SAP WM – Pushing the limitsMaureen Allison – Halewood International
Introduction to HIL
• HIL Corporate Video
Our SAP Journey so far….
• ERP Implementation 2004
• BW 3 months later
• Extended SAP in to other HIL Businesses 2005
• SCM Implementation for DP – 2010/2011
• ERP Upgrade to ECC6 2011
• Expansion of SCM footprint - SNP/PPDS 2012-2014
TIMELINE
2004 - Date
Warehouse fully racked
ERP Go-live inc WM FG
Warehouse Review
•WM configured as part of ERP – there have been physical changes and associated layout changes but processes are largely the same.
WM
WM DG
Project Dickens
Current Warehouse set-up• Finished Goods – Fully racked17,000 pallet
spaces
– 14 loading bays
– 40 Marshalling lanes
• Dry Goods – Mixture of Rack and Bulk Stack 4000 pallet spaces
– Pick and return for 5 high speed production lines
– JIT Glass delivery – 24/7 operation
Issues• Had not looked at the operational side for some
years – FG 8 years + DG 6 years• List of minor requests/developments• Internal team stretched• Issues with picking of dry goods for production• Incomplete traceability in FG warehouse at case
picking level• Not fully utilising what we had• Complexity of raw materials increasing
– Crabbies labels
Approach
• Discussion with The Config Team
– Shared our open issues and development requests
– Undertook a full review of both DG and FG warehousing
– Workshops with our end users
– Presented findings
– Drew up a joint project plan
– Project kick off – Late summer
Roadmap PrinciplesIncreased
Warehouse
Productivity
Greater
Transparency
Increased
Accuracy
Better Service
Level
Customer/
Vendor ASN
Connectivity
Operational
Process
Improvement
Dry Goods Project Roadmap
Project Roadmap
Finished Goods Roadmap
Project Roadmap
Project PlanJul-13 Aug-13 Sep-13 Oct-13 Nov-13 Dec-13 Jan-14 Feb-14 Mar-14 Apr-14 May-14 Jun-14
WM roadmap
Fit-gap investigation
Project scoping & development plan agreed
Design & Functional specs
Review / update Baseline Config & data
Dry Goods
Design & functional specs
Review / update Baseline Config & data
Gap Build
Unit & system testing
Super User Training
User Acceptance testing
User Training
Go-live
ELS
Finished Goods
Design & functional specs
Review / update Baseline Config & data
Gap Build
Unit & system testing
User Acceptance testing
User Training
Cut-over prep
Go-live
ELS
Dry Goods Improvements
• ASN process for inbound goods where possible
EDI ASN
Dry Goods Improvements
• ASN process for inbound goods where possible
• Introduction of HUM – clustered putaway
Dry Goods Improvements
• ASN process for inbound goods where possible
• Introduction of HUM – clustered putaway
• Pick for Production
Dry Goods Improvements
• ASN process for inbound goods where possible
• Introduction of HUM – clustered putaway
• Pick for Production
• Return from Production
Finished Goods
• Introduction of HUM
New Pallet Label
• Now following GS1-128 Standard
• Full Serial Shipping Container Code (SSCC)
• Saving time – do not need to relabel for Customer ASN process
• Retaining full history of pallet moves
• Production of mixed case pallet label – used for case picked pallets
Finished Goods
• Introduction of HUM
• Pickface Replenishment
Pickface Replenishment
• As well as regular batch job to replenish pickface
• Pickface replenishment can be carried out on demand
Finished Goods
• Introduction of HUM
• Pickface Replenishment
• New case picking transaction
New Case Picking Transaction
• Retention of HU label within pickface
• Operative will scan the HU label as part of the pick process
• System also accumulates the weight of the cases picked and this will be printed on the label
• Future development is to interface to weighing scales
Finished Goods
• Introduction of HUM
• Pickface Replenishment
• New case picking transaction
• New loading transaction
New Loading Transaction
• Enter a trailer number which is to be loaded
• List of all deliveries scheduled for this shipment –inc load sequence
• Ability to load out of sequence if required
• Operative scans the HU to be loaded
• Operative scans the door
• Operative receives confirmation message
• The system displays status against each delivery
Project Summary
• Phase 1 Dry Goods – go live 23rd February– Well received in business
– Increased stock accuracy – big benefit on Labels
– Much simpler transactions for operatives
– Post Go –live review held
• Phase 2 Finished Goods – go live 6th May– Improved traceability in pickface
– Reduction in loading errors
– Post Go –live review held
Lessons learnt
• You can do more with what you have got
• Processes change – as business changes
• Review was worthwhile
• Took the opportunity to clear up debris
• Communicate in as many ways as possible as soon as possible
Any Questions
Good Luck
The Crabbies Grand National Festival 9th – 11th April 2015