All of the above issues are typical of departmentalized (manual) operations –all of which could be alleviated with the adoption of an overall integrated system management strategy. Even the most basic Warehouse Management System (WMS) could alleviate most of the above issues. This is especially true if technologies like RF scanning, computer voice directed picking, GPS, etc, are deployed in conjunction with a WMS.
Adopting a System Management Strategy
When you know there are DC performance issues, start by examining the total picture. Make sure a specific problem isn’t a symptom of a still far greater more entrenched problem. While some solutions may seem obvious and easily implemented (referred to as “low-hanging-fruit”), getting everyone’s input and concurrence can be difficult and time-consuming.
An excellent first step would be to construct a flow chart of the current operation, see “Uncovering Pathways To Greater DC Performance”.
Going forward it is important to understand that the incremental labor component of a non-mechanized (manual) solution will over time continue to drive up operating cost. As shipping volume increases, at some point more automated material handling equipment and systems become a necessity. Industry experts agree that the adoption of material handling technologies (equipment & systems) is the proven solution for achieving higher overall performance.
Unfortunately, the “System” term is often misused. Anyone who has a few pieces of equipment that fit together can claim it’s a system and frequently do even though there is no operational integration. In addition, the term “Automated System” is often used to describe highly mechanized systems where human beings are doing most of the work. An example would be manually picking cases to a conveyor that transports them to an automated sorting conveyor that directs them to pre-assigned manual palletizing stations.
The answer to the question as stated at the beginning of this article is: any DC organized around individual departments such as; receiving, storage, picking, packing, and shipping, will benefit from deploying a WMS to achieve a fully integrated system operation. This is essentially the first step a distributor can and should take on the path to adopting a comprehensive system operation.
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