ScottTech Integrated Solutions today announced it will launch a new version of its application, PickPro WCS™, which works with Microsoft Windows® 7, Microsoft SQL Server® 2008, and Microsoft Windows Server® 2008 R2 to offer customers enhanced security, as well as innovative user interface features and reliability improvements.

PickPro WCS™ is a powerful yet easy to use warehouse control system for stockroom and distribution center environments.

PickPro WCS™ is available in either single or multiple workstation versions, operating standalone or networked depending on the customer’s needs.

PickPro WCS™ can control multiple automated horizontal or vertical carousel pods, flow rack, Pick to Light shelving and many other bulk storage locations. It maintains and manages all inventory items in locations, and controls all of the picking, put away, and cycle count processes.

The PickPro WCS™ mobile computer module works with or without voice on Motorola/Symbol, Intermec, and other handheld wireless devices.

“Our ISV community is alive with innovation, and we’re committed to helping our partners drive the next generation of software experiences,” said Ross Brown, Vice President of ISV and Solutions Partners for the Worldwide Partner Group at Microsoft.

“Adding compatibility for the latest Microsoft operating systems helps ISVs to stay ahead of the competition and give their customers access to cutting-edge technologies.”

“ScottTech Integrated Solutions is excited to launch this new version of PickPro WCS™,” said Anthony DeSalvo, Software Development Manager at ScottTech Integrated Solutions.

“Making our application compatible with Microsoft Windows 7 and Microsoft Windows Server 2008 R2 helps us offer our customers compelling benefits, including intuitive user interfaces such as multi-touch, improved security and reliability features, tools to keep them connected to data stored on the Web, advanced graphic hardware acceleration, full support for multi-core processing, sophisticated management features, intelligent power management, and flexible access administration to improve mobile working.”

ScottTech provides clients with innovative solutions using the best technology to improve production. We are committed to exceeding our client’s expectations and delivering complete automation and data management solutions.

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Products or service names mentioned herein are the trademarks of their respective owners.

For more information, press only:
Anthony DeSalvo
Software Development Manager
ScottTech, LLC
6847 Ellicott Drive
East Syracuse, NY 13057
315.413.4871
adesalvo@scotttechllc.com
www.scotttechllc.com

By indicating that an item being received into the warehouse or distribution center is a “Return”, all other stocking algorithms are ignored and FIFO logic is used. This will allow the warehouse control software to choose this item next when satisfying an order.

The induction process directs an operator to place the item in a forward pick location and then assigns that item to the next order requesting that item.

Many times orders are shipped short when there is stock located in the receiving area awaiting disposition and return to stock. PickPro WCS™ has cross dock capability which will send these returned items directly to pack and ship operations. This saves time and money by not having the items placed into stock, and then later picking it for an order.

The return management feature in PickPro WCS™ assists you in maintaining a sustainable supply chain by reducing the time and energy required to manage the inherently problematic returns business process.

Now what? The phone is starting to ring for you hopefully. Are you ready to ramp up quickly to meet the new demand? Do you have a warehouse control system in place? Is your inventory control really in control?

Automating your processes and investing in new technology will help to keep you ahead of your competition. A good choice for identifying what is possible for creating a sustainable business model would be hiring a systems integrator to assess your current system(s).

Now is a great time to have an automation systems expert review your business operations and suggest ways for you to meet your requirements without adding labor resources.

By automating your inventory and warehouse control processes you can keep your labor costs flat through the ebb and tide of your product demand.

Areas that are likely suspects in re-engineering your processes are:

• Inventory Storage
• Order Processing
• Kitting operations
• Order Picking
• Replenishment Processes

Most reputable companies will assess your needs for little or no cost. This effort would be a great investment for your company’s well being now, and into the future.

Why? Well as a kid I was a big fan of Space Ghost and I kind like the idea of pointing my hand at a bar code label / evil space alien and blasting it with my laser. I know you young kids think Space Ghost is a Talk Show host on the Cartoon Network, but in my day he was a full-fledged Super Hero!

Symbol WT4000 Series Wearable PDT

Besides my desire to pretend I’m still a kid with super powers, the WT4090 wearable computer is exactly what is prescribed for data transactions in the warehouse. Other terminals have to be holstered or placed down while the person counts out the number of Salt Water Taffy boxes to send to the Cracker Barrel in Pooler, GA.

Holstering a device takes unnecessary time per transaction. When a person sets a non-tethered terminal down, it is sometimes sucked into the same vortex that many of my socks have entered when I put them into my clothes dryer.

The WT4090 is always on the ready. Patiently waiting on your arm as you thoughtlessly use an Exacto knife to cut the top off of a new carton of “I’m with Stupid” t-shirts. It lightweight and has an easy to read color display. The WT4090 has come a long way from its predecessors which had small monochrome screens and weighed as much as a VW Beetle.

