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dWMS R12 Oracle Case Study
Citation preview
Oracle R12 dWMS
Implementation
Success Story for Implementing
Oracle R12 Distributed WMS
Dale Welsh, Ron Wind
August, 2010
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. All other product or service names are the property of their respective owners. © 2010 Motorola, Inc. All rights reserved.
2
Introduction
Evaluation
Process to define and deliver dWMS
Implementation
Infrastructure Implementation
Implementation Road Map
Benefits of dWMS
Questions
Agenda
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. All other product or service names are the property of their respective owners. © 2010 Motorola, Inc. All rights reserved.
3
Motorola Solutions is a global communications
leader providing next-generation mobile
communication solutions. A few products in our
portfolio include, two-way radios, mobile computers,
secure public safety systems, barcode scanning
and wireless network infrastructure to enterprises
and governments.
Motorola has a global footprint with manufacturing
and fulfillment facilities in the United States, Mexico,
Brazil, Central Europe, Malaysia, and Israel. As we
are trying to rebuild our supply chain systems
footprint and because our operations footprint is
global, it makes the concept of a distributed WMS
all the more relevant.
Introduction
• In 2009 Motorola decided to cease the outsourcing of the Schaumburg warehousing
operations and return it back to in house. Since 2005 the warehousing operations
that support the Schaumburg, IL manufacturing site had been outsourced to a 3PL.
With the decision to no longer outsource warehousing operations, the need for a
WMS system became evident.
Outsourced operations to Third Party Logistics provider
• Performed Receiving, Putaway, Replenishment, Picking and Cycle
Counting in proprietary warehouse management system.
• Integrated with Motorola 11.5.8 ERP
Decision to in source operations based in internal cost savings
• Focus on top tier WMS solution versus custom one off
• Fit within the long term strategic design and architecture
Project Background
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. All other product or service names are the property of their respective owners. © 2010 Motorola, Inc. All rights reserved.
5
Upgrade Oracle 11.5.8 ERP to 11.5.10
• Use WMS module in the 11.5.10 EBS
• Other regions had already upgraded to 11.5.10
• 11.5.8 had many extensions and enhancements to consider in regression testing
• Concern upgrade would take longer than original project timeline
Configure WMS module in the 11.5.8 instance
• Several point releases old
• Significant patching required and impact to other schemas
• Reduced functionality as compared to R12.1.2
Implement 3rd party WMS package
• Step away in long term strategic direction
• Software and licensing costs
• Increase support costs
Evaluation
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. All other product or service names are the property of their respective owners. © 2010 Motorola, Inc. All rights reserved.
6
Implement Oracle R12.1.2 Distributed Warehouse Management System (dWMS)
After evaluating all four options the decision to implement dWMS was best based on the following key points:
• Host ERP will still be on 11.5.8
• dWMS fits into long term strategy
• Ability to leveraged existing internal and external
• resources familiar with Oracle WMS
• Licensing costs covered with existing 11.5.10 WMS implementation in EMEA
• Decoupled from ERP, no dependency on 11.5.8 patching and maintenance
• Quick to deploy with full WMS functionality
Weighing all the aforementioned key points, the selection of Oracle dWMSwas the right choice for Motorola.
Evaluation
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7
Leverage EMEA Oracle WMS Implementation
Although EMEA WMS was considerably different the team analyzed what could
be leveraged from EMEA in terms of design, setup and configuration, and
conversion code reuse.
• Fully defined customer requirements
• Conducted several structured workshops
• Very experienced in warehousing operations
• Bring in lessons learned from EMEA
Process to Define and Delivery R12 dWMS
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. All other product or service names are the property of their respective owners. © 2010 Motorola, Inc. All rights reserved.
8
Stay Standard Oracle
• Standard Oracle met requirements
• Understand new features in R12.1.2
• ODI provides advantages with pre-built maps
• Understand how dWMS is different than WMS
using Oracle standard interfaces
• dWMS white papers from Oracle were valuable aids
Process to Define and Delivery R12 dWMS
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. All other product or service names are the property of their respective owners. © 2010 Motorola, Inc. All rights reserved.
9
Conversion
The section will list the conversion data that was required from 11i and from the former 3PL
legacy WMS.
• Open PO’s in 11i
• All Suppliers in 11i
• All Items in 11i (excluding phantoms, options, option class)
• Item Categories 11i
• Item costs (for cycle count ABC only, no Financial) in11i
• Warehouse Locators
• Locator max capacity from 3PL
• Min/Max values from 3PL for home slot items
• On hand values from 3PL
• Sub inventory creation
Process to Define and Delivery R12 dWMS
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. All other product or service names are the property of their respective owners. © 2010 Motorola, Inc. All rights reserved.
