Automated Data Collection and Tracking System for Inventory Management

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1 Advanced Tracking System for Inventory Automated Data Collection and Tracking System for Inventory Management Developed by Business By Design Version Martin Avenue, Rohnert Park, California Fax

2 TABLE OF CONTENTS Welcome to the advanced tracking system 1 ATS Functions at a Glance:... 1 ATS Inventory Functions 2 Receiving Raw Materials & Label Printing... 2 Put-Away... 2 Order Pick Scheduling... 2 Picking... 2 Kitting... 3 Order Pick Verification... 3 Shipping... 3 Locate Function... 3 Build Common Kit Function... 4 Take Sample Parts... 4 Ats manufacturing/finished goods inventory Labeling functions 4 Product Labeling... 4 Receive Finished Goods to Warehouse... 4 Inventory maintenance functions 5 Setup Inventory Function... 5 Cycle Counting... 5 Physical Inventory... 5 Relocate (move function)... 6 Create Purchase Order Requisition... 6 Print labels... 6 Janus RF Handheld Menu... 8 System architecture... 9

3 Advanced Tracking System for Inventory WELCOME TO THE ADVANCED TRACKING SYSTEM The Advanced Tracking System (ATS) for Inventory is a complete system that operates standalone or as a front-end that interfaces with almost any company information system. It automates data collection and provides a fast and easy place to view critical inventory activity in real time. ATS for Inventory is designed to improve customer service, boost productivity, and provide accurate management information. The system automates time consuming data collection tasks and provides accurate inventory status, bar code labeling, put-away, picking and kitting, shipping, cycle counting and physical inventory, historical data, and much more. Data collection is fast and easy. Transactions are captured quickly and accurately in real time without handwritten forms and manual keyboard entry. Value added work increases dramatically by reducing errors and wasted time. ATS Functions at a Glance: Receiving & Label printing Put-Away Order Pick Scheduling Order Picking Pick to Pallet One Person Pick to Pallet Two or more Kitting Picking Verification Shipping Automatically Prints Packing Slips & Bill of Lading Prints SSCC Pallet Labels Locate using Handheld: Parts, Orders, Parts - where needed, Orders - parts needed Packaging & Finished Goods Labeling Build Stock Kit Function Take Sample Parts Setup Inventory Cycle Counting Physical Inventory Relocate (move function) Create Purchase Order Requisition using handheld Bin Location Labeling

4 ATS INVENTORY FUNCTIONS Receiving Raw Materials & Label Printing Imports purchase orders from your host computer system. Prints bar coded labels for items received. Prints PO receipt report Updates host system with accurate purchase order receipt data. Tracks PO line item receipt number (for accurate lot tracking) of received items. Easily customizable Put-Away Random stocking locations -- allows multiple stocking locations per item and multiple items per location. Allows for PO/lot or serial number identification and tracking. Put-away or receiving function can be configured to display on handheld all partially picked orders on-hold and waiting for item (cross docking). Order Pick Scheduling Picking Schedules open orders by due date and priority Allows manual override of schedule Schedule automatically displayed on picker s portable RF handheld unit. Operator can pick to schedule or pick a different order. Paperless pick with recommended order picking sequence based on system generated picking schedule (see above) with operator override feature. Pick one order -- one picker. Pick one order -- two or more pickers (system tracks each picker s items picked). Pick function includes item location lookup. Pick options: FIFO, by Lot, by Serial number, and customizable for other user definable order. Pick to pallet feature allows items loaded on pallet to be assigned a serial numbered pallet label. Automatically generates a shortage list of all items picked short. The shortage list can be displayed on an RF handheld or as a printed report. Shortage reports on total quantity per item or totals per customer. BUSINESS BY DESIGN ADVANCED TRACKING SYSTEM 2

5 Kitting Kit one order Kit several orders together Substitute a different part for a specified part password protected for control. Locate a needed part (including WIP locations) without exiting kitting function. Order Pick Verification Shipping Operator rescans order previously picked verifies order accuracy prior to shipment. Allows users to verify and ship a partial order or a complete order. Picking verification can be done by pallet. Operator scans pallet number and all items on pallet. Packing list shows detail by pallet number and includes order summary. Very useful for multi-pallet orders. Packing list includes pallet numbers and weights (if available) plus a list of bundles and loose items. Automatically prints bills of lading. Prints UCC128 SSCC pallet labels. Locate Function Users can perform the following lookups using a portable handheld RF unit or system PC: Locate Part: Displays all stocking locations and quantities on hand. Also displays items received but not put-away and, if desired, partially picked or kitted orders that contain the needed part -- helpful when you need parts from a low priority order to fill a high priority order. Locate Order: Displays location of a suspended or staged order. Part Number - Where Needed: Displays or prints a list of orders on hold waiting for part. Kit (or Order) - Parts Needed: Displays parts and quantities needed to complete kitting or picking an order. ADVANCED TRACKING SYSTEM BUSINESS BY DESIGN 3

