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Warehouse management and control plus (WM+)
Integration made easy
Glen Road Systems, Inc.
Founded in 1987, Glen Road Systems, Inc. has spent more than twenty years positioning itself as a premier distribution center system integrator. Solutions are designed with the pervasive belief that a warehouse system is only as good as it is reliable and supportable. As a result, GRSI’s top priority is to design systems for which it can offer superior support. Novel, value added features and a large install base in diverse ® warehouses has molded GRSI’s core software offering, FastTrak WM+, into an essential tool for optimizing warehouse operation and automation.
GRSI 401 East Elm St., Suite 100 Conshohocken, PA 19428
.Contents FastTrak WM+ overview System architecture Warehouse management plus (WM+) Warehouse management system (WMS) Warehouse control system (WCS) 3-4 5-6 7-8 9-11 12 13-14 15-16 17-18 FastTrak tools Order management system (OMS) Packaging integration (PI) FastTrak WM+ ® is the solution to: • Inform • Automate • Coordinate • Integrate • Manage Warehouse and distribution operations “Clients for life..” 2 .
and RF picking and putting technologies. The FastTrak WMS utilizes light. A-frames. The result is minimally attended. WCS coordinates. material handlers. warehouse automation. automated guided vehicles. wireless. and material handling equipment from any supplier into a single uniﬁed process. ongoing support for the entire warehouse process. print and apply. messages. The FastTrak WCS includes support for conveyor sorting and routing. and order check-out. automated storage and retrieval systems (AS/RS). and accurate processing of orders. Packaging integration (PI) PI encompasses last-100-feet (L1F™) operations such as packaging. a wide range of methods for resource optimization are included. Transactional detail is logged for inquiries. and audits. It tracks the movement of inventory throughout the entire distribution center from receiving to shipping. throughput. PPTL modules. cost effective. voice. Features such as waveless picking. picking. shipping systems. It is software for inventory management. literature and packing list insertion. in-motion inventory. and cartonization are standard mechanisms used to optimize the fulﬁllment process. Warehouse management system (WMS) WMS seamlessly controls and integrates receiving. and diverse warehouse vehicle types. performs with exceptional stability and reliability. weighing. Graphical user interfaces display real-time material ﬂow. and vast reporting. and lends itself to superior support. reports. The FastTrak WM+ is composed of two modules that work together in various combinations. sealing. Targeted resources include automation equipment. labeling. waving. controls. storage media. bar code. storage media.GRSI FastTrak WM+ ® GRSI FastTrak WM+ (warehouse management plus) consists of a WMS and WCS. The FastTrak WMS also incorporates slotting. warehouse management systems (WMS). Additionally. and resource utilization. and system control from receiving to shipping. and sorting. storage. diagnostics. and laser picking. Warehouse management plus Warehouse execution suite ( WES ) (WM+) WM+ interfaces and facilitates communication between Warehouse control system (WCS) enterprise software (ERP). pick/put-to-light. storage. minimal interruption. inventory management and planning. Single-point host communication simpliﬁes design and implementation. and equipment. and pick location replenishment. and RFID. and monitors material handling equipment and fulﬁllment methods. putaway. in-motion manifesting. manifesting. packaging equipment. replenishing. voice-directed. It combines and automates all subsystems. 3 . pick carts. Order management system (OMS) OMS organizes orders for efﬁcient and accurate picking by combining both operator and automation-based fulﬁllment methods. The FastTrak WM+ is one suite of software controlling what heretofore might have been separately controlled subsystems. efﬁciency. and optimization tools to view operator efﬁciency and error troubleshooting messages. The result is exceptional stability. It coordinates and directs resources and equipment including carousels. and performance metrics. cartonization. batching. Automated equipment and computer-aided manual transactions are handled in a coordinated manner aimed at optimizing the full warehouse with regard to accuracy. automates. and other AS/RS. and superior end-to-end. The FastTrak OMS has a full range of inventory management features to control putaway.