10
Interfaces
This section will list the interfaces that were created between 11i and the dWMS system.
Informatica Power Center was the approved ETL tool and therefore new maps where required
for this project.
• PO new, change, includes an inspection DFF flag (11i to R12)
• PO Receipts (R12 to 11i)
• Item New, Change (11i to R12)
• Subinventory Transfers
• WIP picks in 11i (11i to R12)
• Ship Confirm (R12 to 11i)
• Return to Stock (R12 to 11i)
• New Suppliers (11i to R12)
Process to Define and Delivery R12 dWMS
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. All other product or service names are the property of their respective owners. © 2010 Motorola, Inc. All rights reserved.
11
Aggressive Schedule, but Skilled Resources
• Oracle Data Integrator (ODI) evaluation
• Recommend approach by Oracle, with provided “Maps” for integration
• No in house expertise
• Resistance
• Informatica Power Center selected
• Existing Integration Challenges
• Previous Integration between 3PL WMS and Oracle 11i
• Custom application acting as part ETL-forced to retain
• Retain file format
• Used open interfaces with staging table approach
• Five month implementation
• Tight schedule- condensed system integration testing and UAT
• Skilled resources leveraged
• Functionality that met all business requirements
Implementation
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12
Once deployed operations quickly began to realize the systems capabilities and
rapidly began to ramp to normal operating transactional volumes.
The following graph illustrates the ramp up for sales order picks. Within 3 full days of
application use, operations were just slightly below the target MFG picking goal.
Deployment Ramp
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13
The next graph illustrates how operations were to ramp to the target pick volumes in
just 7 days from actually go live. Ramping to this volume with the previous 3PL and
WMS system took over a month to accomplish.
Post Deployment Ramp
Daily WMS Activity
GMT Day
0500
1000150020002500300035004000
5/30
/201
0
6/1/
2010
6/3/
2010
6/5/
2010
6/7/
2010
6/9/
2010
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/201
0
6/13
/201
0
6/15
/201
0
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/201
0
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/201
0
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/201
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/201
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/201
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7/1/
2010
Date
Co
mp
lete
d P
ick
/Rc
pt
Pick/drop MFG
Warehouse/Rcpt
Total Sch
MFG Goal
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. All other product or service names are the property of their respective owners. © 2010 Motorola, Inc. All rights reserved.
14
Deployment Ramp
This last graph illustrates how operations ramped with Oracle WMS compared to a previous
experience with a custom WMS application utilizing an outsourced 3PL
Daily WMS Activity
vs 3PL Logistic ramp
0
500
1000
1500
2000
2500
3000
3500
4000
5/30
/201
0
6/1/
2010
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2010
6/5/
2010
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2010
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/201
0
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/201
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7/1/
2010
Date
Co
mp
lete
d P
ick
/Rc
pt
Total Sch
MFG Goal
3PL Ramp
Operation's comments:- 3PL startup was difficult, nearly zero week 1.
- R12 dWMS in the first week = 3PL first month.
- 3PL used a lot of OT to keep up (historically)
Operations doesnt use much OT even now.
f
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. All other product or service names are the property of their respective owners. © 2010 Motorola, Inc. All rights reserved.
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The Schaumburg, IL warehouse - 24 x 5 operation
Need solution that would be scalable, provide high availability, and fit within the
Motorola architecture framework
Selected low cost Sun solution using Oracle Enterprise Linux on x86-64 servers
First implementation for Motorola in using a smaller, yet robust Linux solution.
Infrastructure Design and Implementation
• Linux x86-64 OS platform.
• Sun Green Server X4170.
• 2 x 2 architecture design.
• Load balancing for application and using hardware load balancer
and database server using Oracle RAC.
• Oracle 11g RAC with 11g Grid (ASM and Oracle Clusterware)
• Warm standby DR site with Oracle data guard and Rsync for DB and
file replication respectively.
• SAN Raid 5 for business data, and internal disks for OS binary
and temp files.
The advantage of this architecture solution is providing for high availability (no
single point of failure), both application and database layers are load balanced
to fully utilize the hardware and incremental capacity can be added with no
downtime.
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. All other product or service names are the property of their respective owners. © 2010 Motorola, Inc. All rights reserved.
16
Infrastructure Design and Implementation
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. All other product or service names are the property of their respective owners. © 2010 Motorola, Inc. All rights reserved.
17
Prior to the dWMS Implementation there was only one region leveraging the
capabilities of Oracle WMS.
