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How Firestone Industrial Products Used Handling Unit Management Mobile RF
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How Firestone Industrial Products Used Handling Unit Management and Mobile RF Technology to Improve Customer Satisfaction
John Fearnow – Firestone Industrial Products John Gardner – Dickinson + Associates
AGENDA
Who is Firestone
Who is Dickinson + Associates
Business Problem
Handling Units
Solution
Wrap Up
LEARNING POINTS
How Handling Units can be used for Load validation
Generating customer specific label formats at the point of use
Using Handling Units and Standard Transfer Order functionality to help pickers report correctly as they pick
Corporate Profile
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Firestone Building Products
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http://www.firestonebpco.com/ Ipad App http://www.firestonebpco.com/Tools/iPad_App/
Firestone Industrial Products – Markets
http://www.firestoneip.com/
Firestone Industrial Products – HD Truck & Trailer
Potentially up to 18 air springs on a class 8 truck & trailer application
31 U.S. Locations
Headquarters
Carmel, IN
Brussels, Belgium
Sao Paulo, Brazil
Rotterdam, Holland
Wolstzyn,Poland
Beijing, China
Mississauga, Ontario Woodstock, Ontario,
Turrialba, Costa Rica
Singapore
Gurgaon, India
Monterrey, Mexico
Firestone Industrial / Building Products – Global Reach
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Firestone Business Technology Vision
To provide innovative, comprehensive, dependable solutions that support and align
with the objectives of the business.
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We Are:
Focus: Delivery of quality SAP ERP, BI/Analytics, Mobility
consulting services to customers across North America,
Europe, and Asia.
Our People: A team of 140+ full-time SAP professionals reflects the
ideal mix of years of relevant business knowledge, very
strong SAP credentials, and solid communication skills.
Our team has an average of 15 years SAP and 19 years
business experience.
Offices: Chicago, IL (Headquarters)
Satellites: New York, NY | Scottsdale, AZ | Cincinnati, OH
Consistent Growth: 15 years revenue growth
We are:
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Service Offerings
SAP Strategy + Implementation
Process Optimization
Services
SAP Upgrade Services
Support Desk
Professional Staffing
ERP
Mobility
Analytics
Customer Labeling Requirements
New labels •Carton Label, Shipping Label, Mixed Load Label
•Unique Packaging ID for each carton/pallet printed on the label
•Shipment ID printed on label
•Specific requirements for applying labels to packaging
New Packing List •Sorted by packaging ID
•Contents of each packaging ID listed on pack list
Changes to EDI ASN (need to transmit packaging ID structure)
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Label to EDI Synchronization
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Requirements for Applying Labels
Requirements for Applying Labels
Business Challenges
Weak print infrastructure Existing labeling infrastructure was on legacy systems Picking was in SAP but packing / load verification was a
manual paper based process Labels were printed after the fact from the legacy system Multiple pallet picks appeared on a transfer order as 1 line
item / pick Inventory discrepancies where noted when found and then
addressed after the fact in SAP Customers require customer specific labels on the pallets Customer shipments contain individual piece picks and
multiple pallet picks Customer requires labels and EDI information to reference a
shipment number Label data and ASN EDI data needs to be aligned
Obstacles for Printing Labels
Label formats vary based on Customer
Packaging material
Device type
How do you manage the complexity without a complicated program?
Handling Unit Management (HUM)
Definition – Process used to identify structures of packages and its material contents
Used to simplify logistics processes Inventory Management
Production Execution
Warehouse Management
Delivery Processing
Shipping
Handling Unit (HU) contains Materials
Other Handling Units (Nesting)
Key Attributes Unique Identification Number
Dimensions, Weights, & Volume
Status
Materials and quantities
Packaging materials
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Handling Unit Structural Overview
123456
3000000051
1000000199
1000000203 1000000205
1000000206
1000000207
1000000208 1000000209
1000000210
Phased Approach
Implement packing functionality for label generation
Validate process and approach
Replace after the fact labeling with real time labeling
Implement Pick Pack into 1 operation to eliminate QA steps after pack
Final Design – Full SAP Solution
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TC/IP Print Service
BFDP SAP Print Server ins140printsap
Smart
Form
Print Program
Output Determination Logic
Output Type
Shipment Packing
RF SAPConsole
Packing
RF SAPConsole Pick + Pack
Customer
Specific
Label Table
PC Label Design
Application
Std Text
Label design with standard tool (Bartender) Load Label format into SAP as standard text Output determination logic setup for different packaging materials (box, pallet, mixed load, etc) Z table links customer label design to packaging material output • Shipping location • Ship To Location • Device type
Pick and Pack – To-Be Process Vision
SAP Console 3
User Selects HU Type.
