Delivery • Monthly average – 800k pieces

Komatsu

• Returns Processing
• Sorting for quick putaway
Receive
Wood crating
Pierc

Package
e

OEM Packaging OEM Labeling Kitting

• 52 acre site
• 684,000 square feet inside storage
Parts Put
(54,312m²)
away • 150,000 square feet outside storage
(13,950m²)
Komatsu

• 38,000 square feet of mezzanine (6,975m²)

• 40 inbound/outbound trucks per day
Pick and
Pack

Shipping Picking Packing

• KLtd manages the core systems consisting of P-Mates, KWMS and Service Parts Portal which will be deployed to other Komatsu affiliates in the future.
• KAC manages important systems: Master Data, Pricing Workbench and Supplier Portal.
• Most of the systems will be connected via ESB: Enterprise Service Bus.

Baan (Peoria)
Managed by System New/Existing
Pricing Workbench System
SAP KLtd P-Mates New
SAP Master Data RIM
Accounting
Extranet Parts Applications KWMS New
Servigistics Service Parts Portal New
Expediting* New
ESB New
Distributors

KAC SAP Master Data Existing & Major change

Supplier Integration
P-Mates Pricing Workbench* New

OEM/Suppliers
DB Integration

Service Supplier Portal* New

Supplier
Parts
Portal Shipping System* New
Portal
Komatsu Affiliates

Reports New
ESB New
Core Tracking Existing or New
KWMS
SAP Accounting Existing & Modification
Servigistics Existing & Modification
Core Tracking Shipping Expediting RIM: Retail Inventory Existing & Modification
Management
Reports
Extranet Parts Applications Existing & Modification
Infrastructure Baan Existing & Modification
*Functionality exists today
 Overview: Receiving Process

Unload it Receive it Open it Count it Stage it Package it Stage it Put away

(& sort it)
KAC Pierce
-The process above is the overview of the receiving process

-Due to One Warehouse now, KAC team will be managing the receiving operation from Go-Live.

-KAC will be responsible to unload the truck, count the parts and sort it for packaging

3 will be responsible to package the freight & sort it for put away
-Pierce
 Receiving Process

① ② ③ ④ ⑤ ⑥ ⑦
Unload it Receive it Open it Count it Stage it Package it Stage it Put away
(& sort it) Pierce
What are the key process steps?
① Receiving: this prints information included on ASN as a barcode receiver report (BRR) which details the parts in the case.
② Open it: Use the BRR to open the ‘case’.

③ Count it: Use the BRR & system to confirm the quantity counted in the case.
Once confirmed, this is the quantity the system is expecting to be put away.
Receiving shortages/damages should be identified here.
Sort it: Sort it by part size (bulk vs handpick)

④ Stage: Parts are then moved to staging area for Packaging (or put away/inspection/cross dock).
 Equipment to be used
There will be specific equipment required to support receiving & count processes:
Receiving Freight Open Case & Count
Equipment Type Computer Laser Printer Zebra RF Scanner Zebra Mobile Zebra Label Wireless Scanner
Printer Printer
(laptop with monitor) TBA MC92 QLn420 ZT410 TBA

No Process & H/W

1 Receiving ◎ ◎
2 Open & Count ◎ ◎
Receiving Freight Open Case & Count

Mobile Stations will be set Open the case and count,

up, it consists of a PC & Laser confirm quantity
printer.

This enables user to find case

5
and print the BRR
 ASN #
1 2
12345678910

5
6 7
4
1. Case No = Case/Packing List Number
2. ASN No = Advance Shipment Number assigned by P-Mates
3. Supplier Information
4. Part Number & Description Information
Note: if applicable a supplier part no will be printed below description
5. Cross Dock, Packaging, Inspection or S/N Indicator
Note: an "X" in these fields indicates part has a requirement for this activity
6. Expected Qty = Qty that should be in Case (P-Mates is expecting)
7. Part Number Barcode
Note: in case of Non Genuine part label, user can scan this barcode for Part No.
For Returns, ASN will start
with claim type (example)
OIE = OIE01211966600001
SIE = SIE01211966600001
Packaging Label Put Away Label Inspection Label
No Packaging Cross Dock /Pick Label
 Key things to know:
1. User must use the BRR to confirm count (also for part number scan)
2. After quantity is confirmed if there is a packaging specification for the part a packaging
label will print
3. If no Packaging specification a put away label will print
4. If there is a back order a cross dock label will print
5. Serialized parts will get an inspection label
6. Damaged parts will get a QA label
 Baan (Peoria)
Pricing Workbench

SAP
SAP Master Data RIM
Accounting
Extranet Parts Applications
Servigistics

Distributors

Supplier Integration
P-Mates

OEM/Suppliers
DB Integration
Service
Supplier
Parts
Portal
Portal
Komatsu Affiliates

KWMS

Core Tracking Shipping Expediting

Reports

Infrastructure
 Shipping

Part Flow
l l Parts
Sma age
Stor
Pa rts
e
Larg age
Receiving Stor
iving ackaging
Rece P
tation
C / Sor
Ce ore
nt
er

ve
i n i strati
Adm ilding
Bu
Pierce Packaging Komatsu Hourly Komatsu Salary
(Direct Labor) (Direct Labor) (Indirect Labor)

39 647
11 55
33
162 155 129

26 15
112 138

446 Campus Wide

Pierce Packaging Komatsu Hourly Komatsu Salary
(Direct Labor) (Direct Labor) (Indirect Labor)

39 647
11 55
33
162 155 129

26 15
112 138

446 Campus Wide

 2

Prime shipping time

1200 200
Shift Hours 145 145
(excludes UPS/FedEx)
1000 150
A 6:00 – 14:30 800 70 85 85 85 85 90 90 90
75 75 75 75 100
70 70 70
B 9:00 – 17:30 600 50
15 15
C 13:00 – 21:30 400 Putaway focus 0
D 15:00 – 23:30 200 -50
0 -100
00 :00 :00 :00 :00 :00 :00 :00 :00 :00 :00 :00 :00 :00 :00 :00 :00 :00 :00 :00
5: 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Stock Emergency Unit Down Head Count

Carrier / Distributor Last Order Pull Time
UPS (Airfreight) 17:00 21:30
FedEx (Airfreight) 17:00 22:20
FedEx Frt LTL 14:00 15:30
Roland 14:00 16:00
Anderson / Rish / Road Machinery 15:30 17:00
T & E (Alabama) 15:30 17:00
Affiliates 13:30 17:00
Brandies / Columbus 15:30 17:45
WPI 15:30 17:45
Linder / T&E (Georgia) 15:30 18:00
Rish 15:30 18:00
Lyle / H&E 15:30 18:00
Emergency Orders (varies) 15:30 18:00
Power Equipment 15:30 18:30
Rish (Virgina) 15:30 18:00
Ground EO (Linder/S.A.) Florida ‘AAA’ 17:00 19:00
Heavy Emergency Orders 17:30 19:30
Modern / Power Motive / KEC 17:30 19:30
 INBOUND / OUTBOUND STEPS

Delivery
Komatsu

Receive
Pierc

Package
e

OEM Labeling Kitting

Parts Put
away
Komatsu

Pick and
Pack