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.
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.
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.
Through a set of several measures, processes in warehouse management and shipping processing have been largely optimized:
- All transaction processes from production to goods receipt to loading are carried out via RF/barcode scanning
- A central access database from clavis ensures the reconciliation of storage and retrieval indicators and palletizing data between the individual business areas.
- The mobile processes in the warehouse are supported by barcode labelling of the transfer order lists.
- Further mobile transactions for stock transfer processes, re-palletizing, inventory, picking and goods issue have been implemented.