The distribution warehouse handles far greater volumes thanks to flexible receiving, picking and palletisation processes.

Flexible warehouse management

This company is a regional petfood distributor. Their vehicles deliver to most of their retail customers on a schedule weekly. They load vehicles in the evening for next day delivery.

The problem

Capacity

The company was growing and the warehouse was at capacity.

Inaccurate stock

Manual stock counts were inaccurate. The result was stock-outs and nowhere to put extra stock. The warehouse manager wanted to use barcodes to count stocks.

Standard software unsuitable

They operated a Sage system for order processing and accounting. Goods receiving, picking and despatch were manual processes. Standard add-ons for Sage did not cater for their methods of working.

Flexible working methods for bulky goods

Petfood is bulky, much of it in large bags. The overall pattern of the day is to receive and put away in the morning, pick in the afternoon and load in the evening. This means storemen have to work flexibly, often working together on receving or picking orders. A complication is pallets have to be picked and stacked haeviest items first.

Solution

Stock movement tracking

The company agreed to split their Warehouse Management project into phases. The first phase was to record all receipts and despatches, to track all stock movements, and to integrate with Sage purchase and sales order transactions. The second phase would include counting and other stock management functions.

RF terminals

Codetrack runs on rugged handhelds and truck terminals for bulk operations. Picker have wearable terminals with handsfree ring scanners for smaller packs and items.

Flexible operations

Storemen can log on to, or log off, any receiving, putaway, picking or palletisation operation. The receiving module works with purchase orders, ASNs, contract deliveries and returns.

Results

1. Warehouse productivity has increased by eliminating paperwork and allowing for flexible working.
2. Codetrack records match physical stock.
3. The company has grown without increasing warehouse capacity.

The warehouse manager commented, "Codetrack is entirely accurate. There is no need for stock counts!"

PROCESS POINT SOLUTION

Problem Inaccurate stocks due recoded at goods-in, working methods, limited warehouse capacity.

ERP Sage

Solution Implement multi-mode goods in and flexible working to handle peak loads in receiving, picking and loading.

Company Turnover: £25-50 million. Employees: 100-250