Warehouse management automation and organisation of warehouse and order picking systems

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Title:

Personal Author:

Ten Hompel, Michael

Publication Information:

Berlin : Springer, 2007

Physical Description:

1 CD-ROM; 12cm .

ISBN:

9783540352181

General Note:

Accompanies text of the same title : HF5485 T46 2007

Subject Term:

Warehouses -- Management

Added Author:

Schmidt, Thorsten

Available:*

Library	Item Barcode	Call Number	Material Type	Item Category 1	Status
Searching... PSZ JB	30000010122955	CP 10384	Computer File Accompanies Open Access Book	Compact Disc Accompanies Open Access Book	Searching... Unknown

Modern warehouse and distribution systems constitute highly complex nodes within the value-added supply chain and have to meet a variety of requirements with regard to time, costs and quality. The efficient operation of such systems is a continuous challenge for anyone in charge. Recent developments of advanced computer-based control technologies have contributed to development of the necessary control and management systems called Warehouse Management Systems (WMS). Nevertheless, due to the high complexity, users often find it hard to handle WMS. The design, choice and operation of a WMS requires extensive know-how and experience because of the large variety of solutions and system requirements. This book gives an overview of possible solutions which help readers to make the right choice. It presents the background and potential, but also the risks and strategies to handle them. It sets the basis for comparisons for all those readers who are responsible for the evaluation and specification of warehouse management systems. Furthermore, it is meant as basic support for students and interested beginners. This book is based on practical knowledge without neglecting the basic context or assuming special technical knowledge. Some basic processes and technologies that are required for a better understanding are described in detail. System-developers will find some new ideas when problems and limits of current developments are discussed. New approaches with regard to the structure and design of WMS are presented.

Readers can expect a simple and well-documented explantion of WMS based on the open-source initiative myWMS. The software can be operated on a common PC independent of the platform and without any obligatory user login data. Thus, the operation, function and benefits of a WMS can be visualized.

Author Notes

Prof. Dr. Michael ten Hompel was born in 1958. He studied Electrical Engineering focusing on technical informatics at the RWTH in Aachen and graduated as PhD from the University of Witten/Herdecke. He started his professional career as scientist at the chair of Transportation and Warehousing of the University of Dortmund and at the Fraunhofer-Institute for Transport Technology and Goods Distribution. From 1989 to 1991 he was director of the Dortmund branch of IGS GmbH & Co. KG in Aachen, a company developing computer systems and networks. In 1988 Prof. ten Hompel founded GamBit GmbH, a company developing software for production and logistics management, today one of Germany's most successful companies in logistics. In 2000 he resigned from the board to become director of the Fraunhofer-Institute for Material Flow and Logistics (since 2005 managing director) where he is also head of the department "Material Flow Systems". He also holds the chair of Transportation and Warehousingat the University of Dortmund.

Dr. Thorsten Schmidt, M.S. holds degrees in mechanical engineering from the University of Dortmund and industrial engineering from the Georgia Institute of Technology. He currently heads the department machinery and systems at the Fraunhofer-Institute for Material Flow and Logistics, focusing on the design and technology of in-house material flow systems.

