sap supply chain day - stefan hecking trilux

www.inconso.de

SAP EWM project for TRILUX:

Flexible warehouse management systems

optimize logistics processes

http://www.inconso.de/

17.09.2013 //// 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


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


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


INDOOR LIGHTING


OUTDOOR LIGHTING


http://www.trilux.com/de/produkte/neuheiten/lumega-600-mlt/

MEDICAL


SHOP LIGHTING


WEATHER-PROOF LUMINAIRES


PROJECT SOLUTIONS


• Zaragoza

• Alhama de Argon

• Arnsberg (HQ)

• Cologne

• Bonn

Germany

Spain

• Pune

India

• Zhuhai

• Guangzhou

China

• Manila

Philippines

luminaires Electronics

Global locations


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


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


http://www.fernstudium-fernschulen.de/assets/images/sap.jpg

http://www.fernstudium-fernschulen.de/assets/images/sap.jpg

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


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


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


Quality Assurance in retrofit project


• 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


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


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


European Distribution Center EDC


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)


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


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


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


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


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


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


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


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


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)


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


– 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


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 - stefan hecking trilux

Technology

sap solutions

sap ag

shertogenbosch sap ewm

trilux sap supply chain

partner sap tm

areas of sap ewm

sap tm inconso

sap ewm projects