Hompel / Schmidt Warehouse Management

Automation and Organisation of Warehouse and Order Picking Systems
1. Auflage 2006
ISBN: 978-3-540-35220-4
Verlag: Springer Berlin Heidelberg
Format: PDF
Kopierschutz: 1 - PDF Watermark

E-Book, Englisch, 356 Seiten

Reihe: Intralogistik

This book helps readers evaluate and specificy the best Warehouse Management System (WMS) for their need. The advice is based on practical knowledge, describing in detail fundamental processes and technologies needed for a basic understanding. New approaches in the structure and design of WMS are presented, along with discussion of the limitations of current systems. The book shows how to operate a simple WMS based on the open-source initiative myWMS.

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 Warehousing at 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.  

Autoren/Hrsg.

Hompel, Michael

Schmidt, Thorsten

Inhaltsverzeichnis

1;Foreword;5
2;Contents;7
3;1. Introduction;13
3.1;1.1 Requirements;14
3.1.1;1.1.1 Warehousing;14
3.1.2;1.1.2 Characteristics of warehouse systems;16
3.1.3;1.1.3 Optimization of warehouse systems;17
3.2;1.2 Warehouse Management;18
3.3;1.3 System interfaces and definitions;19
3.3.1;Merchandize management system (MMS);19
3.3.2;Management information system (MIS);19
3.3.3;Production planning and control (PPC);20
3.3.4;Enterprise resource planning (ERP);20
3.3.5;Material .ow controller (MFC);20
3.3.6;Warehouse control system (WCS);20
3.4;1.4 Structure and goal of this book;23
4;2. Management of Warehouse Systems;25
4.1;2.1 Logistic frameworks;25
4.1.1;2.1.1 Logistic principles The term logistics;25
4.1.2;2.1.2 Packaging and logistic units;28
4.2;2.2 Functions in warehouse systems;32
4.2.1;2.2.1 Goods acceptance and receipt;32
4.2.2;2.2.2 Storage;37
4.2.3;2.2.3 Retrieval / picking;40
4.2.4;2.2.4 Consolidation point;42
4.2.5;2.2.5 Order-picking;42
4.2.6;2.2.6 Packaging department;56
4.2.7;2.2.7 Shipping department;57
4.3;2.3 Warehouse management system;58
4.3.1;2.3.1 Warehouse management;58
4.3.2;2.3.2 Reorganization;62
4.3.3;2.3.3 Conveyor management and control systems;62
4.3.4;2.3.4 Data collection, processing and visualization;63
4.3.5;2.3.5 Stocktaking;65
4.4;2.4 Basic data and key performance indicators of warehouse systems;68
4.4.1;2.4.1 Basic data Master data;68
4.4.2;2.4.2 Logistic key performance indicators;69
4.5;2.5 Special procedures and methods;71
4.5.1;2.5.1 Cross docking;71
4.5.2;2.5.2 Outsourcing of the physical distribution and warehousing processes;73
4.5.3;2.5.3 Application Service Providing;74
5;3. Fundamentals of an Operational Optimization;75
5.1;3.1 Optimization in short;75
5.1.1;3.1.1 Background;75
5.1.2;3.1.2 Classification of the operational optimization;77
5.1.3;3.1.3 Terms and elements of dispatching;79
5.2;3.2 Optimization processes in a warehouse;80
5.2.1;3.2.1 Transport optimization;80
5.2.2;3.2.2 Sequencing of picking orders;88
5.2.3;3.2.3 Routing in the warehouse;90
5.2.4;3.2.4 Comprehensive order dispatching;91
5.3;3.3 Optimization of solutions;93
5.3.1;3.3.1 General aspects;93
5.3.2;3.3.2 Overview over the optimization procedures;94
5.3.3;3.3.3 Examples of known methods;96
6;4. Warehousing and Conveying Principles;103
6.1;4.1 Warehouse systems;103
6.1.1;4.1.1 Ground store;104
6.1.2;4.1.2 Statical racking systems;106
6.1.3;4.1.3 Dynamical racking system;114
6.1.4;4.1.4 Pre-rack zone;117
6.2;4.2 Transport systems;118
6.2.1;4.2.1 Conveyors Roller conveyors;119
6.2.2;4.2.2 Transporters;122
6.3;4.3 Sorting and distribution systems;138
6.3.1;4.3.1 Applications;138
6.3.2;4.3.2 The basic structure of sorting systems;140
6.3.3;4.3.3 Distribution technology;144
6.3.4;4.3.4 Control and strategies;147
6.4;4.4 Robots in warehouse systems;148
6.4.1;4.4.1 Palletizing robots;148
6.4.2;4.4.2 Order-picking robots;148
7;5. Automation of the Material Flow;149
7.1;5.1 Basics of automation;149
7.1.1;5.1.1 History of the material flow automation;150
7.1.2;5.1.2 Terms and definitions;151
7.1.3;5.1.3 The structure of control systems;152
7.2;5.2 Control engineering;156
7.2.1;5.2.1 Classification of controls;156
7.2.2;5.2.2 Programmable logic controllers;159
7.2.3;5.2.3 Computer control;164
7.3;5.3 Sensors;165
7.3.1;5.3.1 Sensor classi.cations;165
7.3.2;5.3.2 Mechanically operated sensors;166
7.3.3;5.3.3 Optical sensors;166
7.3.4;5.3.4 Magnetic and inductive sensors;170
7.3.5;5.3.5 Ultrasonic sensors;171
7.4;5.4 Actuators;172
7.4.1;5.4.1 The tasks and structures of actuator systems;172
7.4.2;5.4.2 Electrical drives;174
7.4.3;5.4.3 Fluid drives;180
7.5;5.5 Interfaces in automation systems;181
7.5.1;5.5.1 Analogous and binary data transmission;182
7.5.2;5.5.2 Digital data transmission;183
7.5.3;5.5.3 Field bus systems;185