Click here to see Symbol’s WT4000 in action.

You always knew when you walked into a warehouse that used the old wearables because some of the women had large forearms and squinty eyes. They kind of looked a little like Popeye after a while!

RS507 Hands-Free Corded/Cordless Imager

The only things I have not liked on the WT4000 Series is the lack of a Touch Screen and the fact there is a cord running along the back of your hand connecting the scanner to the CPU (could be a safety issue).

Both of these shortcomings are now available options on the wearable device. Kudos to the project manager at Motorola for listening to those of us who believe that whining incessantly is a good thing.

In our effort to continue the development of the PickPro™ WCS (Warehouse Control System) family of products, ScottTech has released an enhancement that allows the operator to replenish forward picking zones during the picking process.

These zones can be comprised of carousel pods, horizontal carousels, shuttles, vertical carousels, mini storage systems, and other ASRS devices.

Description of Functionality

Opportunity replenishment allows the operator to choose when to put away incoming parts or to replenish forward stocking locations during the picking operation. The function can be configured to operate as a standard put away or replenishment, or intermingled with picking to optimize the operation of the carousel system.

Flow racking within a carousel pod creates what is called a Universal Pod. Flow rack traditionally has been used to store items that require more cube than what currently is available in a carousel bin, or for items that will require replenishment during the picking process

The flow racking is outfitted with lights for each lane and the PickPro™ software system directs the operator to the location of an item. At the same time the carousels are spinning to the next picking location. This allows the operator to be busy during the wait time that occurs while the carousel/ASRS positions the bins for the orders being processed.

The Opportunity Put Away and Replenishment Module take this functionality one step further by giving the operator the ability to fill the location during the picking operation. The concept uses the same technology in the Universal Pod, during design of a system ScottTech includes 2 bays (or more) of flow racking in the Universal Pod. The first bay is used for storing items, the traditional Universal Pod concept; the second bay is used as put away or replenishment lanes.

When a picker starts a batch they are prompted to scan in the first items in each lane of flow racking, the system assigns that items to a light and adds the items to the spin sort list in the PickPro™ software. From there the system automatically starts the batch for picking, directing the operator to the right pick location in either the picking zones from flow racking, or from the carousels in the pod. The system uses lights to direct the operator to the right location for picking.

When the system detects that it is in a location that has an item for put away/replenishment, it automatically changes all light functions and directs the operator to take an item from the put away/ replenishment flow racking lane and place it into the correct carousel bin location. These put away transactions are intermingled with picks so the carousel operator need not reset or restart a new batch to perform the put away/replenishment.

This feature is employed along with the BulkPro™ RF (with or without Voice integration) to allow the system to direct the off-carousel operator to fill the carton flow zones being used for put away or replenishment transactions.

The PickPro™ system knows if the items are required if the forward carousel picking zone and directs the off-carousel operator to place the items in a flow lane. PickPro™ directs that off-carousel operator to scan a bar code lane identifier on the back of the flow racking thus linking the item to a location.

Benefits

• Reduces batch setup spin time
• Reduces the number of carousel spins
• Reduces electricity associated with moving a carousel bin
• Increases operator performance
• Reduces operator wait time
• Reduces wear and tear on motors, gears, tracks, and other mechanical parts
• Increases equipment life

Using the PickPro™ Opportunity Put Away and Replenishment Module allows systems integrators the ability to utilize an efficient carousel picking system where one may not have been applicable due to the size of items being stored, the total amount of cube space required, and the number of replenishment cycles that may be needed to maintain pick levels.

Case Study: Music Industry Supply

ScottTech deployed this technology to a musical instrument string manufacturer. The customer is utilizing the following PickPro™ modules to operate their worldwide distribution center in New York. The PickPro™ WCS system is configured as:

• PickPro™ ICS Version 8.0 (inventory control)
• BatchPro CCS Version 2.1 (automated picking system)
• Bucket Brigade (radio frequency data collection type)
• BulkPro RF Bulk Picking System (radio frequency data collection)
• Conveyor Tote Routing System (conveyor control and tote tracking)
• Administration Manager (supervisor and management system)
• Consolidation Pack Verify Manager (shipping and pack verify)
• Induction Manager (receiving)

Using traditional carousel technology in their DC, the operators could not keep enough inventories in a carousel location to sustain the picking for a single shift, requiring multiple replenishment cycles during the day, constant stock shortages, and short orders being sent to customers. This caused too many items that should have been stocked in forward picking locations to be put away in a less efficient bulk storage location.

