Project completion of automation of a warehouse of auto parts of Avtospeys company

The Avtospeys company was founded in 1995. Today Avtospeys - one of the largest suppliers to Republic of Belarus of spare parts, parts and accessories for passenger and trucks from world leading manufacturers, such as FUCHS, BAREN, ZF, BOGE, SACHS, BOSCH, RUVILLE, LEMFORDER, VICTOR REINZ, etc.

The distributive center of Avtospeys company placed in the city of Minsk performs the wholesale and small wholesale supplies of auto parts to dealers and also supply of network of retail stores. Expansion of business of the company and transition to just-in-time technology resulted in need of full automation of management of the distributive center.

In addition to a standard task of traffic control of a trade flow there were relevant also questions of the cost accounting, time and cost value of accomplishment of warehouse transactions, reduction of costs for accomplishment of warehouse transactions, performance improvements of work, capacity of storage and capacity of a warehouse, speed and quality of goods issue, ensuring transparency of work of a warehouse and other indicators of functioning of a warehouse.

The company management made the decision on need of implementation of a modern full-function warehouse management system (WMS) capable to provide effective solution of all above-mentioned tasks.

Characteristics of an automation object

Just-in-time technology. High intensity of shipments – over 1500 orders within working day. Shipment and delivery of orders to clients within 2 hours from the moment of receipt of orders. Over 80 transport runs within working day. An operation mode 24х7 in 3 changes. Total number of personnel of a warehouse about 120 people.

The warehouse consists of two buildings with 2 floors, plus on each floor for close-meshed storage storage in 2 tiers is organized. The total area of storage about 6000 sq.m, on 1000 pallets and 15000 cells of close-meshed and shelf storage, the commodity reference book about 100000 positions, the reference book is separated into brands about 80, classes and groups of storage, in the reference book are supported accounting of different standard sizes: pieces, boxes, pairs, pallets. Account is kept both in the whole units of measure, and in fractional. On some commodity groups account is kept on expiration dates of batches. Account and processing of goods of safe custody with access to the storage area of authorized storekeepers is kept.

Automation based on Open Source HH.WMS

In the project progress specialists of Konsid Resheniya company performed full automation of all requirements stated to work of a warehouse for each zone and the floor.

System implementation of management of the warehouse OHE.WMS was made on 10 dispatching places, jointly with specialists of the customer performed setup of the necessary equipment for automatic identification – 52 data collection terminals of Motorola (Symbol), 5 stationary Zebra printers.

For goods the different strategy of management of a trade flow connected with processing of the diverse range were implemented. The unique algorithms of processing of goods allowing to use optimum an address space and to minimize the costs connected with processing were developed for each of zones of a warehouse. At the same time processing of goods of each zone of a warehouse closely interacts among themselves. Zones of a warehouse are separated on brands and commodity groups, have the common area of acceptance and the common area of shipment and packaging of goods. The last are divided into a set of the cells tables tied to the different directions of delivery - to runs.

Acceptance

In connection with complexity in ensuring standard approach at acceptance of different brands for a warehouse, several options of acceptance were implemented:

• primary acceptance of the come cargo-places of goods
• by the piece in cells
• acceptance with formation mono and a mix a pallet
• acceptance of several arrivals along with automatic sorting of the accepted goods quantity on arrivals.

Placement and selection

Existence of a good selection of spare parts promoted development of processes of placement (movement) of the goods reducing labor input of transactions:

• poartikulno from a cell
• poartikulno from pallets/container
• entirely pallety
• poartikulny set on a container with the subsequent poartikulny placement on warehouse cells.

For business processing of orders the unique algorithm of group selection allowing to select several orders separated on different warehouses, quantity of goods items, weight for one pass was implemented. After completion of selection a system automatically consolidates a stock in complete set zone cells, separating orders in the directions of delivery (one of 40 possible).

The print engine of labels of the collected order after selection was developed for minimization of paper document flow by specialists of the company. Further this label is used as the identifier at stages of accomplishment of check and repacking of orders and at a stage of shipment of orders. At a stage of check poartikulny check and formation of shipping units is executed.

Shipment

Specialists of Konsid Resheniya company paid special attention to implementation of business processes of work with delivery routes to the consumer of the purchased products. The specifics of a company performance of the client with end consumers assume the goods delivery to the buyer. Because on processing of one order it is taken away from 1 to 12 hours, about 80 runs of delivery which are required to be created together with a WMS system daily form.

Result of joint work of the company - the client and the supplier of the solution was the interface of exchange between 1C 8.1 and WMS providing operational change of a delivery route up to shipment of a collected pallet to the machine. This interface was closely integrated with business processes into WMS that provided a possibility of operational change and control of routes in WMS.