Integration made easy support. The FastTrak WM+ integrates full-function. system engineering. The GRSI team is dedicated to as one-off customizations. remote system visibility for GRSI support personnel. and replenishment operations to assure that they work as efﬁciently and as effectively as possible. FastTrak is designed from end-to-end with this as an objective. has been highly successful TM in establishing a large install base of ongoing. number of users. picking/putting. Previously.Open architecture FastTrak is built on Microsoft . WM+ Warehouse management system (WMS) Warehouse execution system (WES) Warehouse Control System (WCS) Order Management System (OMS) Cartonization Packaging Integration (PI) solutions. The architecture allows FastTrak to maintain continuity with its past and its future. and device integration engineering.NET. and. lead to successful implementations. 4 . electrical controls engineering. Support for a wide range of equipment and consideration for options ranging from high-tech to low-tech has allowed GRSI to offer each client a solution that is ideally suited FastTrak highly scalable and able to provide solutions for both large and small operations. user accessible data highlighting critical operational states. This architecture makes Full service warehouse systems integration Warehouse system integration has been GRSI’s core competency for over twenty years. distinguishes GRSI from other system providers. Remote support enable GRSI to provide complex warehouse fulﬁllment Electrical controls Warehouse fulﬁllment center FastTrak WM+ ® Fast Trak WM+ release. 24x7 lifecycle support GRSI considers no job complete without provision for comprehensive life-cycle support. and automation control response time requirements. WM+ is a extension of previous FastTrak manages inventory. highly integrated and supportable offering. GRSI’s structured yet ﬂexible approach to projects. Host ERP to its needs. Defensive design methods assure that problems can be rapidly diagnosed and resolved. and Microsoft Windows operating systems thereby facilitating compatibility with the support capabilities of most enterprise IT departments. FastTrak provided these capabilities • Voice and RF assisted operators • Pick/put-to-light activities • Conveyor routing and sorting • Automated storage and retrieval equipment (AS/RS) • Automated packaging equipment • Specialized vehicles and static storage Resources Support is part of every GRSI solution. and monitoring tools. satisﬁed clients. Techniques to achieve this goal include integrated scripting and diagnostic software. Skills such as software development. combined with its powerful software tools. wall-to-wall warehouse management system capabilities into the core product. storage. FastTrak now handles the full range of automation control and inventory management as a single. It is able to control equipment and subsystems from any manufacturer. as a result. satisfying diverse operational needs varying in terms of transaction volume. GRSI believes that support. as much as if not more than functionality. AS/RS. Microsoft SQL Server.
System architecture Host systems: • SAP • Oracle • JD Edwards • RedPrairie • Infor • Manhattan • HighJump • Legacy • More..WCS . ERP/WMS Single-point connectivity ® FastTrak WM+ Ethernet backbone Electrical controls Equipment .WMS • Receiving • Putaway • Picking • Packing/shipping • Manifesting • Batching/waving • Replenishment • Cartonization • Robots 5 ..WES • Conveyors • AS/RS • Carousels • Scanners/cameras • Scales • Sorters Inventory .
voice.HOST Platforms: • Windows • Unix • IBM. or AS/400 • Mainframe PLCs Information • Picking: light. RISC. and paper • Robots • Print and apply • Document insertion • Packaging systems • Human machine interfaces • Dashboard displays • E-mail/browser alerts • RF handhelds • Diagnostics and reporting 6 . RF.
Packaging systems Pick/put-to-light systems Shipping systems Inventory Computer networks Conveyors and sorters FastTrak WM+ ® Data collection and integration Scanners and camera Printer applicators AS/RS. and pick/put-to-light. it provides the basis for comprehensive single-source warehouse operations support without artiﬁcial and confusing divisions of responsibility amongst suppliers.Warehouse management plus (WM+) Automated pick systems such as storage and retrieval. high speed item sorters. inventory management. robots. and carousels Scales and dimensioners System interfaces GRSI 24x7 support • Single-point contact for support • Rapid response • Remote assistance • Maximum up-time 7 . involve large capital investments and are central to the function of many modern fulﬁllment centers. FastTrak WM+ provides the total solution. and device control. These include coordinated order management. Furthermore. The automation equipment must be operated at peak performance and utilization in order to satisfy ﬁnancial expectations. Special software tools and methodology are required to achieve these goals in a fashion that is integrated seamlessly into to the overall warehouse operation.
Quick troubleshooting and support times . screen shots.Less operator training . GRSI writes a meticulously crafted functional speciﬁcation document for every client detailing the entire system’s processes. messages.Decreased bottlenecks . and equipment with complete visibility. throughput. WM+ is the tool for complete warehouse integration. There is no ﬁnger-pointing. layouts. and more. and uptime of its systems.Maximize system uptime Last-100-foot (L1FTM) packaging system 8 . subsystems. communications. The beneﬁts of an integrated and streamlined system include: . FastTrak WM+ is an extremely ﬂexible software suite that manages all warehouse processes.Equipment runs at its full potential .Expandable and upgradable . data transfers.Increased throughput .No ﬁnger-pointing . GRSI takes full 24x7x365 responsibility for the functionality.Why WM+ Efﬁcient distribution centers need a tightly managed and integrated system from receiving to order shipment Automatic and manual packaging Buffering Conveyor routing and tracking Print and apply labeling Receiving Picking/putting Manifesting Order shipment FastTrak WM+ Inventory management Shipping sortation Integration made easy TM Typical software solutions fail to utilize and manage equipment made by various manufacturers with multiple pieces of software running independently.