6 Build Common Kit Function Functions as a simple MRP system using inventoried parts as raw materials to make commonly needed items, such as assemblies, service part kits, retail displays, etc. Includes database of common kits and their bills of materials. Allows operator, using a portable handheld, to scan or enter a kit number and quantity of kits needed. System checks inventory for on-hand quantities of parts needed and displays number of kits that can be built from available inventory. Take Sample Parts Tracks parts taken from inventory for customer samples, engineering prototypes, as obsolete, etc. Using a portable handheld, a reason code is scanned, along with the part number, quantity, and bin location. The system updates inventory and provides a report with summaries for each category. ATS MANUFACTURING/FINISHED GOODS INVENTORY LABELING FUNCTIONS Product Labeling Automated labeling feature prints product labels on-demand for work order items being packaged. User simply scans work order and all relevant information is sent to printer. User may specify which printer to output labels (convenient when more than one printer is used). Product labels are customizable and can include company logo and/or specific graphics using economical blank label stock. Transfers items packaged from WIP to finished goods. Automatically generates summary pallet label for both single item pallets and mixed item pallets. User can enter serial number ranges or individual serial number of products packaged. User can delete or add serial numbers to a previously entered range. Serial numbers are useful to track products returned for repair or for ISO 9000 product and component part tracking requirements. Receive Finished Goods to Warehouse Function transfers goods from manufacturing (WIP) to receiving location in warehouse (finished goods). Automatic lookup feature displays (on RF handheld) all staged orders on-hold waiting for received items. Provides ability to print list of staged orders picked short and on-hold in shipping area. Report lists orders and items short. ADVANCED TRACKING SYSTEM BUSINESS BY DESIGN 4

7 INVENTORY MAINTENANCE FUNCTIONS Setup Inventory Function Setup Inventory is a special function used to enter the initial ATS inventory and automatically print bar coded labels as needed. This function allows users to scan bin locations, enter part numbers, PO numbers, and quantities for each part. Part labels are printed as needed and data is entered into the system. The data may be exported to the host accounting system to synchronize both systems. Cycle Counting User can cycle count parts in all departments/locations or one department/location. User can cycle count one part to quickly adjust a quantity or change a location. Allows definition of cycle count codes and frequency Last cycle count date is kept for each item detail. Physical Inventory User can start a directed count from any bin location. After first bin is scanned, system directs operator in bin location order to count each item. Allows multiple part numbers in a location. Allows multiple bin locations for a part number. Verifies items, quantities, and locations are correct/not correct. System directs user to each bin location, part number, and PO lot number (if tracked) in bin location order. Verifies items and quantities are correct/not correct. User can terminate cycle count at any time and update system with counts completed. Operator can add an item at a location to update system database. Several users can take physical inventory at the same time. Provides exception reports and host update. ADVANCED TRACKING SYSTEM BUSINESS BY DESIGN 5

8 Relocate (move function) Moves raw materials or finished goods across stock room or warehouse. Between stock rooms or warehouses. Move to replenish dedicated locations, such as a pull slot. Move within warehouse to temporary storage location. From one picked order to another picked order. Useful when items are needed to fill a hot order. Unpick an order and return the item to a stocking location. Can be used for cross docking to move items from pallets of finished goods received to the warehouse to an order on-hold for the item. Create Purchase Order Requisition Operator can build a purchase order requisition using a handheld by simply scanning parts to be ordered. System can look up last order quantity or user can enter quantity to be ordered. System automatically prints out PO requisitions sorted by vendor (if desired). Print labels Bin location labels Raw material labels Manufactured part labels Kit Labels Finished goods product Labels. Pallet labels. UCC 128 SSCC pallet shipping labels. ADVANCED TRACKING SYSTEM BUSINESS BY DESIGN 6

9 Sample Raw Material Label: Logo preprint if desired Sample Bin Label Dept Aisle Bay Shelf ADVANCED TRACKING SYSTEM BUSINESS BY DESIGN 7

10 Portable RF Handheld Menu Handheld Menu for Manufacturer of Build to Order & Build to Stock Products MAIN MENU LOCATE MENU Main Menu 1-RECEIVE & LABEL 2-LABEL, MFG. PART 3-PUT-AWAY 4-PICK WORK ORDER 5-PICK FINISHED GOODS 6-BUILD KIT 7-RELOCATE 8-LOCATE 5-CREATE PURCH ORDER 0-CHANGE USER M-MORE SELECTIONS Locate Function 1-LOCATE PART 2-PART- WHERE NEEDED 3-LOCATE SUSP. ORDER Enter Selection: Enter Selection: More Selections MAIN MENU-CONT. 1-CYCLE COUNT 2-PHYSICAL INVENTORY 3-TAKE SAMPLE PARTS 4-SETUP INVENTORY 5-RELABEL PURCH PART 6-RELABEL MFG PART 7-DATE AND TIME When user selects [M] "More selections" (above main menu) this menu is displayed Enter Selection: ADVANCED TRACKING SYSTEM BUSINESS BY DESIGN 8

11 System architecture The Advanced Tracking System was developed in Microsoft Access for Windows and can be operated on a local area network or as a stand-alone system. It is usually connected to a Novell or Windows NT network as well as an Intermec bar code data collection network, consisting of one or more wireless radio frequency (RF) gateways, and portable RF linked handheld units with built-in laser scanner. The ATS system receives input from several sources: your existing information system, directly from scanned or keyed input, and from the portable handheld units. The system provides information output to both the handheld units and work stations on the network and can export data to your existing information system. The system is tailored to your company s needs. This outline provides a brief overview of some of the system s many capabilities. Our programming staff is able to make custom modifications and interface the Advanced Tracking System to your existing system. ADVANCED TRACKING SYSTEM BUSINESS BY DESIGN 9

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