For business process of shipment different mechanisms of loading of shipping units taking into account an order type, priority of the order, priority of run and time of shipment are implemented. At accomplishment of loading and completion of shipment of the order of run the statuses of order processing and the status of processing of shipping unit are considered.

Electronic document management with ERP

Within the project of automation by specialists of Konsid Resheniya company the setup of the data exchange interface with a corporate system of 1C providing seamless integration between systems was made:

• loading and change of orders
• loading, change, removal of runs
• unloading of results of accomplishment of orders
• unloading of the statuses of loading of documents and statuses of order processing and runs
• loading of inventories and reconciliations of a remaining balance
• unloading of results of accomplishment of inventories, reconciliations and corrections of a trade inventory.

Technique of automation of a warehouse of auto parts

Separately it is necessary to select a technique of implementation of this project. Due to the good selection of products, a large number of orders for shipment (more than 1500 a day) and complexity of business processes the special technique on brands was developed. This technique allowed to automate a warehouse without the slightest decrease in volume of shipments, without stress and discomfort for personnel of a warehouse and clients of the company. In the quiet mode to train all personnel of a warehouse and to transfer work of a warehouse to the full-function mode within three months (time of transfer of all brands for full-function work to OHE.WMS).

Especially It should be noted that in the course of start any shipment to the client was not broken.

Results of automation of a warehouse of avtozapchaty

As a result of automation of a warehouse of spare parts accounting of the movement of inventory items was organized, the required transparency of work of a warehouse is provided. The efficiency of goods acceptance increased: need of sorting of goods disappeared during acceptance

• there was an opportunity to host an installment delivery that increased goods receipt speed in * sale and also allowed to use the area of a zone of acceptance more effectively
• there was an opportunity to accept goods at once in the storage addresses, passing an acceptance zone
• there was an opportunity to accept goods pallety one scan
• preparation of commodity labels is performed in the course of acceptance.

An address system with special fitting algorithms of the recommended cell allowed to place quickly without involvement of experts of a warehouse goods on storage locations as a result of acceptance - a system automatically recommends a cell for placement of goods.

The efficiency of use of the warehouse space of the storage area of goods increased – need of sorting and grouping of the commodity nomenclature for the storage area disappeared.

At selection of goods a system builds an optimal route of a bypass of cells. Accuracy of selection increased up to 99.9% - situations of search of goods are almost excluded.

Algorithms of formation and job control of selection and check allow to prepare the order of any complexity for shipment within 20 minutes.

The system of formation and management of runs allowed to display quickly changes of the directions (routes) of shipment and to control the accuracy of shipment of all orders along the set routes.

The system of synchronization of data between CIS and WMS allowed employees and clients of the company to trace quickly a status of orders from the status "Is created" to the status "In Way".

6 regional warehouses on 5 user licenses on a warehouse are automated

Autospace Polotsk of Ltd company

Characteristics of an object warehouse Type: A warehouse at outlet, Auto parts. Region: Polotsk Storage: 800 sq.m, the Mezzanine of Nomenclature positions - 100,000 articles Users: 5 licenses.

• 2013/05 - 2013/05

Autospace Grodno of Ltd company

Characteristics of an object warehouse Type: A warehouse at outlet, Auto parts. Storage: 600 sq.m. Nomenclature positions - 100,000 articles Users: 5 licenses.

• 2013/03 - 2013/03

Autospace Mogilev of Ltd company

Characteristics of an object warehouse Type: A warehouse at outlet, Auto parts. Region: Mogilev Storage: 800 sq.m, the Mezzanine of Nomenclature positions - 100,000 articles Users: 6 licenses.

• 2013/09 - 2013/09

Autospace Brest of Ltd company

Characteristics of an object warehouse Type: A warehouse at outlet, Auto parts. Region: Brest Storage: 600 sq.m, the Mezzanine of Nomenclature positions - 100,000 articles Users: 5 licenses.

• 2013/07 - 2013/07

Autospace of service station Mogilev Ltd company

Characteristics of an object warehouse Type: A warehouse at service station, Auto parts. Region: Minsk Storage: 1000 sq.m, the Mezzanine of Nomenclature positions - 100,000 articles Users: 7 licenses.

• 2014/05 - 2014/05

Autospace Gomel of Ltd company

Characteristics of an object warehouse Type: A warehouse at outlet, Auto parts. Region: Gomel Storage: 800 sq.m, the Mezzanine of Nomenclature positions - 100,000 articles, 90 brands Users: 6 licenses.

• 2013/11 - 2013/11

Autospace Vitebsk of Ltd company

Characteristics of an object warehouse Type: A warehouse at outlet, Auto parts. Region: Vitebsk Storage: 600 sq.m, the Mezzanine of Nomenclature positions - 100,000 articles Users: 5 licenses.

• 2014/07 - 2014/08