Author: Kallol Nandi

WMS and SAP Integration

Posted on by Kallol Nandi

 

WMS and SAP Integration

 

Our client was a privately owned company and in business of manufacturing premium workwear over 100 years.

Situation:

  • Incompatible data elements between WMS and SAP
  • Transactions needs to be moved to between systems in real-time

LIFE GOES NO AS PLANNED, UNTIL …

Our client was in the process of implementing SAP and replacing their existing host system. We have helped them by doing data analysis, writing custom programs, making cut-over plan, and data migration processes. The real challenge came when our client tried to integrate WMS with SAP in real-time.

Since WMS and SAP looked at the inventory in two different perspectives, WMS looked at the inventory in material movement point of view, whereas SAP looked at the inventory from the financial point of view, the inventory transactions data of these two systems were not directly compatible. Our client failed to use the system that they had used to communicate with their old Host system.

INITECHS’ EXPERIENCE AND IN-DEPTH KNOWLEDGE MADE IT POSSIBLE

Initechs’ long experience with these applications and technical expertise helped our client to overcome this problem. We first understood the problem and did a gap analysis. With these, it become clear what were needed to solve the problem. Our innovative architecture allowed our client to run both applications as usual, but let the data pass through our custom built layer which summarized and converted the data elements the way both applications expected.

We provided tools to maintain and change the business rules as things will progress without changing the program of this layer.

MAKE IT POSSIBLE

If two people, not knowing languages of each other ,can communicate, why cannot WMS and SAP exchange the information. Initechs did it successfully; it was the result of the deep understanding of the technology and domain knowledge.

 

RESULTS

 

  • WMS talks to SAP in real-time
  • No limitations on any application usage
  • Total flexibility and control to the user

 

 

WMS Upgrade to A Modern DC

Posted on by Kallol Nandi

 

WMS Upgrade to A Modern DC

 

Our client was a $2.7 billion global footwear company having 1350+ stores in North America. They put more than 100 million pairs of shoes on the feet of women, men and kids around the world each year.

Situation:

To keep up with the tremendous growth across the nation our client built a new distribution center to a very high standard and incorporated latest in automated material handling systems and processing workflows, on the west coast in order to serve existing retail stores as well as highly-anticipated future store openings.

Lack of in-depth technical knowledge of the product required to design and build a large-scale and highly complex warehouse management system using WM2008R0.

RETAIL, D2C, .COM, ALL MUST BE SERVED FROM THE SAME WAREHOUSE

We took the multifaceted challenge that includes the integration of a existing homegrown Wave Planning tool, a highly-customized product Allocation and Picking/Packing process, a complex MHE integration, as well as ensuring that both their Retail business and booming Internet direct-to-consumer dot com business could co-exist within the same systematic warehouse environment.

PROJECT MANAGEMENT, PROCESS DESIGN AND CONTROL, AND QUALITY ASSURANCE

Our consultants worked with software vendor, Manhattan Associates, and the client to come up with a technical design that supported the project plan and designed Wave Rules based solely on Route/Store demand, to a more Gender-based level (i.e.. – Men, Women, and Children).

Our team worked closely with Manhattan Associates for the design and programming of the MHE integration as well as the Allocation and Picking/Packing processes, we were solely responsible for total Quality Assurance for all Manhattan Associates software deliverable, implementation, and testing processes.

Additionally, Initechs ensured that all legacy interfaces and business reports were modified as needed to ensure compatibility with the new WM version. A lot of Mark Magic labels were also modified and created by Initechs based on newly defined business requirements.

PROJECT COMPLETED BEFORE THE DEADLINE

Initechs took sole responsibility for the design, programming, and testing initiative to make this happen. The end-product was delivered well before the deadline and was an outstanding success.

 

RESULTS

 

A fully functional modern distribution center was made ready before time, which gave our client a ample of time to be ahead of the competition.

 

 

 

WMS Upgrade

Posted on by Kallol Nandi

 

WMS Upgrade

 

Our client was a privately owned company and in business of manufacturing premium work-wear over 100 years.

Situation:

  • Process was very complex with random patches all over the system
  • 400+ custom programs
  • Little understanding of capabilities of latest WMS version

ELIMINATING UNNECESSARY MODIFICATIONS

Our client had over 400 modified programs with very little organization and almost no documentation. They brought in Initechs to help them sort through the mess and bring them up to the latest version of their WMS.

