wms与库存管理的比较.ppt

1、SAP IM vs. WM: How to Choose, Use, and Optimize,天马行空官方博客： ；QQ:1318241189；QQ群：175569632,What Well Cover ,Understanding the difference between WM and IM Choosing between WM and IM Optimizing and overcoming limitations with IM and WM,天马行空官方博客： ；QQ:1318241189；QQ群：175569632,Inventory Management (IM),Key

2、features/strengths Inventory management by quantity Visibility of on-hand quantity by storage location Management of special stocks Entry and documentation of all material movements Real-time updates of inventory Documentation of all receipts, issues and transfers Physical inventory Carry out physic

3、al inventory at the material level Perform inventory adjustments,R/3 Inventory Management (IM) (cont.),Key features/strengths (cont.): Inventory management by value Postings update account assignments for cost accounting Updates G/L account for financial accounting Key integration points Integrates

4、directly with MRP, purchasing and invoice verification Provides information for MRP, updates PO; used to check conformity during invoice verification Real-time updates When transactions are entered, the results the stock updates real time to reflect actual changes,SAP Organizational Structure,Organi

5、zational Structure at the IM Level,Challenges with Inventory Management,Lack of detailed visibility to material flow e.g. When the delivery pick list is generated, the deliverys “actual pick quantity” is updated prior to actual picking Requires manual updates when quantities differ Inability to assi

6、gn incoming materials to outbound demand to avoid multiple material handling continued.,Challenges with Inventory Management (cont.),Immediate update of inventory receipts and issues System inventory and status NOT representative of the physical process Limited visibility to locations of materials O

7、nly possible to assign a single fixed bin location per storage location Bin location is “text” only; no strategies are available,Solution: R/3 Warehouse Management,Initially released with R/2 as an Extension of IM IM-WM integration is real-time and automatic Enables granular traceability and control

8、 Ability to synchronize the system and material flow Simple-to-complex placement and removal strategies Assignment of inbound orders to outbound deliveries Allocation of storage bins Processing of all stock movements valid for WM Receipts, issues, transfers Utilizes stock placement and removal strat

9、egies e.g. Next empty bin, addition to stock, FIFO, LG/SM qtys.,天马行空官方博客： ；QQ:1318241189；QQ群：175569632,Solution: R/3 Warehouse Management (cont.),Infancy to maturity Functionality considerably expanded with 4.6x and higher Two-step picking, two-step confirmation, managing multiple storage locations

10、with a single warehouse Extension set 2.0 for Enterprise to include Cross Docking, Yard Management, Value Added Services,WM Picks Up Where IM Leaves Off,Typical assignment is one storage location to one warehouse It is possible to have multiple storage locations managed by a single warehouse,Quant,B

11、in 1,Quant,Quant,Quant,Bin 2,Stor. Type 2,Stor. Type 3,Warehouse1,Stor. Location 1,Stor. Type 1,Warehouse 2,Stor. Location 2,Plant 1,Location 1,Plant 2,Company,IM Level,WM Level,Stor. Type 1,Key WM Features,Management of materials Provides bin-level tracking Inventory management functions Various pl

12、acement and removal strategies Value-added services e.g. Special handling requirements (labeling, packaging) Powerful picking control Two-step picking, wave picking FIFO, LIFO, large/small quantity picking strategies,Key WM Features (cont.),Warehouse activity monitors WAM, RF Monitor, outbound deliv

13、ery monitor, wave picking monitor, TRM Monitor, Yard Management Cockpit, Cross- Docking Monitor Cross-docking Management of inbound and outbound movements Yard Management Appointment scheduling, check in and check out, assignment of dock doors, loading/unloading activities Task Resource Management E

14、nhances WM by breaking work down into distinct task,Fully Integrated with the other SAP Applications Features: Flexible Warehouse Structures Goods Movements Control Inventory,WM Integration With Other Key R/3 Modules (cont.),Source: SAP WM LO530,WM Integration With Other Key R/3 Modules (cont.),IM-W

15、M Processing of all material movements Automated communication with configurable processing SD-WM Two-step picking with SD-WM integration Wave picking opportunities Processing individual deliveries PP-WM Production support with PP-WM integration Supplying materials to the shop floor Internal and ext

16、ernal automated replenishment options,天马行空官方博客： ；QQ:1318241189；QQ群：175569632,WM Integration With Other Key R/3 Modules (cont.),QM-WM Handling of inventory samples Inspection lot is maintained with the material data Hand-held terminals-WM Processing of transfer requirements Processing of transfer ord

17、ers Bin and material inquiries,Benefits of WM,Benefits Better control of inventory More accurate inventory Able to maintain lower inventory levels Better control of information Visibility to picking and put away status Reduced cycle time Gartner: 16-25% Picking Productivity Improvement Better manage

18、 work and workforce to gain efficiencies Tools to balance and optimize resources Increased picking / shipping accuracy 11-25% Reduction in Customer Returns,Benefits of WM (cont.),Measurable benefits 16-25% Picking Productivity Improvement 11-25% Reduction in Customer Returns 10-25% Savings in Materi