It provides the necessary tools and visibility to identify physical locations of static and in-motion inventory. sorting transfer vehicles (STV). and goods-to-man operations. FastTrak allocates the necessary resources for optimal throughput performance. FastTrak WMS utilizes multiple inventory and labor zones to provide batching. FastTrak WMS and the ERP communicate order. It identiﬁes and allocates inbound inventory to the required areas of the warehouse and tracks its location. Replenishment times can vary throughout the day. checkin.Warehouse management system (WMS) ERP/WMS integration • • • • • SAP Sage Epicor Oracle JD Edwards • • • • • PeopleSoft Homegrown Microsoft and others FastTrak WMS interfaces to many ERP systems using single-port connectivity. FastTrak analyzes inventory and resource usage. and others. picking and passing. Equipment – AS/RS and goods-to-man specialization WMS coordinates and controls all material handling equipment from any supplier into one cohesive unit. waveless operating. AS/RS equipment. unit loaders. sequential picking. and RF devices. and during peak and non-peak seasons. The inventory can be arranged and assigned by customer speciﬁc business rules. Its ability to control carousels. automatic guided vehicles (AGV). and replenishing. weight. allocation. voice picking. vertical lift modules (VLM). It is the ideal software to manage AS/RS. receiving. This allows product to be appropriately distributed to its proper location. fragility. It Software AND hardware integration is essential. dimensions. FastTrak WMS also enhances the functionality. and other AS/RS greatly improve stock organization and inventory ﬂow. Some ERP systems include: Great Plains Inventory management FastTrak WMS inventory management features include inventory forecasting. FastTrak is highly ﬂexible and customized to handle customer-speciﬁc requirements. self-guided robots. Batches Parcel Orders Items History 9 . and other in-motion inventory equipment when inventory is running low. The software can interface to pick/put-tolight modules. cost. and customer data through seamless integration. and system controls of existing WMS systems. inventory locations. and future workloads to replenish necessary inventory. week. waving. speed. inventory. It interfaces to numerous WMS systems via single-port connectivity including: • • • • RedPrairie Accellos Infor Manhattan • • • • HighJump Legacy Homegrown and others Recording and tracking inventory usage is critical for replenishment. stocking. and tracking. picking requirements. lot numbers. FastTrak WMS identiﬁes and notiﬁes operators. in-motion inventory. labeling.
which is ideal for e-commerce solutions). The software selects the best suited packaging available using material inventory data. and order information are also available for viewing. and alerts provide a tool to manage and grow within the size limitations of each client’s distribution center. RFID increases visibility and enables clients to wirelessly track items. decreases order returns. reporting. superbatch (batching of single-item orders. It is an organization tool. and wave items for maximum performance. weight. Cartonization lowers material and freight costs. and adjusts for peak and seasonal demands. Kitting Displays FastTrak incorporates user-friendly HMIs. and increases Slotting throughput. FastTrak can batch.RFID FastTrak interfaces with RF access points to communicate information from scanned RF tags throughout the warehouse. This provides a signiﬁcant number of cost-reduction scenarios when integrated with GRSI’s cartonization and shipping programs. 10 Scanning the volume of the order using DimScanTM . Returned items may be designated to a speciﬁc area of the warehouse. Cartonization FastTrak includes cartonization software that uses SKU and order data with business rules to make improved packaging decisions. picking. It releases batches to multiple picking operations to fulﬁll these orders in a timely manner. report veriﬁcations. and workﬂow data using these screens. paper. and packing. and troubleshooting tools. improves replenishment. The slotting process improves picking productivity. Picking technologies FastTrak WMS and OMS work to efﬁciently manage various picking technologies including pick-to-light and RF. and voice picking. Item and order movement is tracked and recorded by FastTrak. slot management. which complements replenishment. and special needs of each item in an order and the interaction of items in the order to determine the order’s packaging requirements. dashboards. It examines the dimensions. provides space utilization. SKU history. Returned orders FastTrak WMS allows returned orders (RMAs) to be received back into the warehouse and generates the proper paperwork for the order. throughput rates. reduces “walk” labor. It manages multiple locations for the same SKU and provides lot and serial number controls. position. fragility. The error percentages. reduces labor. Management is able to remotely analyze reporting data to see operator efﬁciency and perform benchmark comparisons. Graphic and history displays. Notiﬁcations are browser based and accessible by any PC or cell phone with Internet connectivity. FastTrak WMS consolidates items originating from different areas of the warehouse to fulﬁll and complete orders. error messages. transactional data. Operators can view the location of orders. FastTrak also records inventory and manages replenishment.