Motorola’s Alsdorf, Germany facility running Oracle 11.5.10 with integrated Oracle WMS.
Other regions using 3PL WMS solutions, home grown, or 3rd party solutions
Prior implementation of Oracle WMS in EMEA provided the Motorola IT staff the necessary
experience to implement R12 Oracle dWMS under an aggressive time line.
The implementation of the R12 dWMS in Schaumburg, IL has provided Motorola
the first successful install of a distributed Oracle Warehouse Management System,
as well as provided the initial footprint of an implementation road map to get all
other regions on R12 dWMS.
Implementation Road Map
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. All other product or service names are the property of their respective owners. © 2010 Motorola, Inc. All rights reserved.
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Tel Aviv,
Isreal
Schaumburg, ILBerlin, Germany
Alsdorf, Germany
Penang, Malaysia
McAllen, TX
11.5.8 ERP
11.5.10 ERP/wWMS
11.5.10 ERP
11.5.10 ERPSAP
EBS and WMS Architecture Prior to dWMS Implementation
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. All other product or service names are the property of their respective owners. © 2010 Motorola, Inc. All rights reserved.
19
Tel Aviv,
Isreal
Schaumburg, ILBerlin, Germany
Alsdorf, Germany
Penang, Malaysia
McAllen, TX
11.5.8 ERP
11.5.10 ERP/wWMS
11.5.10 ERP
11.5.10 ERPSAP
EBS and WMS Architecture Post dWMS Implementation
R12
dWMS
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. All other product or service names are the property of their respective owners. © 2010 Motorola, Inc. All rights reserved.
20
EBS and WMS Architecture- Future End State
Tel Aviv,
Isreal
Schaumburg, ILBerlin, Germany
Alsdorf, Germany
Penang, Malaysia
McAllen, TX
Consolidated
R12 ERPR12 dWMS
R12 dWMS
R12 dWMS
R12
dWMS
R12 dWMS
Integration
Layer
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. All other product or service names are the property of their respective owners. © 2010 Motorola, Inc. All rights reserved.
21
Benefits of dWMS-IT View
Decoupled form ERP, which allows for periodic maintenance on the
host, while the dWMS is fully operational
Regional installation approach with the application, database, and
MWA server residing in close proximity to the warehouse/factory
reduced the concern of data latency
Patching or future upgrades to the software require localized dWMS
regression testing only
Low Cost, quick deployment, maintain Oracle footprint
The rollout of dWMS to other regional sites provides greater flexibility
in deployment options as there are no dependencies on the host R12
system. This flexibility will provide Motorola a faster return on
investment and greater internal customer satisfaction and allow
replicated deliveries in other manufacturing and warehouse centers.
Summary
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. All other product or service names are the property of their respective owners. © 2010 Motorola, Inc. All rights reserved.
22
Benefits of dWMS- “Comments from Operations”
Transfer of material from location to location is significantly faster. By
not having pick levels (Previous 3PL had material stored as Pallet,
Carton, Case and unit). They had to change the pick level of the
material if moving from pallet to unit. They could only move 1 level at
a time.
Transaction efficiency -Receiving is done with a hand held. Previous
3PL received all via desktop computer
Shipping is simpler as only 1 screen and transaction required. Use of
Quick Ship by delivery id simplified ship confirm process
Picking cycle time has increased by 20%. The picking process in
dWMS is faster and has reduced the need for personnel overtime.
Summary
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. All other product or service names are the property of their respective owners. © 2010 Motorola, Inc. All rights reserved.
23
Lessons Learned
dWMS has unique data interface needs from the Host ERP. Separate
that Dependency from WMS functions and activities. .
dWMS has a great benefit in decoupling patch set and other functionality
from OM ERP’s.
Purchasing (PO) status should be managed (open/closed/reopen)
Consider using 3rd party packages, such as Optio or Loftware for
document bar codes, page breaks, sorts, and text location/format.
Wireless Mobile application performance focus is key to user success.
Schedule a re-boot of WMA daily to clear any active user tasks.
WMS is easily extendible and will require understanding of Oracle data
objects.
dWMS activity monitoring via MTL table referenced flags.
Oracle failover and DR architecture deployed for dWMS is rather new to
Motorola. To reduce complexity deployed same architecture as
production
A strong post go-live team is essential for the subtle issues encountered.
The DBA will be very active for the first 3 months monitoring table usage
and system capacity as it will all be new.
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. All other product or service names are the property of their respective owners. © 2010 Motorola, Inc. All rights reserved.
25
Questions ?
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office. All other product or service names are the property of their respective owners. © 2010 Motorola, Inc. All rights reserved.
26