ScottTech was contracted to designing the new World Fulfillment Center. During the design process ScottTech preformed a study of parts activity. ScottTech designed into the carousel picking zones the universal pod along with the opportunity replenishment. This concept would allow the operator to keep the order fulfillment rate high by keeping the replenishment inventory for the carousels available in flow racking for opportunity replenishment. We also utilized the standard Universal Pod concept for those items that were being picked for every order, readily available in the flow racking zone.

By introducing the opportunity put away and replenishment along with the RF Bulk for off-carousel we were able to keep items in the pod and available for picking. Utilizing the carton flow universal pod with opportunity replenishment we were able to keep the operators busy during batch set up and spin up times, directly impacting the overall performance of the system. Once the system was installed, the customer decided to move additional items from dedicated carton flow zones into the carousel zones.

The total system included; automated tote induction, conveyor line balancing, RF bulk picking, automated tote return, automated carousels picking zones, and flow racking with bucket brigade type picking. Using all of these technologies this customer was able to process 35% more orders a day with a 20% reduction in operators.

Overall system design included:

• WMS and WCS Software (ScottTech)
• Engineering and Project Management (ScottTech)
• Conveyor System (Ermanco)
• Horizontal Carousels (White System)
• Pallet Racking (Ridge U Rack)
• Turret and Order Picking Trucks (Crown)
• Carton Flow Racking (Unex)
• Push Back Racking (Unarco)
• PLC Controls (AEI)
• Mechanical Installation (GMY Inc)
• Electrical Installation (All Phase Electric)
• RF Data Terminals (Symbol)

Let’s take a brief look at why a WCS can assist in attaining a green, sustainable warehouse:

• Change is the only constant; a business model that works today may not work in the near future. The ability to be agile when it comes to modifying your systems will distance you from the competition.

• less returns = less packing material to dispose
• Time and energy resources are reduced having less items to re-stock

In summary, a warehouse control system will;
• Generate more inventory turns
• Increase the functional and operational capacity of your business
• Reduce total labor costs
• Consume less energy and resources
• Improve picking and shipping accuracy
• Quicken process cycle times
• Provide greater customer satisfaction

President Obama has taken a lead role in sustainable processes not only in government operations but also within the private sector. The guiding document is Executive Order 13423 which can be found at: http://www.ofee.gov/eo/eo13423_main.asp

Every business has a supply chain.  Simply stated; Input  –>  Transformation –> Output.

A sustainable supply chain is friendly as possible to the environment as it attempts to uses materials and processes that reduce waste.

All supply chains cost money; raw materials, energy, material handling, transportation, etc.  The movement towards a sustainable green supply chain will lead businesses to discovering new opportunities to decrease costs.

There generally are two methods to “greening” a supply chain;

• Move existing processes towards a green supply chain model
• Design and implement new processes under that model

Goals of a Green Sustainable Supply Chain

• Reduce Costs and Help the Environment
• Lower Energy Consumption
• Use less Natural Resources Consumption
• Less Environmentally Unfriendly Chemicals

Some excellent resources on this subject are Green Supply Chain Network and  Greenprofs.

A WCS utilizes very innovative technologies within the warehouse or distribution center that reduces the floor space needed and uses less human and/or natural resources.

One technology that is used is Automated Storage and Retrieval Systems (ASRS) such as horizontal or vertical carousels.

Below is a presentation from Remstar on Sustainable High Performance Storage & Retrieval Systems:

Companies must focus on three core areas when greening the supply chain: organization, process, and technology.

However, most companies do not have an organizational structure, or have processes in place that enable an “end-to-end” view of their carbon footprint or environmental impact of their supply chain.

Technology follows the organizational and procedural changes put in place. Taking on any technology investments without first understanding the alignment of the overall strategies is obviously not a good idea.

Warehouse automation, whether applied in part or all, delivers a wide range of benefits that Include:
- Improved Productivity
- Better Material Handling Efficiencies
-Increased Accuracy
-Reduced On-Hand Inventory

These benefits are usually achieved utilizing less people and within a smaller footprint. These two benefits can figure heavily in determining the ROI for the automation project(s).

Once your project is defined and designed, the labor savings can be calculated and required floor space can be determined. Effective use of space can reduce building costs and frees up space for the storage of additional products, or for manufacturing activities.

The use of automated storage and retrieval systems make the best use of both the horizontal and vertical warehouse space. ASRS devices have dense storage capabilities and can increase storage capacity to upwards of 350-400%.

Another benefit of automated material movement is the reduced need for forklifts and narrow aisle trucks. Fewer trucks mean a “greener” warehouse creating less of a carbon foot print. The elimination of the trucks also increases safety, reducing operator and pedestrian injuries.

The costs involved in re-fueling and/or the recharging of batteries, mechanical and electrical preventive maintenance and warehouse lighting are also reduced.

