Optimisation of Mobile Processes in Warehouse and Shipping
for DuPont Automotive Systems

DuPont Automotive Systems (DAS) produces automotive refinishing paints. In the course of the global SAP implementation at DuPont almost the complete range of SAP modules has been launched at the DAS division, too. In a comprehensive rollout over several years, clavis was responsible for the implementation of the warehouse and the shipping functionality.

The Starting Situation

And finally an RF/barcode scanning solution was implemented, partly consisting of SAP® standard transactions but also of specially programmed mobile transactions, that covers the complete process from production over goods receipt to loading.

Before they introduced SAP, DAS used an external warehouse management system. This system had to be substituted by SAP WM. As a consequence, the structures of the central warehouse for raw materials, semi-finished and finished products had to be redefined. Thus, also the warehouse procedures and the shipping processing needed to be adapted to the new structures. Additionally interfaces to external stock and transportation service agents had to be installed.

The Implementation

To import data from the present warehouse management into SAP, also the master data (material master and warehouse structures) had to be redefined. As three divisions with different warehouse types are consolidated in one warehouse number, a specific logic had to be implemented when using the type and division IDs for the maintenance of the material master data, and thus to provide for the correct flow of materials from the central goods receipt to the different destinations. For this purpose a central Access data base designed by clavis has been used to ensure that the division related master data were created synchronously.

Subsequently, for more effective processing several additional mobile transactions have been implemented. I.e., for goods receipt posting from production a new transaction is used that combines the functionality of MIGO and LT06. So by use of the barcode, the staff at the ID point is able to post the goods receipt for goods from production (process order number taken from the putaway message), to divide them into pallets in WM (generate storage units), and to create transfer orders for putaway. Subsequently the warehouse staff just has to scan the storage unit via mobile confirmation transaction to identify the destination storage data and finally to confirm the transfer order on-site. A transfer order print is no longer needed, for the storage unit label is used instead.

In supply-to-production production halls are mapped into supply areas. The staging of material is triggered order-related via LP10 or LB01. Goods issues are consequently posted by back flushing (RF). Supply area stock must be monitored and adjusted regularly, for differences to the actual withdrawing or shrinkage cannot always be corrected immediately.

Each shop floor is represented by a separate storage type/storage bin. Thus, it was necessary to post also the movement inside a warehouse area using RF transactions.

The Effect

By a set of optimising measures the warehouse management process and shipping processing have been improved significantly:

  • Any transaction from production over goods receipt to loading is processed via RF/barcode scanning
  • A central Access data base designed by clavis ensures that the division related putaway and picking IDs were matched respectively
  • All mobile warehouse processes are supplied by barcode labels in the transfer order lists
  • Additional mobile transactions have been implemented for stock transfer, re-palletising, inventory, picking and goods issue