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Archive for Warehouse Management Systems

I attended the SAP Insider Logistics and Supply Chain Management 2010 conference in Orlando, Florida a couple of weeks ago. My colleagues attended other SAP Insider conferences held at the same time focused on manufacturing and product lifecycle management (PLM). You can read their takeaways about those conferences and the keynote presentations by Richard Campione, Executive Vice President of Suite Solution Management, and Peter Graf, SAP’s Chief Sustainability Officer and Executive Vice President of Sustainability Solutions, at the ARC website.

The main reason I attend these types of events is to speak with customers and to hear about their implementations. Simply put, the presentations from Indigo Books & Music, Dow Corning, and Newell Rubbermaid were among the best I’ve attended so far this year. But before I share what I learned from these case studies, let me first make some general observations about SAP (an ARC client).

All of the keynote presenters from SAP emphasized “end-to-end processes” and “implementable steps”—i.e., despite the economic challenges, companies shouldn’t lose sight of the big picture and their long-term objectives. They should focus on transforming their end-to-end business processes, but they don’t have to get there all at once. Companies can get there in steps, by implementing targeted solutions that address their immediate pain points first and then build from there.

This focus on processes is much more tangible and grounded, in my opinion, than SAP’s high-level messaging last year about “Clear Enterprises,” which was centered on business intelligence (BI) and analytics. While BI remains important for customers, leading with processes, and mapping solutions to them, is arguably a better strategy for SAP. The end-to-end logistics and fulfillment process for SAP includes Global Available-to-Promise, Supply Network Collaboration, Extended Warehouse Management, Transportation Management, Event Management, and Global Trade Services.

Is this “end to end” messaging really new or differentiated? Not really, but in many ways SAP is going back to basics, which is a good thing.

The real question is around implementable steps, on whether SAP can shed the perception that there’s no such thing as an affordable, quick time-to-benefit SAP implementation. There’s only one way for the company to do this effectively: share customer success stories with the public, or with the analyst community at a minimum, even if under NDA. Compared with other vendors, SAP is much more conservative about sharing details about customer deals and implementations, hence the reason I was so impressed (and pleasantly surprised) by the customer presentations at SAP Insider.

Indigo Books & Music: Indigo is Canada’s largest book retailer with $1B revenue, 247 stores nationwide, and an e-commerce site. In early 2009, the company launched a $15M+ “Supply Chain Redesign Project” which included building a new distribution facility and replacing aging material handling equipment and a warehouse management system. According to Sumit Oberai, the CIO at Indigo, the company was historically a “best-of-breed” IT shop, but it adopted a “platform/SAP First” strategy in early 2009 to reduce total cost of ownership and simplify architecture. The decision on WMS was between SAP EWM 7.0 and a best-of-breed solution, and according to Oberai, the decision was difficult because there was little difference in functionality. “EWM’s ability to deliver retail specific business requirements exceeded our expectations – only one customization [was] required,” Oberai stated. In other words, from this retail customer’s perspective, SAP has narrowed (closed?) the functionality gap with best-of-breed WMS solutions. This milestone is reflected in the hockey-stick growth in EWM implementations SAP experienced in 2009 compared to previous years, based on data the company shared with me. Indigo selected SAP in September 2009 and the first EWM implementation (in the new facility for online fulfillment) is on schedule and on budget to go live in Q2 2010.

Newell Rubbermaid: Newell Rubbermaid (“Newell”) is a $6.5 billion global marketer of consumer and commercial products. Its brands include Goody Products, Levlor, and Sharpie. The Newell customer presenter gave a very detailed and insightful presentation on the company’s implementation of a Customer Managed Inventory (CMI) replenishment strategy with Walmart Canada—i.e., move from a purchase order driven model to a scan-based trading model where:

  • Goody receives nightly point-of-sale (POS) data from store-level scans.
  • Goody uses POS to calculate store inventory levels and generate replenishments.
  • Replenishments are sent to Walmart distribution centers where they are cross-docked and shipped to stores.
  • Goody owns the inventory (consignment) at the store until nightly scan information triggers the sale.