The software is also highly involved with reverse logistics management. and address information between the systems. cost. tracking. or existing WMSs. 11 . CMS Worldlink. In addition to managing the information ﬂow. The ASN contains order. FedEx. Clippership. DHL. USPS. outsource operations. and distribution networks with warehouses that span multiple facilities. GRSI provides a wide range of manifesting solutions with direct connection to all carriers. FastTrak also controls all equipment involved with shipping operations including weighing. carrier. and multicarrier software including Logicor. Pitney Bowes. Shipping and manifesting FastTrak WMS works as a middleware that interfaces to shipping systems. shipping label printing and applying.Warehouse management system (WMS) ASN FastTrak links orders to advance shipping notices (ASNs) in the standard EDI format. customer. and carrier sorting. FastTrak WMS provides the central software module and interfaces with 3PL providers. It connects to various shipping systems including UPS. ERPs. Purolator. calculated void-ﬁll inserting. It records and communicates order. and shipment information. shipping. and others. The ASN is communicated to appropriate distributors and customers during the shipment process. Canadian Post. Agile.
12 . Transaction logs Radio frequency scan and voice transactions. The exception data is displayed on screen to help in resolution of speciﬁc exceptions. diagnostic. pallet. Buttons. time stamp.. and pause subsystems with the click of a mouse. etc. stop. Users can view the ﬂow of individual parcels through each subsystem. action detail. Underneath the buttons are real-time performance statistics. Actions might include transfer of a container into a pick zone or sorting of a package to a shipping lane.) is recorded. indicators. Dropdown menus Users can access conﬁguration.. Process logs Each action performed by the automation system upon a container (parcel. and statistics Using the buttons on the bottom of the main screen.Warehouse control system (WCS) Main screen The WCS main screen is a data-oriented view of warehouse operations. interactions between FastTrak and the host system. package. as well as pick/put-to-light transactions are recorded. The status of each subsystem is displayed using a three-color code. The data describing each transaction is available on screen for routine monitoring and is also recorded for subsequent reporting and auditing. The unique identiﬁcation of the container. Exception log Any automation process or transactional error that results in exception handling by a machine or an operator is recorded. In addition. speciﬁc location of the action. the on-screen data is used as an aid for identifying trends that represent reoccurring system performance or data problems. and process duration are displayed on screen for routine monitoring. and transactions involving automated and computer-aided processes. tote. This data is also recorded for subsequent reporting and auditing. and reporting tools from the drop down menus on the main screen. users can start.
events and errors. Messages with conﬁgurable wording Host interface FastTrak is able to connect to any ERP or WMS host operating on any platform. Users can conﬁgure key operational characteristics including timeouts. and remote function calls.Tools Configuration intervals. shared tables. and heartbeat Browser based messaging Custom notiﬁcation levels alert users about system and multilingual support are sent when processes are completed. Tests can diagnoses issues with digital I/O. Notiﬁcations are browser based and accessible remotely by any computer or mobile device with internet connectivity. errors occur. and socket communication. Monitor system operations with a PDA or smartphone! 13 . This powerful connection features conﬁgurable source and destination endpoints using TCP/IP sockets. FTP. or performance lags behind a set threshold. or stopped. serial. Diagnostic and messaging Diagnostic tools allow users to view critical operational data including communication between FastTrak and PLCs. and communication between FastTrak and the host system. started. error count thresholds.
A wide range of standard reports are available as well as custom reports to meet speciﬁc user requirements. audit trails. Dashboard The dashboard is a graphic representation of pending versus processed workload. transaction. machine performance reliability. Users can allocate work by dragging and dropping tasks to different resources. These reports can be used for a wide range of purposes including operator productivity. HMIs display a graphic warehouse representation that shows real-time behavior of each subsystem. inventory. details about each parcel. and exception log data is available as spreadsheet reports.Human machine interface ( HMI ) to monitor and control operations. Reports are created by stored procedure calls to the FastTrak database from within the spreadsheet environment. and process performance. HMIs allow users Spreadsheet reporting All process. and shipments. 14 .
