www.inconso.de
SAP EWM project for TRILUX:
Flexible warehouse management systems
optimize logistics processes
17.09.2013 //// Page 2 SAP Supply Chain Day, September 11, 2013, 's-Hertogenbosch, Netherlands
Introduction
Stefan Hecking, Head of Logistics, TRILUX GmbH & Co. KG
Jarrett Leesch, International Business Development, inconso AG
17.09.2013 //// Page 3 SAP Supply Chain Day, September 11, 2013, 's-Hertogenbosch, Netherlands
TRILUX implementation partner
inconso was the partner chosen by Trilux to implement SAP EWM.
inconso offers complete SAP SCE solutions in the warehouse management und transport planning and execution areas
inconso has an SAP branch solution for logistics service providers
inconso works closely with SAP AG in the areas of SAP EWM and SAP TM
inconso and SAP Solutions
17.09.2013 //// Page 4 SAP Supply Chain Day, September 11, 2013, 's-Hertogenbosch, Netherlands
SAP Partner Services
SAP Partner Software with certified interfaces
Special Expertise Partner SAP for SCE / SCM
SAP EWM ramp up Partner
SAP TM ramp up and acceptance testing
SMB Partner Business All-in-One for LSP
SAP Preferred Supplier
This provided Trilux with a strong, knowledgeable partner for their SAP EWM implementation
Strong through partnership
inconso and SAP Partnership
SAP Supply Chain Day, 11 September 2013, 's-Hertogenbosch
SAP EWM at TRILUX Flexible Warehouse Management Systems optimizing the logistics processes in distribution and production at TRILUX
SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
LUMINAIRES
BUSINESS SECTORS
ELECTRONICS
SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
INDOOR LIGHTING
SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
OUTDOOR LIGHTING
SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
MEDICAL
SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
SHOP LIGHTING
SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
WEATHER-PROOF LUMINAIRES
SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
PROJECT SOLUTIONS
SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
• Zaragoza
• Alhama de Argon
• Arnsberg (HQ)
• Cologne
• Bonn
Germany
Spain
• Pune
India
• Zhuhai
• Guangzhou
China
• Manila
Philippines
luminaires Electronics
Global locations
SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
GR Suppliers
Shuttle from
HBW
WE für EDC
Carrier
Parcel Services
TRILUX routes
1 2 3 4 5 7 1
12345678 EO-Kat.
141 40 999 Träger
GR EDC (Shuttle)
GR Suppliers GI Production
We are talking about two warehouses and two SAP EWM projects
1
Production
warehouse HBW
Distribution
warehouse EDC
SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
TRILUX project timeline
Logistics
workshop with
TRILUX
Business
Blueprint
BBP
HBW Production
warehouse
EDC European
Distribution
Center
IT design,
Realization
Test
IT design,
Realization
Test
MS
MS MS
MS MS
2010 2012 2011 2013
Support
Support
GoLive
GoLive
8 months
15 SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
Systems and IT
PLC Dematic
HBW
EDC Mobile
Devices
SAP GUI MDT
TCP/IP
SAP ERP ECC 6.0 EHP 3
EDC + HRL
SAP EWM Rel. 7.01, decentral SCM platform
Development Test Production
MFS
Streamserv
16 SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
Distributionslager EDC
WE Lieferanten
Shuttle aus HRL
WE für EDC
Spedition
KEP-Dienstleister
TRILUX Routen
1 2 3 4 5 7 1
12345678 EO-Kat.
141 40 999 Träger
WE EDC (Shuttle)
WE Lieferanten WA Produktion
Deconsolidation +
QA with QM-QIE
integration
Production warehouse HBW Goods Receiving
• Construction 1987
• 2010 S7 control
• Euro pallets
• 5 aisles, single depth
• Store-out full pallets
• 6 picking locations
• 2 shift operation
17 SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
We were forced to realise the HBW Project
18
Warehouse control was very old (Fortran 77 based!)
Connection to TRILUX network was unstable
WMS application was no longer portable
Support only available through one person
Red alert!
Requirements specification for switch to SAP WM was already available
Workshop with inconso (2010): Strategic decision for EWM also in HBW
SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
Requirements for a switch
19
HBW and prezone (fixed locations, rack warehouse) managed previously
only in SAP MM (inventory view only in SAP ERP system)
Complete management of the whole storage area with SAP EWM
HBW control previously a stand-alone application on Fortran77 basis
Integration in SAP landscape with SAP EWM MFS
single stock removals in HBW previously processed manually
Automatic control via supply process with SAP EWM
SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
Quality Assurance in retrofit project
SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
• Emulator inconsoS/SIM
– Telegram simulation
– Visualization
21
• Emulator inconsoS/SIM
– Telegram emulation
– Visualization
Project accelerator
Conveyor relevant
processes tested without
physical availability
24 hours / day
Quality improvement
Interface test with SAP
EWM MFS as soon as
interface is defined.