Trucks weigh much more that most ASRS devices, this reduces the construction requirements for the warehouse or distribution center floor. More automation allows for “just in time” inventory management which reduces the total amount of inventory required in stock. The accountants love that one!

The increased picking accuracy means the customer gets what that asked for, which reduces returns. Less returns equals less labor and resources that are required for re-stocking activities.

Choose a warehouse automation expert that will not only assist you in your automation design bit also who can help you determine the ROI for the project.

Anthony J. DeSalvo
Software Development Manager-ScottTech, LLC
http://www.scotttechllc.com – http://www.celution.com

mailto:adesalvo@scotttechllc.com

Implementing a “Bucket Brigade” style of picking when possible is therefore one of the easiest ways for a company to save money.

What is “Bucket Brigade”?

I’ve found the easiest way to explain it is by asking you to think about ordering a submarine sandwich at a Subway. The first person in the brigade asks what sandwich you want and the type of bread you want it on. They do not stop there (usually). They cut the bread and begin assembling the sandwich until the second person is bumped down to take over asking which toppings/condiments you would like. At that point the first person starts over with the next customer in line.

Why is this better than each person assembling from start to finish? Why not have people assigned only certain tasks on every sandwich?

The answer is in the word ORGANIZATION.

A “Bucket Brigade” style adds efficiency to the system by keeping people sequentially ordered and always working. You are not waiting for the person next to you to finish putting extra mayo on a sandwich while your customer wants jalapenos on the other side of that person. You are also not waiting because five customers in a row wanted extra bacon and the person in charge of that task is suddenly overwhelmed. The rules of Bucket Brigades lend structure to the system without a word even spoken.

Many Order Picking applications inside of a warehouse have proven “fertile soil” to implementing the structure of Bucket Brigades. Efficiencies have been noted to increase from 10 to 40 percent. Even order accuracy has been documented to increase because the straight-line methodology keeps totes/boxes ordered instead of cluttered.

Bucket Brigades in a forward Pick Zones works as follows:
The first worker begins by starting a batch of orders and completing picks until he/she is bumped off the batch by the second person. The second person is handed off the batch by the first person and starts completing where that person left off. The first person then proceeds to start a new batch of orders. The second person can be bumped down by the third person, and the third by the fourth, etc…

The workers should be organized from the slowest pick rate in the first position to the fastest “all-star” picker. This will lend to the “Six Sigma” principle that product is to be pulled through a system and not pushed through.

Under standard picking methods where workers pick orders all the way through, the workers will have to leap frog one another frequently. This can be time consuming if let’s say the worker’s batch of 12 totes are on roller conveyor and he/she must leapfrog all 12 of them past another’s totes on the line. You can see where this can cause inefficiency and even where totes might get mixed up causing picks being put into the wrong tote.

Bucket Brigade is a Zoneless method of picking. Zone picking eliminates Leap Frogging but is too rigid in that the if one picker has a large number of picks in his/her zone the person in the next zone ends up waiting for totes.

Even adding/subtracting workers to the system is done easily and without having to make adjustments to the software or explain to the group their newly adjusted responsibilities now that a person is being added. The system keeps flowing as normal.

Bucket Brigade picking can be utilized with several manual picking technologies. RF Bar Code Terminals, Pick-to-Voice, and Pick-To-Light all lend themselves to the use of bucket brigades to organize the picking process.

Symbol WT4000 Series Wearable PDT

Both paper lists and Bar Code terminals are easily misplaced and dropped. The time taken to put a Bar Code Terminal in a holster and grab it back out can add significant time to each Pick. Voice is the ideal solution for picking in a freezer where the pickers’ hands are usually gloved.

Where does Voice fit in with other Forward Picking Technologies such as Pick-To-Light, AS/RS, Carousels, etc…?  It is great when dealing with Full Cases being sent direct to shipping or picking large items onto a pallet.

In other scenarios (with smaller and/or high-velocity items), voice is adequate but not as good as some other choices.  It is sort of like the jack-of-all-trades-master-of- …(well, see above) Certain industries, especially grocery distribution, voice is ideal for up to 90% of their operation.

Both the software and hardware for voice has significantly improved over the last thirty years.  Background noise, language recognition, and the common cold are much smaller obstacles than they were in years past.

• User logs on to software using the headset
• The software either knows where that user is assigned or asks the user where they will be picking and for what order(s)
• The headset instructs the picker to the first location
• User reads off the Check Digit for that location and after the software verifies it gives the User the Quantity to Pick
• User verifies the Quantity or performs a Special function (Short Pick, Close Box, etc…)
• The software moves on to the next Pick

In a nutshell, Pick to Voice provides improvements in accuracy and efficiency without a large investment.  It has its place alongside the other technologies ScottTech helps its customers deploy to cut the big-budget operating cost of labor inside the warehouse.