Initechs’ experienced consultants analyzed their modified programs and organized them by functional modification. Using our detailed knowledge of their WMS, we helped them understand which modifications could be replaced by new base functionality. We then revised the modifications so that they would work with the newest version of the WMS without forcing the client to alter their business processes. Initechs was able to eliminate more than 50% of the modifications, giving the client a cleaner, more efficient system that will be easier to upgrade in the future.

INITECHS’ EXPERIENCE AND IN-DEPTH KNOWLEDGE MADE IT POSSIBLE

Our goal was to help our client get the most out of their upgraded WMS. We compared their needs with the offerings of the latest version of the WMS. To do that, we:

  • Mapped the capabilities of the latest version of the WMS software to their business processes
  • Defined the gaps between the company’s requirements and the available system functionality
  • Identified necessary modifications to bridge those gaps
  • Developed a comprehensive upgrade strategy
  • Developed a detailed project plan, including resource and time requirements
  • Executed the project plan to perfection
  • Our experienced hands-on consultants made it possible to do all of this in just a few short months.

UNCOMMON RESULTS, EVERY TIME INITECHS DOES IT WITH PASSION

In the end, our client had a cleaner system, fewer modifications, and better system performance; all for less money than our competition would have charged to do much less.

 

RESULTS

 

  • Eliminated more than 50% of modifications
  • Completed upgrade according to project schedule
  • Completed upgrade within project budget

 

 

 

WMS Upgrade & System Facelift

Posted on by Kallol Nandi

 

WMS Upgrade & System Facelift

 

Our client is a leading distributor of books, videos, and music products to libraries, institutions and retailers. They have been in business for more than 175 years and have customers in more than 120 countries.

Situation: 

  • In need of WMS upgrade
  • Outdated interfacing system
  • Changing landscape for industry bar-code standard
  • Expensive label development process resulting from an outdated approach

IN NEED OF A SYSTEM FACELIFT…

When a leading book distributor needed to upgrade their WMS and update their technological processes, they turned to Initechs. Our client had been using an outdated system to interface data between their ERP and WMS, which had numerous problems and wasn’t suiting their complex needs. Additionally, their industry standard for tracking their products was changing. Finally, they were spending far too much money developing and modifying bar-code labels, and were in desperate need of a new approach.

INITECHS’ EXPERIENCE AND IN-DEPTH KNOWLEDGE MADE IT POSSIBLE

After surveying our clients’ needs we determined that a standard upgrade would fail to correct any of the underlying problems they were experiencing. Instead, we helped them understand what technologies were available so they could make informed strategic decisions. We:

  • Upgraded their WMS on time and within their project budget
  • Replaced their outdated legacy interface system with the MQ series technology
  • Incorporated software to handle their complex business logic needs and real-time alerts to notify IT personnel of network or data integrity issues
  • Altered their interfaces to support the new ISBN-13 (International Standard Book Number) convention, and created an interactive verification program to monitor the results
  • Modified their reports and labels to support the new ISBN-13 convention
  • Modernized their development efforts to allow the use of a GUI interface to design and modify their thermal printer label needs

Our technologically savvy consultants were able to do all of this for about the same amount of money that their WMS vendor would have changed just to perform the WMS upgrade.

EXCELLENT RESULTS, EVERY TIME INITECHS DOES IT WITH PASSION

In the end, our clients’ systems would now be able to meet the needs of their business for many years to come with much lower annual support costs.

 

RESULTS

 

  • Seamless upgrade and addition of new interfacing technology
  • Adaptation to new ISBN-13 standard
  • Update to GUI-based barcode software

 

 

 

Ultimate Customer Satisfaction

Posted on by Kallol Nandi

 

Ultimate Customer Satisfaction

 

Our client is an internationally renowned direct to consumer (D2C) company in the design, marketing and distribution of premium lifestyle products in apparel, home, accessories and fragrances mostly in North America and Europe.

Situation: 

One of a kind packaging was required with all elements to earn ultimate customer satisfaction

STAYING AS A LEADER IN THE FASHION AND DESIGN INDUSTRY IS A CHALLENGE

Our client being the leader in the fashion and design industry, they knew and they maintained extremely high standards in everything they did. Our client knew that their products were the best in the market, and they wanted to give best total customer satisfaction, which required many things beyond the products they sell. As a result of this effort, they wanted to redesign their packages, gift cards that went along with the package and every little things that gave their customers a complete satisfaction when the customer would receive the package in mail and open it at their home. Such a best company sought for only best consultants and Initechs helped them to achieve their goals.

