Warehouse Control Systems

Warehouse control systems (WCS) is a software application that directs the real-time activities within warehouses and distribution centers. As the "traffic cop" for the warehouse/distribution center, the WCS is responsible for keeping everything running smoothly, maximizing the efficiency of the material handling subsystems and often, the activities of the warehouse associates themselves. It provides a uniform interface to a broad range of material handling equipment such as AS/RS, carousels, conveyor systems, sorters, palletizers, etc. The primary functions of a WCS include:

• Interfacing to an upper level host system/Warehouse management system (WMS) and exchanging information required to manage the daily operations of the distribution center.
• Allocating work to the various material handling sub-systems to balance system activity to complete the requested workload.
• Providing real-time directives to operators and material handling equipment controllers to accomplish the order fulfillment and product routing requirements.
• Dynamically assign cartons to divert locations based on defined sortation algorithms or based on routing/order information received from the Host (if applicable).
• Generate result data files for reporting and/or upload by the Host system.
• Operational screens (graphical user interface) and functions to facilitate efficient control and management of the distribution warehouse.
• Collect statistical data on the operational performance of the system to enable operations personnel to maintain the equipment in peak performance.

Each major function is designed to work as part of an integrated process to effectively link the host systems with the lower level control system, while relieving the Host from the real-time requirements such as operator screens and lower level equipment control interfaces

Key capabilities of a WCS systems should include relieving a customer host computer of managing a real-time material handling automation interface, maximizing system throughput and performance while utilizing the most efficient methods for pallet, case and item routing.

You may have read a recent story published by Modern Materials Handling Magazine that outlines how one of the industries most advanced Warehouse Control Systems helped Oriental Trading Company improve productivity, reduce labor costs and maximize order accuracy levels.

This WCS system is PC-based and are designed to handle all the physical aspects of a warehouse or distribution center, including material handling equipment control, stock location mapping, inter-location movement control, inter-zone routing, allocation of stock to dispatches, order management and dock door interface control, all within unlimited operator interface. Material handling equipment control includes control of cranes, trucks, conveyors, carousels, sorters and other equipment using network, radio or infrared communication links.

The WCS picking capabilities include support for various picking models, such as paper pick lists, RF terminals, goods-to-man picking robots, voice controlled and pick-to-light; support for fixed and dynamically assigned picking locations; automatic replenishment based on minimum level or future demand; picked container building to defined rules of height; weight and stock segregation; consolidation of pick requirements into waves' pick walk minimization; and configurable workload balancing.

This Warehouse Control Systems operates as self-maintained units requiring no user interaction for file and system maintenance, providing elaborate statistical and diagnostic graphics and reports for maximum systems uptime and recommending equipment maintenance based on run-time and/or maintenance schedules.

BENEFITS

· Maximizes Throughput & Performance

· Optimizes Material Flow

· Order Management

· Diagnostic & Statistical Graphics & Reports

· Sophisticated Productivity Tracking & Planning

· Real Time Interface to material Handling Equipment

· Universal Sub-System Support

· Relieves WMS/ERP of Real Time Decisions

· One Port Real Time Connectivity to ERP & WMS

· RFID Compatible

· Easy to Use Intuitive GUI/Windows Interface