McAllen. Germany Alsdorf. . Malaysia SAP 19 MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. Germany 11.5.EBS and WMS Architecture Post dWMS Implementation Schaumburg.5. © 2010 Motorola. Inc. All rights reserved. TX R12 dWMS 11.10 ERP/wWMS 11.5. IL Berlin. Isreal 11. All other product or service names are the property of their respective owners.

. Isreal R12 dWMS Penang. Inc. Germany Alsdorf. All rights reserved. © 2010 Motorola.EBS and WMS Architecture.Future End State Schaumburg. Malaysia McAllen. Germany R12 dWMS R12 dWMS R12 dWMS Tel Aviv. IL Consolidated R12 ERP Berlin. All other product or service names are the property of their respective owners. TX R12 dWMS Integration Layer 20 MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.

Summary  Benefits of dWMS-IT View  Decoupled form ERP. All rights reserved. and MWA server residing in close proximity to the warehouse/factory reduced the concern of data latency  Patching or future upgrades to the software require localized dWMS regression testing only  Low Cost. . © 2010 Motorola. 21 MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. which allows for periodic maintenance on the host. All other product or service names are the property of their respective owners. This flexibility will provide Motorola a faster return on investment and greater internal customer satisfaction and allow replicated deliveries in other manufacturing and warehouse centers. maintain Oracle footprint  The rollout of dWMS to other regional sites provides greater flexibility in deployment options as there are no dependencies on the host R12 system. quick deployment. database. while the dWMS is fully operational  Regional installation approach with the application. Inc.

All rights reserved. Case and unit). . All other product or service names are the property of their respective owners.  Transaction efficiency -Receiving is done with a hand held. They had to change the pick level of the material if moving from pallet to unit.Summary  Benefits of dWMS. © 2010 Motorola. Inc.“Comments from Operations”  Transfer of material from location to location is significantly faster. They could only move 1 level at a time. Carton. The picking process in dWMS is faster and has reduced the need for personnel overtime. Use of Quick Ship by delivery id simplified ship confirm process  Picking cycle time has increased by 20%. Previous 3PL received all via desktop computer  Shipping is simpler as only 1 screen and transaction required. 22 MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. By not having pick levels (Previous 3PL had material stored as Pallet.

All rights reserved. . .  dWMS has a great benefit in decoupling patch set and other functionality from OM ERP’s. Separate that Dependency from WMS functions and activities.  WMS is easily extendible and will require understanding of Oracle data objects.  Oracle failover and DR architecture deployed for dWMS is rather new to Motorola. such as Optio or Loftware for document bar codes.  Wireless Mobile application performance focus is key to user success.  dWMS activity monitoring via MTL table referenced flags. page breaks.  The DBA will be very active for the first 3 months monitoring table usage and system capacity as it will all be new.Lessons Learned  dWMS has unique data interface needs from the Host ERP.  Schedule a re-boot of WMA daily to clear any active user tasks.  Purchasing (PO) status should be managed (open/closed/reopen)  Consider using 3rd party packages. and text location/format. All other product or service names are the property of their respective owners. © 2010 Motorola. sorts. To reduce complexity deployed same architecture as production  A strong post go-live team is essential for the subtle issues encountered. Inc. 23 MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.

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© 2010 Motorola.Questions ? 25 MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. All rights reserved. Inc. All other product or service names are the property of their respective owners. .

All rights reserved.26 MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. © 2010 Motorola. . All other product or service names are the property of their respective owners. Inc.

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