According to the presenter, the business case for implementing this new process included the opportunity for Newell to better manage the merchandising space at retail which could be used as a test environment for merchandising concepts, new products, and category management. It also allows for more promotional opportunities, both with inline and off-shelf placement, that could lead to a competitive advantage in the future and further entrench Newell Rubbermaid in the retail market.

I can’t possibly condense a 1.5-hour presentation into a few words, so I won’t try. But as you can imagine, this “pay for scan” transformation was not trivial and it affected various ancillary and sub-processes (the project took 11 months to go live). From an IT perspective, Newell is using SAP Supply Network Collaboration and SAP APO (among other solutions).

Simply put, this case study underscores why I believe SAP’s renewed focus on end-to-end processes is a smart move, and why more customers like Newell Rubbermaid need to share the supply chain and logistics process transformations they are enabling using SAP. It’s like that old philosophical question, “If a tree falls in a forest and no one is around to hear it, does it make a sound?” I suspect there are other interesting supply chain and logistics case studies out there, other examples of implementable steps in practice, but they’ve remained in the shadows of the SAP forest. I look forward to seeing and hearing more of these case studies in the weeks and months ahead.

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I recently spoke to the folks at BabbleWare, a new software vendor with a low-cost warehouse management, manufacturing execution, and mobile field-based execution applications. BabbleWare mentioned that one of its WMS clients is actually experimenting with using the iPhone as their barcode scanning application.

Are they crazy?

Yes, you can buy a barcoding application at Apple’s App Store, and it is cheap—only $1.99 for the RedLaser application. The… Continue reading

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WMS Architecture and Total Cost of Ownership

Posted on Jan 12 2010 | By Steve Banker · Comments (0)

In 2006, I interviewed 22 companies that had implemented or upgraded a Warehouse Management System (WMS) solution at a single site or across many sites. These interviews clearly suggested that the architecture of the solution affected its Total Cost of Ownership (TCO).

I looked at the type of WMS solution that was implemented—traditional configuration versus Business Process Modeling (BPM) configuration. The latter should really be described as “micro BPM”… Continue reading

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Compliance is Top Priority at Chemical Warehouses

Posted on Nov 24 2009 | By Steve Banker · Comments (1)

Last year, I interviewed several warehouse managers in the chemical industry to learn more about their operations and how they are using supply chain execution (SCE) technology. Chemical manufacturers, distributors, and logistics service providers (LSPs) all operate chemical warehouses which differ in complexity. At one end of the spectrum are distributors (or LSPs that handle chemicals on behalf of manufacturing clients) who receive containers, usually drums, from suppliers… Continue reading

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We all remember the story of Goldilocks and the 3 Bears, where one bed was too soft, one was too hard, and third was just right. When it comes to warehousing technologies for food distribution, I see the same thing.

In grocery, most store shipments are composed of mixed-SKU pallets. The layout of a grocery distribution center (DC) generally mirrors a store’s layout. So, if fruits and vegetables are… Continue reading

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Task interleaving is an advanced productivity practice enabled by leading warehouse management systems (WMS) with task management engines. Task interleaving is designed to reduce deadheading—i.e., when a worker, for example, picks products and drops them off at a dock and then returns to the picking area without performing any useful tasks along the way. In most operations, some workers are dedicated to picking, while others are dedicated to put-away. Task… Continue reading

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WMS Labor Productivity Basics: Task Management

Posted on Sep 17 2009 | By Steve Banker · Comments (2)

When you’ve been in a discipline for a long time, you forget sometimes that not everyone is as immersed in a topic as you are.  I was reminded of this when I was asked to participate in a webinar on warehouse management system (WMS) task management, slotting optimization, and labor management with Tom Kozenski, VP of Product Strategy at RedPrairie.  The webinar will air September 29th at 11:30 ET… Continue reading

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The Value of Becoming a Technology-Driven 3PL

Posted on Sep 10 2009 | By John Reichert · Comments (1)

In the past, entering and competing in the Third Party Logistics (3PL) marketplace required sales savvy, options for inexpensive warehouse space and good operational management skills.  With these things in hand, a 3PL could acquire clients, lease space, hire workers and launch operations in very short order. Price was always king and the 3PL with the lowest price usually won.  Contracts were renewed provided the 3PL met its service levels… Continue reading

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