INITECHS’ ATTENTION TO THE DETAILS AND PASSION OF DOING IT – MADE IT POSSIBLE

We realized that, it was not a typical project, we do one after another. So first we focused on our client’s business objectives: as what do they wanted now and how would they want to use our solution to meet their predictable future requirements. After understanding these, we drafted our initial solution and presented it to their marketing and technical teams. After few revisions, we prepared our final solution and finally offered a total solution that would give them an extreme flexibility to meet their demands. With our attention to the details we made sure every little things starting from the packaging, packing list, return instruction, gift card, ribbon, color and style of the box, to the shipping label, everything was perfect. We knew that providing the right instruction to the user was the first step of this process, but following instructions correctly and doing it right would be an error prone process when the volume would become high. So we designed our solution such way that it had the self-check and cross-check mechanisms built-in.

ULTIMATE OBJECTIVE WAS MET: CLIENT’S CUSTOMER SATISFACTION

At the end, client got what they had in their imaginations and their customers are extremely satisfied.

 

RESULTS

 

Client’s customer satisfaction rating went up, which in turn made our client best in the market.

 

 

 

Solution Architecture

Posted on by Kallol Nandi

 

Solution Architecture

 

Our client was a 4.5 billion USD company, a leading independent distributor of natural, organic and specialty foods including nutritional supplements, personal care items and organic produce, in the United States and 40 other countries.

Situation: 

  • Too much information to deal with it
  • Having no clear direction on how to lay them straight
  • Too many demands and restrictions from different departments
  • Conflicting elements to be tied together

ALL SEEM DIFFERENT; HOW TO PROCEED FROM HERE…

Our client had decided to implement one of the most popular and widely used WMS-TMS solution suites that were used by other companies of its size from a leading software provider. Client also inserted its business growth plan into this project plan.

Our client was very knowledgeable in technology but not in the technology this project demanded. This project initiative gave them a paradigm shift. They sought Initechs help.

ONLY A TURN BY TURN DIRECTIONS WERE PROVIDED BY INITECHS

Our client decided to implement all modules of the entire application suites to support their anticipated future business growth in this project which involved highly scalable and latest hardware and middle-ware from IBM. But the application was never implemented and scaled on those types of infrastructures. In addition, our client adopted a very high standard of network security policy and a tiered network architecture, which limited access to the server by allowing one-way traffic, restricted protocol to restricted servers, etc.

Along with all these unknowns and restrictions, our client also had a realistic but tough project deadline.

Our expertise in technology, particularly in heterogeneous network system and network security policy came handy to solve these puzzles.

  • We first studied the client’s requirements and thoroughly understood their existing network architecture and the growth plan.
  • We then clearly put the problem within the domain of constraints that was already set by our client.

We found it was circular chain problem and need to get one end fixed to solve this problem. We then divided the application layers and requirements to match with the network layers and start placing servers, allow restricted ports, and protocols to comply with our client’s security policy. When we completed our long journey we completed our logical diagram and got approval by our client’s various departments.

Taking this logical diagram, our experts first designed physical network architecture from end to end, and then extended it for the entire enterprise level.

MADE A THEME PARK IN THE AMAZON RAINFOREST

We explained every detail of how the request from each client and server would be served at every node and how the security was placed at every level.

It was like making a theme park in the Amazon rainforest, if you were our client’s network traffic, you would be walking within the danger, but feel safe have a nice experience.

 

RESULTS

 

Client knows

    • about each server, hardware and software details and their roles
    • how security was implemented
    • a total solution that will help to go to next level

 

 

 

Change Management

Posted on by Kallol Nandi

 

Change Management

 

Our client is an internationally renowned company in the design, marketing and distribution of premium lifestyle products in apparel, home, accessories and fragrances for more than 44 years.

Situation: 

  • Two DCs, each on their own iSeries Server
  • Many program variances across the two systems
  • No change management system or methodology
  • Upgrade being planned

SOLID CHANGE MANAGEMENT PRACTICE IS ESSENTIAL TO ANY MODERN BUSINESS

A major distributor of designer clothing realized that their lack of synchronization of the software was going to cause them major problems when they would upgrade their WMS. Base fixes and custom modifications were applied inconsistently across their two distribution centers, as required by each DC independently. Because each DC was operating on it’s own iSeries server, the problem was quite rampant. This is a fairly common problem often referred to as “Code Versioning”. With limited time, resources, and expertise, they turned to Initechs to help them sort out the mess.