8;6. Automatic Identification;191
8.1;6.1 Codes and characters;191
8.1.1;6.1.1 Encoding;192
8.1.2;6.1.2 Encoding examples;192
8.2;6.2 1D–Codes;193
8.2.1;6.2.1 Code 2/5;194
8.2.2;6.2.2 Check digit calculation Code 2/5;197
8.2.3;6.2.3 Code 2/5 interleaved;198
8.2.4;6.2.4 Code 128;200
8.2.5;6.2.5 Check digit calculation code 128;203
8.2.6;6.2.6 The character sets of the code 128;204
8.2.7;6.2.7 Mixed character sets in code 128 and their optimization;206
8.2.8;6.2.8 Code sizes, tolerances and reading distances;207
8.3;6.3 Printing method and quality;209
8.3.1;6.3.1 Labelling techniques;209
8.3.2;6.3.2 Quality requirements;210
8.3.3;6.3.3 Selection of the printing technique;210
8.4;6.4 Semantics in the code: EAN 128;212
8.4.1;6.4.1 Global location numbering (GLN);213
8.4.2;6.4.2 International article number (EAN);215
8.4.3;6.4.3 Serial shipping container code (SSCC);215
8.4.4;6.4.4 Characteristics of the code EAN 128;216
8.5;6.5 Scanner technology, devices, interfaces;220
8.5.1;6.5.1 Barcode scanner;220
8.5.2;6.5.2 Handheld scanners;220
8.5.3;6.5.3 Stationary scanners;221
8.6;6.6 2D-Codes;222
8.6.1;6.6.1 Stacked barcodes;223
8.6.2;6.6.2 Matrix codes;224
8.7;6.7 Radio frequency identi.cation;226
8.7.1;6.7.1 Functioning and technical structure;226
8.7.2;6.7.2 Fields of application;231
8.7.3;6.7.3 Comparison with barcode systems;232
9;7. Information and Communication Technology;233
9.1;7.1 Communication technology;233
9.1.1;7.1.1 Layered architectures;234
9.1.2;7.1.2 Protocols;234
9.1.3;7.1.3 Transmission media;237
9.1.4;7.1.4 Network types and internetworking;239
9.1.5;7.1.5 Network addresses;242
9.1.6;7.1.6 Examples Client- server model;244
9.2;7.2 Data management;247
9.2.1;7.2.1 Principles;247
9.2.2;7.2.2 File systems;249
9.2.3;7.2.3 Databases;250
9.2.4;7.2.4 Availability of data;255
9.3;7.3 User interface;257
9.3.1;7.3.1 Terminals;258
9.3.2;7.3.2 Functional point of view;259
9.3.3;7.3.3 Access control;260
9.3.4;7.3.4 Internationalization;261
9.3.5;7.3.5 Help systems and help functions;261
9.4;7.4 Operating systems;262
9.4.1;7.4.1 Tasks;262
9.4.2;7.4.2 Principles;264
9.5;7.5 Programming languages;273
9.5.1;7.5.1 Compilers and interpreters;273
9.5.2;7.5.2 Language concepts;276
9.5.3;7.5.3 Language generations;276
9.6;7.6 Basic principles of object-oriented programming;278
9.6.1;7.6.1 Data abstraction;278
9.6.2;7.6.2 Classes and objects;280
9.6.3;7.6.3 Inheritance;281
9.6.4;7.6.4 Unified modelling language;283
9.7;7.7 Extensible markup language: XML;283
9.7.1;7.7.1 Key-value-coding;283
9.7.2;7.7.2 The syntax of XML;286
9.7.3;7.7.3 Parsers and processors;287
9.7.4;7.7.4 Variety with style sheets;288
9.8;7.8 Safety aspects;289
9.8.1;7.8.1 Secrecy;290
9.8.2;7.8.2 Integrity assurance;292
9.8.3;7.8.3 Authentication;292
9.8.4;7.8.4 Authentication and electronic signature;293
10;8. Realization of Warehouse Management Systems;295
10.1;8.1 Requirement definition;296
10.1.1;8.1.1 As-is analysis;297
10.1.2;8.1.2 Weak-point analysis;298
10.1.3;8.1.3 Development of a target concept;299
10.2;8.2 Preparation of the tender documents;299
10.2.1;8.2.1 Definition of the key performance indicators;300
10.2.2;8.2.2 Preparation of the technical specifications;301
10.2.3;8.2.3 Completion of the tender documents;304
10.3;8.3 The placement of an order;305
10.3.1;8.3.1 Preselection of providers;305
10.3.2;8.3.2 Comparison of offers;305
10.3.3;8.3.3 O.er presentation;305
10.3.4;8.3.4 Selection of a provider;308
10.4;8.4 Implementation;308
10.4.1;8.4.1 Preparation of the technical specifications;308
10.4.2;8.4.2 Realization;312
10.4.3;8.4.3 Project management / Quality assurance;313
10.5;8.5 Start-up;313
10.5.1;8.5.1 Test phase;313
10.5.2;8.5.2 Changeover from old to new WMS;314
10.5.3;8.5.3 Training;314
10.6;8.6 Acceptance;314
10.6.1;8.6.1 Performance test;315
10.6.2;8.6.2 Failure simulation and emergency strategies;315
10.6.3;8.6.3 Formal acceptance;316
11;9. Structure of a WMS from the Example of myWMS;319
11.1;9.1 Data model;319
11.1.1;9.1.1 Data container of the model;320
11.1.2;9.1.2 Data interrelations;322
11.1.3;9.1.3 Interfaces;325
11.2;9.2 Classical implementation of a WMS;325
11.2.1;9.2.1 Functional structure;325
11.2.2;9.2.2 Table structure;327
11.2.3;9.2.3 Securing the logical integrity;330
11.2.4;9.2.4 Generation and query of master data;330
11.3;9.3 myWMS;332
11.3.1;9.3.1 The basic structure of myWMS;332
11.3.2;9.3.2 Business objects;335
11.3.3;9.3.3 Kernel concept;336
11.3.4;9.3.4 Runtime environment;338
11.4;9.4 Example of a distribution system using myWMS;339
11.4.1;9.4.1 Description of the example;339
11.4.2;9.4.2 Topology structure;345
11.4.3;9.4.3 Plug-In – Routing;347
11.4.4;9.4.4 Communication;348
12;Abbreviations;353
13;Bibliography;357
14;Index;363

