Manhattan SCALE 2010 in a warehouse complex of Petro factory (JTI)

At the beginning of 2013 the CORUS Consulting group completed implementation of Manhattan SCALE 2010 in a warehouse complex of Petro factory – the largest production center in global structure of tobacco corporation JTI.

During the project work of warehouses on the area of 70,000 sq.m is automated and also integration of Manhattan SCALE with the system of SAP and other business applications implemented at Petro factory is provided.

Production in JTI company is organized by the principle of "just in time" (supply of materials just in time) for which respect accurate work of all warehouse complex of the enterprise is necessary. Implementation of the WMS system of Manhattan SCALE 2010 allowed to automate a production and warehouse circuit of the enterprise which 4 warehouses with different specifics of processes enter: temporary storage warehouse, warehouse of not tobacco materials, warehouse of production storage and finished goods warehouse.

WMS manages the movement of materials and products not only in the territory of warehouses, but also in the territory of production, all in a system about 2000 active nomenclatures are used. In an information system features of warehouse business processes are considered: conducting lot-based accounting, use of frontal pallet racks in a warehouse of not tobacco materials, stuffed racks with a shattlovy system - on a finished goods warehouse and also big zones of floor storage which are organized in all territory of a complex. In a system a number of the add-on modules providing document transfer between warehouses of the enterprise in real time is also implemented. More than 30 operational logistic report forms are kept.

Interwarehouse movements represented the main complexity for automation: it was necessary to support movement between warehouses of thousands a pallet with materials and finished goods in day. "For us crucially uninterrupted ensuring production with materials and sending finished goods to customers just in time, from here – extremely high intensity of warehouse transactions", – Alexander Ivanov, the director of project management, corporate information technologies, JTI tells.

Thanks to integration with SAP it was succeeded to exclude a huge number of additional actions of users, to synchronize data between the local and global systems and to provide fast formation of the uniform reporting under all divisions in different analytical cuts. It should be noted also advantages of the selected WMS system: Manhattan SCALE has the simple and easily configured user interface which any experienced user of Windows can master.

"During the project we provided execution of requirements of J-SOX (Japanese SOX). Thanks to a combination of the well-known Japanese approaches to internal control to the advanced IT solutions we managed to minimize risk of delays, errors, idle times during the work of a warehouse complex", – Andrey Chmyrev, the project manager from Corus Consulting comments.

The project was carried out in two steps. Optimization of interaction of warehouses and production was a key problem of the first stage begun in October, 2010. The first transactions in a new system from the special terminal were made by the senior vice president of a global network of deliveries of JTI Bill Schultz. In March, 2012 the second step of implementation during which, on the basis of the accumulated operating experience of a system, its completions were carried out was completed and the functionality is expanded. New interfaces for integration with SAP, new forms of the reporting are implemented, the mechanism of regular updating of a system guaranteeing the greatest possible fault tolerance of all software package is created. Now in the Manhattan SCALE system 4 changes of users – about 100 competitive connections work.