INITECHS’ CONSULTANTS UTILIZED DECADES OF EXPERIENCE TO APPLY A SIMPLE, YET EFFECTIVE SOLUTION

Initechs stepped into the project and immediately began analyzing the source codes in order to determine which programs had variances. With this list in place, our consultants worked with the software vendor to gain a full understanding of the modified programs in order to determine which code was inherently unique to a particular facility, and therefore could not be part of the common system.

We then helped our client understand and implement a simple, yet effective three-tiered in-house change management approach. This approach, which serves to minimize the impact of custom code on the production environment, is still being utilized several years later. Some features of their new change management approach included:

  • A well-established methodology for testing and deployment
  • Proper testing and accountability at each level of code promotion
  • Increased visibility for all program changes made on either system
  • Easily refreshable data-sets for each promotion tier of each system

We also created detailed test scripts to aid the implementation of new code to either system, paying special attention to areas likely to be affected by the code changes.

UPGRADES CAN BE A BREEZE!

In the end, we assisted with promotion of all the common software into the production environment without incurring any negative impact. Most importantly, we gave them the knowledge and tools to handle code changes for years to come.

 

Results

 

  • Synchronized all of the code across the two systems
  • Implemented a change management methodology allowing better testing, visibility, and accountability of future code changes

 

 

 

Automating Manual Processes

Posted on by Kallol Nandi

 

Automating Manual Processes

 

Our client was a third party logistic service provider having annual revenue more than 500 million USD, serving one of high-end fashion and apparel company. Our client’s specialty was in large-scale home shopping network direct to consumer operations.

Situation: 

  • USPS documentation gathered by hand from multiple systems
  • Returns required manual monitoring
  • No process capable of sending custom messages with gift cards

AUTOMATING PROCESSES TO INCREASE ORDER ACCURACY, DECREASE FULFILLMENT TIME, AND REDUCE LABOR COSTS

Our client had several manual processes that were causing their labor costs to be high and order fulfillment times to be long. First, some of their most popular shipping options, like FedEx and United States Postal Service (USPS), required the manual gathering of information from numerous separate systems. Secondly, their returns process required ongoing manual communication between receiving personnel and the receiving office, in order to determine when an entire return had been received. Lastly, our client wanted to be able to ship gift cards with customized messages to their customers’ friends and family, but were unable to do that using their base WMS package. They opted to have Initechs help them implement solutions that would pay for themselves in a few months of labor savings.

INITECHS’ IMPLEMENTED AUTOMATED SOLUTIONS

Our goal was to help our client automate these manual processes so that they could return their focus to their business. We worked closely with our client to develop practical solutions to their impractical problems. To make this happen, we:

  • Developed a collate label to combine USPS and FedEx Shipping Label, Packing List, Newgistics Smart Return Label, and Return Instructions into a single document
  • Created an Electronic Data Interchange (EDI) process so that electronic manifests could be sent to USPS and FedEx
  • Automated their Returns process so that their WMS could take the correct action without human intervention when an entire Return shipment had been received
  • Integrated custom messages from their Order Management System so that messages could be easily be sent along with gift cards

SAVING MONEY BY AUTOMATING MANUAL PROCESSES

In the end, our client saw a 100% return on their investment in labor savings in just a few short months. In addition to the labor savings, our client experienced dramatic improvements in order accuracy and fulfillment times. Initechs is delighted to perform short-term projects with big returns for our valued clients.

 

RESULTS

 

  • Parcel documents automatically gather information from multiple systems
  • Streamlined returns process
  • Client able to print custom messages with gift cards

 

 

Running Wholesale & Retail in one DC

Posted on by Kallol Nandi

 

Running Wholesale & Retail in one DC

 

Our client was a distributor of premium life style products in various categories, and have a distinct image in the market with its brands. Our client’s brand names constitute one of the world’s most widely recognized families of consumer brands.

 

Situation: 

  • Our client was shipping retail and wholesale from the same facility
  • Each business had varying rules that were difficult to meet with the current configuration

DISTRIBUTING WHOLESALE AND RETAIL FROM THE SAME DISTRIBUTION CENTER

Our client had been shipping to their wholesale customers as well as their self-owned retail outlet stores from the same DC. While their WMS supported this type of environment, the company soon realized that some of the major components of their warehouse configuration needed to vary across the business units. Several options existed that would allow them to distribute their product, but this was a strategic decision that they needed to get right the first time. They could have had the software vendor guide them through the change. Instead, the chose Initechs to provide them with expertise.

