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by Tom Cutler, Contributing Editor Posted on Sunday, October 01, 2006 2:52:00 PM   | Abstract: | Warehouse Control Systems provide real-time data management and interface responsibilities of the materials handling system as well as offer common user interface screens for monitoring, control and diagnostics. Here's what to look for in a WCS. |
There is a significant shift between (Warehouse Management Systems) WMS and WCS (Warehouse Control Systems) in the area of merging local data warehouses into enterprise data warehouses. This convergence is being caused by: - Technology Advancements: The use of open software, relational databases and componentized applications architectures are enabling WMS vendors to provide real-time data management and interface responsibilities of the material handling system.
- Functional Enhancements: The WMS has, over time, taken over more of the work handled by the ERP system, in areas such as inventory control, resource scheduling and order management.
New software tools are also enabling continuous monitoring and work flow functionality, thereby providing the means to efficiently and economically operate a warehouse or distribution center. Consider the WCS a floor general or a traffic cop. Capturing real-time data such as pick rates and pick efficiencies are more geared toward this type of system than to a generic WMS focused on upper level management data. Traditionally, a WCS executes instructions provided by an upper-level host system, such as an ERP or WMS system. True Tier 1 WCS software, such as QC Software WCS Enterprise Suite, FKI Logistex WCS, and HighJump Software, provide advanced management capabilities including inventory control, resource scheduling and order management. These best-of-breed WCS systems are modular in nature, easily configurable, and platform independent, with a scalable architecture to satisfy the needs of any size warehouse. Not all companies require all the functionality within a WCS, but it is imperative that this functionality can be "plugged in" at any time. Unlike a typical WMS, WCS directs real-time data management and interface responsibilities for the materials handling system and provides common user interface screens for monitoring, control, and diagnostics. Optimal WCS on a Component Level A standard WCS contains the following components: - Conveyor Routing
- Sortation
- Communication with host ERP/WMS
- Communication with Material Handling Equipment
A Tier 1 WCS includes the following: - Conveyor Routing
- Sortation
- Communication with host ERP/WMS (less communication/data passing is needed due to the fact that the WCS is doing more of the WMS functionality)
- Communication with Material Handling Equipment
- Cartonizing
- Zone skipping
- Inventory Management
o Location Control o Receiving
o Put Away
o Replenishment
o Cycle Counting
- Wave Planning
- Picking/Order Fulfillment
- Multi-carrier Shipping
As the focal point for managing the operational aspects of the material handling system, WCS provides a critical link between the batch-time data host and the real-time Programmable Logic Controller (PLC) material handling system. The PLC coordinates the various real-time control devices to accomplish the daily workload. At each decision point in the distribution process, the WCS "determines" the most efficient routing of the product and transmits directives to the Equipment Controllers to achieve the desired result. The decision-making process often is controlled by two separate utilities, the Sort Manager and the Route Director. Inventory Management System Few Warehouse Control Systems contain an Inventory Management System (IMS) because typical WCSs simply manage the conveyor routing and sorting and have not been developed with other business functions in mind. Software packages that have this feature use Linux, Java, and robust databases to enhance the accuracy and efficiency of warehouse operations and data integrity. IMS manages all item numbers and warehouse locations. The major inventory events of an IMS process include bar code label printing, receiving, put-away, cycle counting, picking, and replenishment. Page : 12 3 ... NEXT |