replenishment. Batches drill down to individual orders and items. Batches can be designed based on custom criteria including shipping carrier. Parcel data is accessible by right-clicking any item. and waveless management FastTrak coordinates wave and waveless picking by assigning pickers to designated zones of a warehouse. SKU. Picked items from different zones are consolidated into their respective orders downstream. and idle machine time is used for routine counting and restocking. Batches Parcel Orders Items History Super batches Super batching is a labor effective method to pick large quantities of single-piece orders. When items picked in a super batch reach the outbound process. Batches are designed either to accomplish an immediate business requirement such as consolidation of priority shipment orders. Drill downs The OMS main screen shows active batches and their progress.Order management system (OMS) Real-time data Batching OMS interfaces with the host in a fashion that assures dynamic order. packaging type. Inventory FastTrak inventory management supports rules-based putaway. Waveless picking and sorting provides a streamlined ﬂow of orders through the distribution center. Historic data shows the movement of items from picking to packing to shipping. FastTrak provides automated post-pick carton consolidation. These sophisticated activities are tailored to optimize the use of complex automated material handling pick areas and conveyor routing between them. or pick cart/truck capacity. 15 . Cartons are released to balance workload amongst the pick areas. and replenishment data is current. FastTrak automatically assigns individual pieces to an outstanding order using a reverse lookup. and picking. FastTrak cartonization breaks multi-carton orders into a carton fulﬁllment plan that minimizes pick area visits for each individual carton of the order. wave. Sorting. or to provide an efﬁcient pick walk path through a limited region of the warehouse. Consolidation can be accomplished using a wide range of high-speed sorting technologies or pick/put-to-light systems. Tasks are interleaved as appropriate.
Some of the data the cartonizaton system analyzes includes: • Dimensions (LxWxH) • Weight • Fragility scale • Business rules . FastTrak determines and stores essential item information. cost with sustainable solutions. beneﬁts. To make these decisions. improving throughput and consistency. For each order.Priority customer Inform. and manage • Receiving • Stocking • Picking • Packing • Shipping • Sortation • Packaging automation • Conveyor routing • Advanced shipping notice • RFID • In-motion order fulﬁllment • In-motion print and apply • In motion manifesting 16 . so picking and consumables replenishment can be done with complete packaging foresight.High-end item . and sustainability of all possible packaging options are analyzed to create a cost model. equipment. based on business rules. labor. and freight. Using software to make these important packaging decisions takes the pressure off operators. Cartonization is designed to analyze orders and automatically determine their packaging needs based on business rules. Basic information is gathered via a dimensioning and weighing system. automate. The model compares the cost of packaging materials. freight.Cartonization Cartonization decreases material. integrate. labor. The cartonization system is able to determine packaging needs as soon as orders are placed. the associated costs. damage claims. is fully customizable for each item. coordinate. These factors and the client’s goals guide the cartonization system to make packaging decisions for each order. Additional data. and other related costs from picking to delivery.
pack list. FastTrak uses this unique LPN to track Carton induction Picked orders arrive at carton induction. An operator scans each order’s bar code and scans the carton’s LPN. conveyor routing. and manifesting. FastTrak coordinates all operations into a streamlined in-motion packaging system. Cartons are automatically erected. 17 . FastTrak associates the carton with the order. Carton closing and taping Dynamic document insertion Cold seal induction Shipping label printing. shipping label printing. scanning and tracking.Packaging integration (PI) In-motion packaging system GRSI integrates all L1FTM functions including product. and document inserting. each with code. and verifying Pack list insertion and veriﬁcation Cartons with LPN bar codes a unique license plate number (LPN) bar packages throughout processing. verifying. and shipping carrier sorting. applying. applying. carton closing and taping.
Cold seal line When multi-piece orders arrive at the cold seal line. Merge Sealed cartons are merged with cold-seal orders for shipping operations. For single piece orders. the item bar code is scanned and FastTrak uses a reverse lookup to associate the item with an outstanding order. Shipping carrier sorting In-motion weiging and scanning Void fill and sealing An operator inserts the proper amount of void ﬁll. FastTrak generates the appropriate shipping label and the order is conveyed to a shipping label printer applicator where the proper label is applied. The carton is conveyed to an automated carton sealer. The order is wrapped in the cold seal substrate and identiﬁed by its LPN during subsequent processing. and verifying Final packaging and shipping Sealed orders are conveyed to an in-motion scale and Using the weight. applying. 18 . Integration made easy TM FastTrak scans the label to verify the integrity of its content and the order is conveyed to a shipping sorter. the operator scans each order’s bar code and FastTrak associates the order with an LPN printed on the cold seal substrate. Shipping label printing. The order is weighed and its LPN is scanned. scanner.
com FastTrak WM+ ® Warehouse management and control plus (WM+) Integration made easy TM Glen Road Systems. PA 19428 610-397-1050 © 2010 Glen Road Systems. All rights reserved. www.grsinc.com .Contact us for more information: 610-397-1050 solutions@grsinc. 401 East Elm Street. Inc. Suite 100 Conshohocken. Inc.
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