INITECHS HELPED WITH KNOWLEDGE & EXPERTISE TO MAKE AND EXECUTE STRATEGIC WMS DECISIONS

We examined all of the options, and helped our client conclude that the cleanest and most cost-effective solution to the problems was to create a second systemic warehouse to fulfill their retail stores. Once the decision was made, we:

  • Analyzed the interfaces between the WMS and the client’s three primary host systems and provided a road-map for change
  • Created a detailed project plan identifying the time and resources necessary to implement the change
  • Coded, tested, and implemented the new interfaces
  • Created a new systemic warehouse to meet the needs of their Retail Business
  • Optimized the configuration of the existing warehouse to remove the accommodations for the Retail business
  • Upgraded the conveyor control system to take advantage of faster, more reliable, and flexible technology
  • Upgraded their WMS software to the latest version

INITECHS EXPERIENCE CAN HELP YOU MAKE THE RIGHT DECISION THE FIRST TIME

Initechs has decades of experience designing, developing, testing, and implementing WMS systems. Initechs helps its clients develop and execute comprehensive plans to address their needs. Please contact us today to discuss your needs with an Initechs representative.

 

RESULTS

 

  • Initechs provided expertise on creating a new systemic warehouse
  • Upgraded the conveyor control system to faster, more reliable technology
  • Successfully upgraded the WMS software to the latest version

 

 

ERP WMS vs. Best of Breed WMS

Posted on by Kallol Nandi

A high level, comprehensive comparison between the WMS functionality of an ERP software and a best of breed WMS software. It focuses on fundamental differences and their roots. This does not include any specific ERP or WMS applications.

ERP – Inventory Management Module Warehouse Management Software
The inventory management functions of the ERP views of the stock from an accounting perspective. WMS views the stock from a physical perspective.
The total quantity of a stock item available to sell is maintained. WMS deals with the physical goods and tracks the product and quantities down to bin or location level.
ERP tracks the total quantities into and out of the warehouse, to maintain the current stock levels of each product. In addition to the total stock quantities, WMS tracks the details of the product down to the location level, for full traceability in the physical warehouse. For example, the WMS would track whether the product was in the receiving area, had been placed into the correct storage location, had been picked or dispatched.
The total quantity of a stock item is maintained using various costing models. WMS keeps track of product batch, lot, owner, and expiry etc information down to the location level. The full physical movement history of a product is available in WMS, along with the person responsible for that movement.
Since ERP does not keep track the inventory movements within the warehouse, it cannot optimize the process. By keeping track of the physical aspect of the warehouse, a WMS is able to use this information to optimize the resources used in the warehouse. These resources are the space available, the material handling equipment and the staff.
ERP allows a single pick location to be allocated to a product that is used when storage and picking instructions are issued. By using storage rules, taking the product class, category and dimension information into account, an optimum pick and bulk storage location can be allocated to the products received.
Replenishment is generated in batch and given to the user as a paper pick, it is not a real time update. Since the system tracks the product location quantities, in both bin and bulk, replenishment instructions can be generated on the WMS. These can be issued to the warehouse workers in real time.
ERP works in batch mode and no real time optimization is done. If radio frequency equipment is used or will be printed out in a batch environment, a pick sequence can be defined in the warehouse, to optimize the picker’s movements through the warehouse, ensuring that the picker walks the smallest distance possible to pick the products required for an order or a pick group.
ERP fulfills the order one at a time, results the picker to visit the same location many times. This decreases the operational efficiency. The WMS is able to group the items on dispatch orders, allowing a picker to visit a location once per group of orders, rather than many times for the same group of orders.
ERP focuses on invoicing of sales order. WMS focuses on correct delivery of sales order and comply with customers requirements. Using the date of entry or the date of expiry, the WMS is able to ensure that the oldest product is picked first, thus eliminating wastage due to product expiry or write-offs due to products damaged or dirtied over time in the racking.
ERP generally deals with a huge database and response of the system may not be instantaneous. WMS is expected to be up 24×7 as many warehouses run 3 shifts 7 days a week. That means, there is no down time in the system. WMS is ready to work for a heavy operations and work force that has high expectations of readiness (up-time) for both the software and hardware involved.
ERP generally does not communicate with the real time system, material handling equipments such as conveyor, sorter, diverter etc. WMS communicates with real time systems with quick response time. WMS serves as mission critical sub-system in the warehouse.

WMS interfaces to the host system, to allow passing of data between the systems, so that the inventory (accounting) system and the physical (warehouse) system appear seamless to the user. Warehouse management and inventory management complement each other, both providing a different, yet useful view of the same data. By using warehouse management functionality, a business can optimize many of the aspects of stock control, ultimately providing better client service though better delivery mechanisms.