Fixed warehouse locations can result in underutilisation of storage space.Image: Constructor Group

This pharmaceuticals company installed a BellHawk system to solve a specific problem. They needed to convert part their main warehouse into a manufacturing facility for a new product line.

The 60,000 square foot warehouse had defined locations for raw materials and finished goods. BellHawk, enable to halve the size of the warehouse by using dynamic binning.

Dynamic binning

Staff with wireless mobile computers put materials away wherever is space available. For retrieval the mobile units display the locations of the materials in age–first order.

Barcoded location labels identify bins, racks and pallet storage.

Reasons for choosing BellHawk

The major factor was the availability of source code for the company client to modify to fit their needs. They had started to develop their own software but came to realise this would take far too long. BellHawk enabled rapid deployment to free space for production and provided 90% of the capability they would need out of the box.

Another major factor in selecting the BellHawk software was its compliance with 21 CFR Part 11 (equivalent to EU GMP Annex 11).

Extensions

With the assistance of the technical staff at BellHawk Systems, the company has expanded the capabilities of the system.

1. Track raw materials from receiving to consumption on the automated production lines.
2. Track finished goods from the production lines to picking, packing and shipping for customers.
3. Track the lot number and expiry date of pallets, barrels, bags, cans, and other containers of raw material.
4. Track the QC status of raw materials and print out red and green control labels
5. Fetch materials from a remote warehouse to a production line on a just–in–time basis.
6. Track vendor owned consignment packaging material.

Growth

New facilities

The company acquired another manufacturing plant and warehouse over 1,000 miles away. They use BellHawk wireless mobile computer store and forward technology to enable data collection in these facilities. They have VPN links over the Internet to the central BellHawk server.

ERP implementation

The use of BellHawk enabled the company to implement an ERP system without disrupting production or warehouse operations.

EDI integration

Customer orders received by the company's EDI system are automatically entered into BellHawk. At shipment BellHawk generates Advanced Shipment Notices sent to customers by EDI.

Virtual shipping docks

In the shipping area, the company uses the BellHawk system to stage shipments to over 20 virtual docks. These are then shipped through 4 physical docks. This maximises use of dock space, minimising turnaround times.

Flexible reporting

The IT department has expanded on the Microsoft VBA source code of the BellHawk reports module to respond to many requests for custom reports from within the company and customers.

Mobile computer and network utilisation

BellHawk enabled the company to add new Zebra mobile computers to its fleet of older Hand Held Products units, and to utilise existing wireless networks with BellHawk store and forward technology.

Payback

The company estimated the BellHawk system paid for itself in much less than a year. It provided capacity for a substantial increase in sales with no increase in warehouse staff.