User picks and packs material.
User confirms activity.
Pallet Carton
User accesses Shipment.
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User prints labels. Attaches to the HU.
Nest HUs as required.
User stages complete HUs to
outbound Staging Lane.
TOs
Delivery
SAP Delivery Processing.
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Transfer Order Creation.
Shipment Creation. 2
Assign Deliveries (Link TO’s)
Delivery Delivery
Delivery
TOs TOs
TOs
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Business Process Flow
Pick and Pack Process Flow
Pick and Pack Start Screen / Dashboard
Provides overview of shipment How many picks remain Status of pack operation Total Number of Handling Units on the shipment Total number of Parent Handling Units Expected total weight of the shipment # of handling units that have been packed but not capped
General Operation
Enter the Packaging Material being packed. Press Enter
Handling unit is created.
Confirm the bin and quantity. Press enter to Validate
Confirm becomes active. Confirm to pack item into Handling unit
Item 1 is complete
Select Diff. Indicator Press F1 Confirm User is routed accordingly • F1 – Item is confirmed and packed • F7 – User is routed to Full Pallet
Screen
Enter bin and shortage quantity. Press F1 or F7
Pick / Pack item – Short Pick Process
Diff. Indicator Shipment being packed
1 Theft Difference will be posed to Storage Type “999” Storage Bin “LOST&FOUND”
2 Source Storage Bin
Difference will be posted back to the source Storage Type and Storage Bin (i.e. Stype “F1F” Bin “D1031019”)
3 Pick Difference
Difference will be posed to Storage Type “999” Storage Bin “DIFFERENCE”
New Post Processing Feature:
When a short pick occurs, RF will automatically attempt to create another pick to fulfill the shortage quantity.
IF a new item is created, it is added and sequenced in the list.
IF not, a warning message will be displayed.
Picking short and less material in the BIN than the system
System says pick 4, but only 1 in the bin
Tell system there is a quantity difference in the bin.
System will post the difference quantity to the differences bin. It will then create a new TO if there is more material available in the warehouse
For full Pallet, a shortcut
Selecting New HU prints out a label for the current handling unit and allows creating a new handling unit.
Multiple handling units of the same type can be created in 2 steps.
Confirm Bin and Quantity and select FulPal
Enter how many handling units the quantity represent and how many of parts in each HU.
Confirm and Cap creates the Number of handling unit labels
Handling Unit Management Screen
This shows detail of what should be in Handling Unit, Reprint of labels and deleting an uncapped handling unit. Capped handling units must be deleted using the SAP GUI Enter the selector number for the handling unit and F1 Sel to move to the packing screen
Lessons learned
Have to use gun and labels to design and test. This is a case where you have to do it exactly as an operator would
Work closely with people that do this every day during design and testing
Have a good partner and developer
BEST PRACTICES
Leverage standard SAP BAPI’s and Function Modules
Design the screen flow to enhance the physical flow
Look for creative ways to simplify processing and data maintenance
Don’t over engineer or under engineer, make it just right! Too much information can be an overload
Not enough feature / functionality causes additional overhead
Partnership
Extensive SAP Experience Right resources with the right skills
Project methodologies and tools
Transparent Communication
Cost-effective Solutions
A REAL partnership
Shared approach to risk management
Dedicated to IT and Business Success
Commitment to strategic SAP Roadmap
“Let’s just do it!!!” Because it’s the right thing to do!!!
THANK YOU FOR PARTICIPATING
Please provide feedback on this session by completing a short survey via the event mobile
application.
SESSION CODE: 1003
For ongoing education on this area of focus, visit www.ASUG.com