1 Introduction	p. 1
1.1 Requirements	p. 2
1.1.1 Warehousing	p. 2
1.1.2 Characteristics of warehouse systems	p. 4
1.1.3 Optimization of warehouse systems	p. 5
1.2 Warehouse Management	p. 6
1.3 System interfaces and definitions	p. 7
1.4 Structure and goal of this book	p. 11
2 Management of Warehouse Systems	p. 13
2.1 Logistic frameworks	p. 13
2.1.1 Logistic principles	p. 13
2.1.2 Packaging and logistic units	p. 16
2.2 Functions in warehouse systems	p. 20
2.2.1 Goods acceptance and receipt	p. 20
2.2.2 Storage	p. 25
2.2.3 Retrieval / picking	p. 28
2.2.4 Consolidation point	p. 30
2.2.5 Order-picking	p. 30
2.2.6 Packaging department	p. 44
2.2.7 Shipping department	p. 45
2.3 Warehouse management system	p. 46
2.3.1 Warehouse management	p. 46
2.3.2 Reorganization	p. 50
2.3.3 Conveyor management and control systems	p. 50
2.3.4 Data collection, processing and visualization	p. 51
2.3.5 Stocktaking	p. 53
2.4 Basic data and key performance indicators of warehouse systems	p. 56
2.4.1 Basic data	p. 56
2.4.2 Logistic key performance indicators	p. 57
2.5 Special procedures and methods	p. 59
2.5.1 Cross docking	p. 59
2.5.2 Outsourcing of the physical distribution and warehousing processes	p. 61
2.5.3 Application Service Providing	p. 62
3 Fundamentals of an Operational Optimization	p. 63
3.1 Optimization in short	p. 63
3.1.1 Background	p. 63
3.1.2 Classification of the operational optimization	p. 65
3.1.3 Terms and elements of dispatching	p. 67
3.2 Optimization processes in a warehouse	p. 68
3.2.1 Transport optimization	p. 68
3.2.2 Sequencing of picking orders	p. 76
3.2.3 Routing in the warehouse	p. 78
3.2.4 Comprehensive order dispatching	p. 79
3.3 Optimization of solutions	p. 81
3.3.1 General aspects	p. 81
3.3.2 Overview over the optimization procedures	p. 82
3.3.3 Examples of known methods	p. 84
4 Warehousing and Conveying Principles	p. 91
4.1 Warehouse systems	p. 91
4.1.1 Ground store	p. 92
4.1.2 Statical racking systems	p. 94
4.1.3 Dynamical racking system	p. 102
4.1.4 Pre-rack zone	p. 105
4.2 Transport systems	p. 106
4.2.1 Conveyors	p. 107
4.2.2 Transporters	p. 110
4.3 Sorting and distribution systems	p. 126
4.3.1 Applications	p. 126
4.3.2 The basic structure of sorting systems	p. 128
4.3.3 Distribution technology	p. 132
4.3.4 Control and strategies	p. 135
4.4 Robots in warehouse systems	p. 136
4.4.1 Palletizing robots	p. 136
4.4.2 Order-picking robots	p. 136
5 Automation of the Material Flow	p. 137
5.1 Basics of automation	p. 137
5.1.1 History of the material flow automation	p. 138
5.1.2 Terms and definitions	p. 139
5.1.3 The structure of control systems	p. 140
5.2 Control engineering	p. 144
5.2.1 Classification of controls	p. 144
5.2.2 Programmable logic controllers	p. 147
5.2.3 Computer control	p. 152
5.3 Sensors	p. 153
5.3.1 Sensor classifications	p. 153
5.3.2 Mechanically operated sensors	p. 154
5.3.3 Optical sensors	p. 154
5.3.4 Magnetic and inductive sensors	p. 158
5.3.5 Ultrasonic sensors	p. 159
5.4 Actuators	p. 160
5.4.1 The tasks and structures of actuator systems	p. 160
5.4.2 Electrical drives	p. 162
5.4.3 Fluid drives	p. 168
5.5 Interfaces in automation systems	p. 169
5.5.1 Analogous and binary data transmission	p. 170
5.5.2 Digital data transmission	p. 171
5.5.3 Field bus systems	p. 173
6 Automatic Identification	p. 179
6.1 Codes and characters	p. 179
6.1.1 Encoding	p. 180
6.1.2 Encoding examples	p. 180
6.2 ID-Codes	p. 181
6.2.1 Code 2/5	p. 182
6.2.2 Check digit calculation Code 2/5	p. 185
6.2.3 Code 2/5 interleaved	p. 186
6.2.4 Code 128	p. 188
6.2.5 Check digit calculation code 128	p. 191
6.2.6 The character sets of the code 128	p. 192
6.2.7 Mixed character sets in code 128 and their optimization	p. 194
6.2.8 Code sizes, tolerances and reading distances	p. 195
6.3 Printing method and quality	p. 197
6.3.1 Labelling techniques	p. 197
6.3.2 Quality requirements	p. 198
