SAP WM – Pushing the limitsMaureen Allison – Halewood International

Introduction to HIL

• HIL Corporate Video

Our SAP Journey so far….

• ERP Implementation 2004

• BW 3 months later

• Extended SAP in to other HIL Businesses 2005

• SCM Implementation for DP – 2010/2011

• ERP Upgrade to ECC6 2011

• Expansion of SCM footprint - SNP/PPDS 2012-2014

TIMELINE

2004 - Date

Warehouse fully racked

ERP Go-live inc WM FG

Warehouse Review

•WM configured as part of ERP – there have been physical changes and associated layout changes but processes are largely the same.

WM

WM DG

Project Dickens

Current Warehouse set-up• Finished Goods – Fully racked17,000 pallet

spaces

– 14 loading bays

– 40 Marshalling lanes

• Dry Goods – Mixture of Rack and Bulk Stack 4000 pallet spaces

– Pick and return for 5 high speed production lines

– JIT Glass delivery – 24/7 operation

Issues• Had not looked at the operational side for some

years – FG 8 years + DG 6 years• List of minor requests/developments• Internal team stretched• Issues with picking of dry goods for production• Incomplete traceability in FG warehouse at case

picking level• Not fully utilising what we had• Complexity of raw materials increasing

– Crabbies labels

Approach

• Discussion with The Config Team

– Shared our open issues and development requests

– Undertook a full review of both DG and FG warehousing

– Workshops with our end users

– Presented findings

– Drew up a joint project plan

– Project kick off – Late summer

Roadmap PrinciplesIncreased

Warehouse

Productivity

Greater

Transparency

Increased

Accuracy

Better Service

Level

Customer/

Vendor ASN

Connectivity

Operational

Process

Improvement

Dry Goods Project Roadmap

Project Roadmap

Finished Goods Roadmap

Project Roadmap

Project PlanJul-13 Aug-13 Sep-13 Oct-13 Nov-13 Dec-13 Jan-14 Feb-14 Mar-14 Apr-14 May-14 Jun-14

WM roadmap

Fit-gap investigation

Project scoping & development plan agreed

Design & Functional specs

Review / update Baseline Config & data

Dry Goods

Design & functional specs

Review / update Baseline Config & data

Gap Build

Unit & system testing

Super User Training

User Acceptance testing

User Training

Go-live

ELS

Finished Goods

Design & functional specs

Review / update Baseline Config & data

Gap Build

Unit & system testing

User Acceptance testing

User Training

Cut-over prep

Go-live

ELS

Dry Goods Improvements

• ASN process for inbound goods where possible

EDI ASN

Dry Goods Improvements

• ASN process for inbound goods where possible

• Introduction of HUM – clustered putaway

Dry Goods Improvements

• ASN process for inbound goods where possible

• Introduction of HUM – clustered putaway

• Pick for Production

Dry Goods Improvements

• ASN process for inbound goods where possible

• Introduction of HUM – clustered putaway

• Pick for Production

• Return from Production

Finished Goods

• Introduction of HUM

New Pallet Label

• Now following GS1-128 Standard

• Full Serial Shipping Container Code (SSCC)

• Saving time – do not need to relabel for Customer ASN process

• Retaining full history of pallet moves

• Production of mixed case pallet label – used for case picked pallets

Finished Goods

• Introduction of HUM

• Pickface Replenishment

Pickface Replenishment

• As well as regular batch job to replenish pickface

• Pickface replenishment can be carried out on demand

Finished Goods

• Introduction of HUM

• Pickface Replenishment

• New case picking transaction

New Case Picking Transaction

• Retention of HU label within pickface

• Operative will scan the HU label as part of the pick process

• System also accumulates the weight of the cases picked and this will be printed on the label

• Future development is to interface to weighing scales

Finished Goods

• Introduction of HUM

• Pickface Replenishment

• New case picking transaction

• New loading transaction

New Loading Transaction

• Enter a trailer number which is to be loaded

• List of all deliveries scheduled for this shipment –inc load sequence

• Ability to load out of sequence if required

• Operative scans the HU to be loaded

• Operative scans the door

• Operative receives confirmation message

• The system displays status against each delivery

Project Summary

• Phase 1 Dry Goods – go live 23rd February– Well received in business

– Increased stock accuracy – big benefit on Labels

– Much simpler transactions for operatives

– Post Go –live review held

• Phase 2 Finished Goods – go live 6th May– Improved traceability in pickface

– Reduction in loading errors

– Post Go –live review held

Lessons learnt

• You can do more with what you have got

• Processes change – as business changes

• Review was worthwhile

• Took the opportunity to clear up debris

• Communicate in as many ways as possible as soon as possible

Any Questions

Good Luck

The Crabbies Grand National Festival 9th – 11th April 2015