19、al Handling Labor 10-40% Space Utilization Improvement 13-30% Reduction in Scrap 8-15% Reduction in Carrying Costs Source: Gartner Report,What Well Cover ,Understanding the difference between WM and IM Choosing between WM and IM Optimizing and overcoming limitations with IM and WM,When Is Inventory

20、Management the Answer?,IM is great when. Small facility Lower levels of inventory on hand Simplistic material handling processes Lower volume of activity Outsourced warehouse operations Only need storage location or bucket of inventory visibility,Key Elements With IM,Required data for IM Plant, valu

21、ation and storage location data Relevant data for IM Work scheduling, accounting, materials planning, purchasing, classification, storage and quality management IM menu Goods movements Material documents Reservations Environment Focused on reporting, lists and LIS,When is Warehouse Management the An

22、swer?,WM is great when Larger facilities Large number of materials on hand Higher volume or flow through Traceability and visibility is critical Track material flow, status, inventory levels Complex processes Automated systems, wide spread site,Key Elements With WM,Extend material master Warehouse m

23、anagement view No required data Define warehouse structure Minimize the number of storage types Define based on similar and different rules for storing materials Mixed stock, Storage or Handling Unit Management Define the WM Processes Automatic, semi-automatic and manual processing Transfer order cr

24、eation, confirmation, posting changes,Evaluating IM vs. WM,1 Define business processes 2 Evaluate ROI of a WMS solution 3 Consider RF functionality 4 Training resources and schedule 5 Focus on optimization opportunities,Step 1 - Define Business Processes,Start with receiving, inventory and pick/ship

25、 first Create and evaluate process flow charts Look at process improvement opportunities Score the level of complexity Target areas for improvement Reduce travel time Inventory accuracy Reduce material handling Map improvements to IM and WM functionality,1 - Define Business Processes (cont.),“The le

26、vel of functionality that customers need in a WMS is completely dependent upon their environment. Customers have to define their needs before they can realistically look for a WMS.” Source: Integrated Solutions,Step 2 - Evaluate ROI of a WMS Solution,Measure productivity and accuracy before and afte

27、r the WMS installation Review and analyze picking operations Key area of improvement Review and analyze inventory accuracy When supported with RF, accuracy can reach 98%,2 - Evaluate ROI of a WMS Solution (cont.),“There is no right time for paying back a WMS, but typical paybacks are within six to 1

28、8 months, depending on the inefficiencies of the current operation and how much safety stock was needed to cover daily operations.” Source: Total Supply Chain,Step 3 - Consider RF Functionality,RF supports improves warehouse bin accuracy Bin accuracy 98% is possible Reduces order fill process cycle

29、time RF projects often have a 1 year or less payback period Source: Intermec,Compare current receipt process to the time saved when the task is aided by automatic data collection (ADC),3 - Consider RF Functionality: Example,As-is 1,000 pallets at five minutes / pallet = 5,000 minutes With two minute

30、s saved per pallet 2 minutes * 1,000 pallets = 2,000 minutes 2,000 / 480 minutes worked by each receiver per day = 4.16 receivers saved from the pallet receiving process,Step 4 - Training Resources and Schedule,Resources to evaluate, guide and support a WM solution A full-time, dedicated WM resource

31、 is critical This may or may not be the same IM resource Training schedule A WM solution will require a certain level of IM training WM training will vary based on the degree of functionality Support resources Consider a single resource for IM and WM if possible,5 - Optimization Opportunities,Pickin

32、g operations and inventory accuracy What are your baseline requirements What is the volume of activity Evaluate picking paths and demand Look at your accuracy numbers over a period of time Perhaps monthly, quarterly, annually Material handling labor costs Space utilization improvements Packing tasks

33、 Can you benefit from packing while picking,What is the BEST Stock Management Solution?,1 - Inventory Management 2 - Lean Warehouse Management 3 - Full Warehouse Management 4 - Decentralized Warehouse Management,Option #1 - Inventory Management,Pros Simplistic Key receipt, issue or transfer in a sin

34、gle step transaction Immediate update of inventory Requires less training commitment Fewer transactions to document and present Trace-ability of all material postings into SAP R/3 Date, user, material, quantity, storage location Real-time update of accounting information,1 - Inventory Management (co

35、nt.),Cons Does not handle complex warehouses operations well Unable to monitor activities Lacks tools to manage resources and tasks Lacks functionality to optimize key processes (picking) Inaccurate system inventory Inventory updated before the physical movement Requires additional work if there are

36、 discrepancies Limited trace-ability Only visibility is when the system posting took place No visibility to the follow on physical activities,Option #2 - “Lean” Warehouse Management,Use of very small portion of WM capabilities You do not process goods receipts or issues as a subsequent process in WM

37、, No storage bins are managed in the WM application Evolved from SD pick list Put-away and pick from 1 or more fixed bins Bin is hard assigned on material master TOs are created for picks and put away, and pick list is created from TOs,2 - “Lean” Warehouse Management (cont.),Pros Requires less confi

