Harry_David_Best Practices in EWM 040414

8/10/2019 Harry_David_Best Practices in EWM 040414

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Best Practices in Extended

Warehouse Management at

Heather KruppManager, Manufacturing & Warehouse Systems



Harry & David Introduction & History

Harry & David Operational Overview Harry & David SAP History

Current IT Environment

Process for Reviewing EWM

Project Expectations

EWM Processes

Enhancements

Migration Process Lessons Learned

AGENDA

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Harry & David History

Founders Harry and David Holmes

Through the 20s business boomed and the fame of RoyalRiviera Pears spread

Great Depression 1934 – trips to San Francisco and New York to market to

the captains of industry

It was the beginning of Harry and David as America's

premier direct marketer of fruit and food gifts

We are proud to be one of the nation's oldest catalog

mail order companies

















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Harry & David Operational Overview

Vertically Integrated

Orchards located in Medford, Oregon Bakery located in Medford, Oregon

Manufacturing and Packing of Gifts

Order Entry and Fulfillment

Direct Marketing

Catalog

E-Commerce

Business to Business

Stores

60 Specialty and Outlet

Wholesale

Manufacturing


















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Harry & David SAP History Goals

Implement state of the art ERP and Warehouse system

Establish a common system, with the breadth and depth of

functionality, that can be leveraged for a majority of future

systems deployment projects

Retire old mainframe MRP and Purchasing application

Enhance capabilities for multi-site manufacturing and sourcing

Standardize operations between facilities

Upgrade and retire Catalyst WMS with SAP WM

Provide a robust solution for the Wholesale divisions to support

a growing business

Improve customer responsiveness, be more flexible and

improve efficiencies
















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Harry & David SAP History (cont.)

Meeting the Challenges of a Growing Business

Improve the speed and efficiency of the Product Design process Plan and re-plan manufacturing activities on the fly

Manage various manufacturing plants independently and

isolate the procurement and production activities by plant

Evaluate product cost variances during the course of themonth, rather than just at the end of the month

Reduce the amount of time it takes to train a new employee in

the use of our H&D Wholesale, Accounts Payable, Purchasing and

Manufacturing applications

Eliminate redundant entry (item data, customers, etc.)

Simplify IT support of our software applications

















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Harry & David SAP History (cont.)

Our Progress

ERP project kicked off in October of 2006 Phases completed

Blue-printing (design)

Development of interfaces and conversions (coding)

Realization

Three phases of increasingly complex testing

Implementation in February of 2008

SD

FICO

MM

PP

IM

BI (Pass Through)

PI

Solution Manager

Seeburger EDI



















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Current IT Environment

A complex application architecture, with disparate

applications requiring significant integration Homegrown Order Entry System

Numerous departmental “side systems” to support unmet

requirements

Lack of formal consistently shared information











Current WMS Systems

WM systems are extremely back versioned and certain

aspects are unsupported

Catalyst Warehouse Management version 9.2

RedPrairie Warehouse Management version 6.0

Retail Management System for Stores (custom inventory

system written in-house)

Numerous complex interfaces and custom error handling

within SAP ERP

10













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Process for Reviewing EWM

Provide end-to-end warehouse management capabilities for

all sites and all divisions

Provide full visibility to all materials across all locations

Close integration between EWM and Manufacturing

License plate bar coding and tracking required

Full RF capabilities

Wave creation and assignment

Elimination of manual processes

Clerical

Order close Data entry

Improve inventory transfers between sites & plants

Improve batch control at the end customer level

















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Rationale for selecting EWM

EWM is now a mature system

Simplify the IT Landscape Consolidate aging and custom applications under one platform

Reduce IT complexity – Single Platform

Reduce excel, access and other “side” systems

Reduce maintenance cost of two disparate WM systems

Reduce interface complexity and maintenance cost

Enhanced Capabilities

Labor Management

Full HU tracking (LPN)

Value Added Services Cross Docking

Yard Management




















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Project Expectations Provide the business with the means to manufacture and

fulfill orders in the quickest, most cost effective manner

Gain increased capabilities for labor management

Increased stability and functionality

Utilize current RF infrastructure

Eliminate the need for: Maintaining data in external local sources

External tools like EXCEL, ACCESS

Condensed project timeline

Project started October 2011 Planned go-live July 2012

Delayed go-live until March 2013


















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EWM Processes

Inbound using Layout and Process Oriented Storage Control

Receiving Grown Fruit(Auto Pack) Receiving External Vendors

Receiving STOs

Receiving Subcontracting Purchase Orders

Transfer Staging Process











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EWM Processes Outbound Process

Outbound DM

Outbound Wholesale process using process oriented storage

control

Outbound Shipments to H&D Stores

Outbound Transfers

ECC Shipment to EWM TU Integration

Wave Management

Automatic Wave Release

Manual Wave Release

Picking

Two Step Picking

One Step Picking


















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Storage Control overview

Process Oriented Storage Control in Outbound Process

Considers the material attributes to determine an appropriate

sequence of process steps

Status of individual process steps can be monitored as they are

executed

Handling Units are required











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Storage Control overview

Layout Oriented Storage Control in Outbound Process

Considers physical layout of the warehouse Utilization of interim storage areas (pick points, ID points, etc.)








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EWM Processes





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Labor Management

Track people throughout the day and measure performance

on individual tasks

Capture direct vs. indirect time



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Work Centers Now Warehouse Managed



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EWM Outbound process flow





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Enhancements

Quality Management – Place products automatically on

incubation hold and remove it from incubation hold. Providing

additional functionality to place product on hold based on class

characteristics.

Legacy System Interfaces

World Pick Face – The ability to replenish the running bins

based on order quantity (warehouse request quantity) up to

maximum bin quantity.

Perform

Replenish

ment

Wave released

Replenishment

program runs in

background

Create

replenishments

No

No YesReplenishment

program again as

scheduled.

Yes































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Enhancements

RF Pick and Pack Process - provides RF users the ability to

view the Wave description and Wave number on the RF.

Stock Removal Rules - Create delivery types which would

then be mapped to the different ODO document types in EWM.

The next step in the process is to create a Warehouse Task

which is where the BADI would be called to select the Stock

Removal Rule based on the ODO document type.

Production Replenishment Tool - Assembly personnel create,

and launch the production replenishment requests to produce

based on their production schedule by selecting specific

amount of component quantities to replenish the productionfloor.



















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Migration Process

Started on Thursday afternoon.

Closed all open orders for production and shipping.

Extracted and cleansed data pulled from previous WMS.

Database backups and system setup.

Configuration and transport migration.

Extract and master data load and validation.

Inventory load, reconciliation and sign off.

System turn over to business 1:00 pm Sunday afternoon.

Controlled processing.















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Lessons Learned

Early inf ormational training to key users is vital for the success

of the project. Defining reporting requirements early in blueprint. Don’t

leave reporting needs to the last minute.

Know your master data. Master data drives everything!

Spend the time cleansing your data to ensure smoothtransition.

Need to have a willingness to accept change process.

Without it, the project will not be successful.

Test! Test! Test! Think about exception processing. Plan for error handling and stuck queues after go-live.

Volume testing and hardware sizing.

















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Questions



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