Leseproben

5. Automation of the Material Flow ( P. 137)

Automation comprises the independent operation of a technical system in line with high performance and economy. With regard to computer-aided and thus mostly stand-alone functions, warehouse management is also a part of automation, however on a superior business management level (cf. Chapter 2 and 7). Here, above all the strategic and anticipated warehouse and distribution functions are automated.

The automation of the material flow aims at controlling and supervising the operative handling of the material flow. This chapter describes the basics of the material flow automation. Based on a hierarchical classification, we present first the main terms, requirements and tasks. The main elements of an automation technology are the control, sensors and drives to record and influence the material flow processes. The basic structure and functioning of the devices is described in the example of a typical application.

5.1 Basics of automation

Technological and economical aspects affect the technical design and operation of material flow systems and in many cases offer a possibility for automation. Although these requirements di.er from case to case the goals are identical:

– Improved system performance (transshipment rate, shorter order lead times)

– Quality assurance (continuous quality of the products and processes, observance of deadlines)

– Cost savings

– Relief of personnel from uniform, strenuous activities

Whether or not these requirements are met mainly depends on the choice, dimensioning and arrangement of the function areas in the warehouse as well as the used conveyors and storage facilities (cf. Chapter 4). The main task of the automation technology is to ensure the smooth functioning of the single conveyors and storage facilities or their components and to coordinate interlinked systems.

Automation does not always make sense since manual solutions may be more simple or economical. An alternative to the in-house transport of pallets, for example, are the manual transport with a hand pallet truck, a semi-automated transport by stacker or the fully automated transport on driven conveyor belts and automated guided transport systems. Which solution should be preferred depends on the frame conditions set by the overall system and is not studied in detail here.

5.1.1 History of the material flow automation

Modern automation technology was largely affected by inventions in the field of electrical engineering and electronics some of which are listed below (cf. Table 5.1). Obviously, computer-aided data processing has had a considerable in.uence on the development of the modern automation technology, above all the development of microprocessors and the introduction of standardized computer architectures [24].

Almost all digital controls which are currently used in material flow technology are based on these principles. Advanced processors and memories in line with an increasing integration of electronic components set the basis for systems the size of a check card and the performance of a common PC. In addition to central process computers, more and more mobile PC and handheld devices are being used. These are described in more detail in section 5.2.3.