6.3.3 Selection of the printing technique	p. 198
6.4 Semantics in the code: EAN 128	p. 200
6.4.1 Global location numbering (GLN)	p. 201
6.4.2 International article number (EAN)	p. 203
6.4.3 Serial shipping container code (SSCC)	p. 203
6.4.4 Characteristics of the code EAN 128	p. 204
6.5 Scanner technology, devices, interfaces	p. 208
6.5.1 Barcode scanner	p. 208
6.5.2 Handheld scanners	p. 208
6.5.3 Stationary scanners	p. 209
6.6 2D-Codes	p. 210
6.6.1 Stacked barcodes	p. 211
6.6.2 Matrix codes	p. 212
6.7 Radio frequency identification	p. 214
6.7.1 Functioning and technical structure	p. 214
6.7.2 Fields of application	p. 219
6.7.3 Comparison with barcode systems	p. 220
7 Information and Communication Technology	p. 221
7.1 Communication technology	p. 221
7.1.1 Layered architectures	p. 222
7.1.2 Protocols	p. 222
7.1.3 Transmission media	p. 225
7.1.4 Network types and internetworking	p. 227
7.1.5 Network addresses	p. 230
7.1.6 Examples	p. 232
7.2 Data management	p. 235
7.2.1 Principles	p. 235
7.2.2 File systems	p. 237
7.2.3 Databases	p. 238
7.2.4 Availability of data	p. 243
7.3 User interface	p. 245
7.3.1 Terminals	p. 246
7.3.2 Functional point of view	p. 247
7.3.3 Access control	p. 248
7.3.4 Internationalization	p. 249
7.3.5 Help systems and help functions	p. 249
7.4 Operating systems	p. 250
7.4.1 Tasks	p. 250
7.4.2 Principles	p. 252
7.5 Programming languages	p. 261
7.5.1 Compilers and interpreters	p. 261
7.5.2 Language concepts	p. 264
7.5.3 Language generations	p. 264
7.6 Basic principles of object-oriented programming	p. 266
7.6.1 Data abstraction	p. 266
7.6.2 Classes and objects	p. 268
7.6.3 Inheritance	p. 269
7.6.4 Unified modelling language	p. 271
7.7 Extensible markup language: XML	p. 271
7.7.1 Key-value-coding	p. 271
7.7.2 The syntax of XML	p. 274
7.7.3 Parsers and processors	p. 275
7.7.4 Variety with style sheets	p. 276
7.8 Safety aspects	p. 277
7.8.1 Secrecy	p. 278
7.8.2 Integrity assurance	p. 280
7.8.3 Authentication	p. 280
7.8.4 Authentication and electronic signature	p. 281
8 Realization of Warehouse Management Systems	p. 283
8.1 Requirement definition	p. 284
8.1.1 As-is analysis	p. 285
8.1.2 Weak-point analysis	p. 286
8.1.3 Development of a target concept	p. 287
8.2 Preparation of the tender documents	p. 287
8.2.1 Definition of the key performance indicators	p. 288
8.2.2 Preparation of the technical specifications	p. 289
8.2.3 Completion of the tender documents	p. 292
8.3 The placement of an order	p. 293
8.3.1 Preselection of providers	p. 293
8.3.2 Comparison of offers	p. 293
8.3.3 Offer presentation	p. 293
8.3.4 Selection of a provider	p. 296
8.4 Implementation	p. 296
8.4.1 Preparation of the technical specifications	p. 296
8.4.2 Realization	p. 300
8.4.3 Project management / Quality assurance	p. 301
8.5 Start-up	p. 301
8.5.1 Test phase	p. 301
8.5.2 Changeover from old to new WMS	p. 302
8.5.3 Training	p. 302
8.6 Acceptance	p. 302
8.6.1 Performance test	p. 303
8.6.2 Failure simulation and emergency strategies	p. 303
8.6.3 Formal acceptance	p. 304
9 Structure of a WMS from the Example of my WMS	p. 307
9.1 Data model	p. 307
9.1.1 Data container of the model	p. 308
9.1.2 Data interrelations	p. 310
9.1.3 Interfaces	p. 313
9.2 Classical implementation of a WMS	p. 313
9.2.1 Functional structure	p. 313
9.2.2 Table structure	p. 315
9.2.3 Securing the logical integrity	p. 318
9.2.4 Generation and query of master data	p. 318
9.3 MyWMS	p. 320
9.3.1 The basic structure of myWMS	p. 320
9.3.2 Business objects	p. 323
9.3.3 Kernel concept	p. 324
9.3.4 Runtime environment	p. 326
9.4 Example of a distribution system using myWMS	p. 327
9.4.1 Description of the example	p. 327
9.4.2 Topology structure	p. 333
9.4.3 Plug-In - Routing	p. 335
9.4.4 Communication	p. 336
Abbreviations	p. 341
Bibliography	p. 345
Index	p. 351

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Table of Contents