38、guration than full WM Reduced number of steps in the process Use of transfer orders as pick lists Confirmation is not required Additional processing options Confirm put-away, picking, over-deliveries, shortages, batches Print transfer orders Integration to HR Additional picking functionality Wave pi

39、cking is possible with Lean WM,2 - “Lean” Warehouse Management (cont.),Cons Must have a fixed bin assigned for all materials Random storage is not possible Inventory is still under IM functionality only Inventory options are at the storage location Stock differences can only be processed in MM-IM La

40、cks additional optimization opportunities Picking, packing, bin accuracy No strategies are used Lack of picking and put away strategies,Option #3 - Full Warehouse Management,Pros Optimization opportunities Picking - Two step picking Packing - Pick and pack in a single step Cross-docking - Inbound, o

41、utbound, prod. materials Monitoring and real time visibility to process status Visual queues at the detailed steps Open tasks, completed tasks Additional inventory methods (annual, zero stock) The module is FREE with the purchase of SAP,3 - Full Warehouse Management (cont.),Cons Inventory counting i

42、nterferes with operations without RF Prior to 4.7 extension set 2.0 Initial overhead to set up depending on design Master data Capacity checking, control cycles Configuration requirements Designing the warehouse layout and set up Potential for additional steps to support processing Confirmations Cle

43、aring differences Processing posting changes,Option #4 - Decentralized Warehouse Management,Use of SAP as a standalone WMS With SAP or other ERP/host as the core system Core system and decentralized WM run on separate machines Communication is through BAPIs for transactions and IDOCs for master data

44、 Goods movements done through delivery notes to the stand-alone SAP WM system,4 - Decentralized Warehouse Management (cont.),Pros On a separate machine Decreases criticality of down time 24x7 operation Can leverage newer SAP R/3 releases Even if core system is on an older release Can add additional

45、warehouses without impact to the core system Can communicate to multiple core ERP systems,4 - Decentralized Warehouse Management (cont.),Cons Core system is not 24x7 operation IDOC and/or BAPI errors IDOC failures Human intervention is required to work the error queue IDOC overhead IDOCs do not offe

46、r all of the available field options that a user may or may not use with the PC transaction Must modify the IDOC SAPConsole has to be set up in the decentralized system and in the core system,Scaling the Solution,Operational Complexity,Transaction Volume,IM Only,Lean WM,WM,Decentralized WM,TRM,What

47、Well Cover ,Understanding the difference between WM and IM Choosing between WM and IM Optimizing and overcoming limitations with IM and WM,Optimizing and Overcoming Limitations With IM and WM,1 - Physical Inventory tips 2 - Enhance visibility of material flow and locations 3 - Automate picking and p

48、ut-away 4 - Automatically replenish fixed bins 5 - Consolidate your picking activities 6 - Overcome bottlenecks with RF,1 - Physical Inventory Tips (IM),Only possible if the storage location data has been maintained Solution: Activate automatic storage location for movement types that receive materi

49、al into the plant Avoids the need to create storage data manually For materials with multiple storage location reqmts. Use the mass creation option for entering all valid storage locations at one time into a single entry screen Transaction code = MMSC,2 - Enhance Visibility of Material Flow and Loca

50、tions (IM),Use fixed bin assignment to gain additional visibility Material master storage location view Two-step transfers vs. one-step movements Storage location-to-storage location (movements 313, 315) Plant-to-plant (movements 303, 305, 351, 352) Outbound delivery monitor Use to view outbound del

51、iveries, shipments and loading activities,3 - Automate Picking and Put-away (WM),Define a picking strategy per storage type A - Partial quantity management If picking results in partial quantities, pick from here first to avoid breaking new pallets M - Large/small quantities included Use to facilita

52、te larger quantity picks from bulk areas and smaller quantity picks from rack areas P - Fixed bin from material master For fast moving items, assign a dedication location toward the front of the warehouse Use replenishment to enough maintain stock for demand,3 - Automate Picking and Put-away (WM) (c

53、ont.),Define a put away strategy per storage type AVOID manual put away practices C - Open storage Use for large items that dont require a specific bin assignment I - Addition to existing stock Useful for consolidating receipts of the same material upon put-away Caution: Since only one quant resides

54、 in a bin, all materials in the bin adopt the same receipt date (unless batch or storage unit managed),3 - Automate Picking and Put-away (WM) (cont.),Define a picking strategy per storage type (cont.) L - Next empty bin Great fit for high rack storage; whereby a standard rack section can hold 2-3 un

55、its of storage Useful for storing pallets of material; one pallet per bin location,4 - Automatically Replenish Fwd. Picking Locations (WM),Batch program A scheduled job to read fixed bin data and generate replenishment transfer orders 2 required programs RLLNACH1 RLAUTA10 “Upon transfer order confir

56、mation” option Creates an automatic replenishment TO when a pick confirmation drives the fixed bin location below the min. stock level,5 - Consolidate Your Picking Activities (WM),Two-step picking Based on selection criteria, relevant deliveries are read and like material requests are collected This collection results in a single aggregated picking order and task for each like material (fi