Royal pipe plant (TopLog WMS)

2010

The organization of effective warehouse economy using the WMS solution was a priority task of Royal pipe plant.

For project implementation as the contractor the TopLog company was selected. The possibility of its fast adaptation under specific features of storage and processing of metal was the main criterion when choosing the TopLog WMS system:

• need of accounting of products, raw materials and semi-finished products at the same time for several units of measure – weight electronic, weight in accordance with GOST, quantity of packs, the number of pieces in a pack;
• different structure of properties for different types of products (a roll, the strip, a pipe, an armature, a corner, a channel, the sheet). For example, for a profile rectangular pipe it is length, wall thickness, width of the parties. For the strip – thickness of a wall and band width. These characteristics are key on all processing of metal rolling;
• issue of warehouse tasks is based not on free personnel and not in line clients, and on availability of gantry and tower cranes. Each client is serviced in turn by several cranes to load all ordered product assortment;
• existence of the processes, atypical for a normal warehouse, connected with additional processing of products, for example, galvanization and cutting.

During the course of performance works the formulated warehouse task received the logical continuation and the ambitious goal on additional automation of production processes of the enterprise, including calculation of raw cost value and also personnel management was set.

Joint efforts in 6 months automated "turnkey" following sections:

• a warehouse (address accounting in the enclosed space and on the open areas, application of radio data collection terminals and barcodes on all transactions, accounting of products at the same time in several cuts – tons, packs, pieces);
• production (scheduling of production of the strip and a pipe, operational management of production process, accounting of all stages of processing of metal using barcoding, control weighing and accounting of waste at each production stage, rejection of products discarded by the defectoscope);
• cost accounting (registration of purchase prices of raw materials at revenues to a warehouse, lot-based accounting of raw materials and semi-finished products by transfer to production, automatic cost accounting of a pipe taking into account waste and defects by packs, specialized reports for assessment of formation of raw product cost on production stages);
• personnel (access control on the enterprise territory, accounting of development of production and warehouse personnel, registration of the reasons of idle times of work centers, automatic formation of replaceable official reports and sheets of accounting of the worker of time).

The management of the enterprise received full control over all types of a remaining balance and stages of processing of products in real time. The human resource department is supplied with detailed information on the number of the fulfilled hours and development of each employee and also on the reasons of idle time of sections that allows to make the correct management decisions.

Finance division of the enterprise is provided with real digits at raw cost value with a possibility of detailing to each unit of production which is in a warehouse. This huge competitive advantage allowing to manage selling prices of own metal products in the conditions of unstable raw material prices.