Application area
Development, testing,
training and further
development
Quality Assurance in retrofit project
SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
WE Lieferanten
Production supply
1 2 3 4 5 7 1
12345678 EO-Kat.
141 40 999 Träger
Replenishment
Subcontractor
The HBW delivers three different areas
Consolidation groups
22 SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
Summary of HBW project
• Project goals achieved
– Large functional scope in short time
– Implementation very near to standard
– Stable and comprehensive CT connection with SAP EWM MFS
• Lessons Learned
– Optimization with SAP EWM finds the limits of the material handling systems
– Short project duration requires full concentration and power
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European Distribution Center EDC
24 SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
Characteristics of EDC
25
Area:
Hall area 15,500 m²
Office space and break/socializing space 900 m²
Hall height 12 m (Bottom level beams)
Warehouse numbers (max. extension):
23,750 Pallet locations
400 running meters of cantilever racking
up to 10,000 small parts warehouse locations (variable shelf
occupation)
SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
Quantity structure (related to one work day)
26
26
Goods Receiving
700 Load units (pallets, carton, etc.)
24 Shuttle trucks from plant
8 External delivery trucks
Goods Issue
450 Pallets
200 Packages
2,000 delivery note positions to 300 receivers
SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
What are the requirements on the EDC?
27
Maintain high level of deadline punctuality
Integrate short-term deliveries flexibly
Support customer requirements for example for packing schemes and labeling
Cover Kit-To-Order process
Ensure multi-company capability for TRILUX group
Consignment stock
Increase warehouse efficiency together with logistics service provider
27
SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
Change of WMS system in EDC
28
Previous WMS system
+ Simple, reliable system
+ Individually tailored to use
− Lack of continuous further development
− Lack of transparency
− New requirements were time-consuming, complex and expensive
TRILUX decided for the WMS system SAP EWM
Integration in the TRILUX SAP landscape
Larger functional coverage
Continuous further development by SAP
Flexible system modifications can be done by TRILUX
28
SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
Requirements on project and implementation partner
29
Requirements on the project
On-time completion and within the budget framework
Take over process responsibility from service provider
Requirement on the implementation partner
Experience with implementing very complex SAP EWM systems
Sufficient availability of competent team members
Work together as partners in project
Knowledge transfer to TRILUX project team
SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
Requirements on the TRILUX project team
30
A lot of work!
Main focuses:
Definition of processes in advance – Business requirements –
Business Blueprint
Testing, Testing, Testing
Training users
SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
Goods Flow TRILUX EWM
Distributionslager EDC
WE Lieferanten
Shuttle aus HRL
WE für EDC
Spedition
KEP-DL
TRILUX
Routen
1 2 3 4 5 7 1
12345678 EO-Kat.
141 40 999 Träger
WE EDC (Shuttle)
WE Lieferanten WA Produktion
Distribution warehouse EDC Layout
Cantilever long
goods
Pallet Medium Movers
Pallet Fast A
Shelving 2 Level
Pallet Fast B
Narrow aisle
Special Dimensions
GR zone
GI zone
31 SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
Goods Flow TRILUX EWM
GI zone
Long
goods Special pack
location
KEP
Cantilever long
goods
Pallet Medium Movers
Pallets Fast A
Shelving 2 Level
Pallets Fast B
Narrow aisle
Special Dimensions
Orders
Consolidation
Picking and Packing
SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
Use of wave management
– Pre-planning of transports in SAP ERP with LE-TRA integration
– Use of wave templates with latest start times
– Flexibility
• Use of special waves (i.e. for long goods)
• Demand driven fitting of waves
• Manual wave start for the load balancing
Picking
– New warehouse type for super fast movers
– Multi-order picking with brackets around transports (shipments)
Forklift management
– Extensive use of resource management
Solution approach EWM
SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
Special requirements Goods Issue
Different receiver groups:
Wholesaler
– Warehouse supply
– Project related deliveries to warehouse
construction sites
TRILUX
– Subsidiaries inland and in foreign countries
– Projects Construction sites
Others
– Individual delivery of replacement parts
– Individual delivery for installers
– Export (Container)
SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
Customer requirement: Specific packaging per transport
1 1 1 1 1 1
1 1
2 2 2 2 2 2
3 3 3
3 3 3 3 3 3 3 3 3
5
4 4
6 6 7 7 8 9
4 4 4
2 2 2 2 2 2 3 3 3
3 3 3 4 4
Supply Wholesaler
Hold together same article
Different article / pallet A
10
1 1 1 2 2 3 4 5 6
1 2 2 3 4 5
1 1 1 2 2 2 6 6 9 10
6 6 6 7 7 8
1 2 2 2 2 2
3 3 3 E2
E1 E3
E4
E5 B
Projects for Wholesaler
Single receiver oriented,
compressed
Different receivers may be on
same pallet
1 1 1
2 2 3
4 5 6
E1
1 2 2
3 4 5 E2
6 6 6
7 7 8 E3
1 2 2
2 2 2
3 3 3
E4
10
1 1 1
2 2 2
6 6 9
10
E5 C
Construction site - High rise
1 pallet / level
Single receiver oriented
For several receivers
Special requirements Goods Issue
Packaging code
SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
– Use of search logic in SAP EWM for staging areas
– Creation of shipping HU using consolidation groups
– Extended standard packing dialog supports packer
• Transport oriented overview
• Simplified dialogs
– Use intelligence of packer
Solution EWM
SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch
Summary of EDC project
• Achieved project goals
– Process design in line with requirements
– High flexibility in the processing
– Waves drive the warehouse
– Predictability for logistics service provider
• Lessons Learned
– Efficient process design does not stop with the business blueprint
– Use far reaching capabilities of SAP EWM with good judgement
– High integration with SAP ERP requires appropriate resources
SAP Supply Chain Day, 11 september 2013, 's-Hertogenbosch