The core design team members of LeanWMS Warehouse management and material control system V4.0 are all from senior personnel who have been providing in-house logistics planning services to leading international manufacturing companies for years. LeanWMS committed to helping modern enterprises cope with the increasing material management needs regarding fine-grained material attributes management, real-time stock data, automated and unmanned material system co-working, unitloadized material handling, horizontal and vertical system and process integration requirement in the background of intellegent manufacturing and Industrial 4.0 upgradation.
LeanWMS has now successfully helped a number of industry-leading international corporate customers successfully implemented a modern in-plant material control system that covers these characteristic needs.

The fascination of LeanWMS

• Real-time material inventory data. Get detailed and reliable real-time inventory information at any time to eliminate inventory information lag
• Fine-grained material attributes management. Comprehensive management of material batches, versions, life cycle, quality status, ownership, sources, project attributes and other detailed information, to adapt to modern enterprise material control needs
• Native load-unitized material management capability. LeanWMS natively supports load-unitized material handling, different types of unit load (pallets, bins, liquid containers, special containers, etc.) and different unitloading modes (single item, mixing item, disassembled) can be effectively managed in LeanWMS system
• Intelligent, paperless operation. With the collaboration of LeanWMS operation control center and on-site RF terminal sub-system, real-time operation instruction, concurrent job coordination, monitoring and intervention are realised for the whole process
• Full traceability of material operation process. For each warehousing operation, WMS will carry out comprehensive information collection and recording of the operation process, and can easily trace the entire operation details of each material from receiving to release. Further, for the material that has been released to the workshop, LeanWMS is also possible to trace back to its complete warehouse process
• Easy to adapt to different warehousing form/technologies and different warehouse topologies. LeanWMS can easily adpt to different warehouse form/technologies, such as VNA, high-density storage (e.g. drive-in, push-back), block storage, AS/RS, shuttle warehouse, AGV unmanned silos, picking supermarkets etc. and provide corresponding optimization operations according to different warehouse modes. LeanWMS supports complex warehouse topologies, by configuration, LeanWMS can be easily applied to different warehouse topologies
• Support different modern material line-feeding pull/supply modes: such as e-KANBAN, SPS (Set Parts Supply), JIT (Just-In-Time), JIS (Just-In-Sequence), Andon, etc.
• Seamless horizontal and vertical integration capabilities with external enterprise systems. Seamless integration with horizontal and vertical enterprise system, such as ERP (e.g. SAP, oracle), MES, APS, BOM, SRM, Ebuy systems, etc.
• Automation, unmanned warehousing technology integration and controlling capabilities. LeanWMS has rich experience in integrating and controlling AGV unmanned warehouses, automatic vertical storage systems, AS/RS, automatic sorting systems, VNA auto-navigation systems, etc.

LeanWMS drives significant improvements in warehouse operations efficiency

By using RF-based field wireless data exchange and terminal technology, as well as barcode/RFID-based material identification, LeanWMS provides full transparent material inventory information (both on-site or in back stage) and real-time (next) operational guidelines to drive significant improvements in warehouse operations efficiency.

The following diagram shows a typical LeanWMS working scenario:

==> Goods receipt

Work with on-site RF handheld terminal, material inbound identification, material information collection, unitload assigment, and barcode printing can be completed in one operation. LeanWMS supports RFID-based batch identification, which can help customers further improve the efficiency of the goods receipt.

==> QC, Put-away

Through the handheld terminal of LeanWMS, the quality inspection status of material in receiving buffer can be easily obtained on-site, as well as the next operation instructions, for example, waiting for quality inspection, putting-away to storage location, or forwarding for line feeding. For put-away, LeanWMS will suggest the best storage location for the material, and guide the operator’s operation through the RF vehicle terminal or RF handheld terminal. In multi-operator operating situations, LeanWMS will properly coordinate the parallel operation, and all of this is based on real-time strategy algorithms.

==> Stock move, replenish

LeanWMS is able to automate the management of most in-house material movement based on real-time policies, automatically generate various required material transfer instructions, and assign instructions to the RF terminal of the operator of the business unit in real time. For example, when the picking area needs replenishment, LeanWMS automatically selects the best replenishment container for the operator, suggests the best replenishment location, and directs the operator’s operation through the on-site RF vehicle terminal or handheld terminal.

==> Stock maintenance

Through the RF terminal, various types of stock maintenance operations, such as stock-taking, material consolidation, unitload splitting, unit load transfer, stock status maintenance, printing labels, etc., can be easily and quickly completed.

==> Picking

Whenever a new outbound order is released from host system or by manually input, LeanWMS will automatically process the order and deploy the picking position for the outbound order according to the material control strategy. The planned picking task will reach the RF vehicle terminal or RF handheld terminal of the different business unit operators in the warehouse in real time, and guide through the on-site terminal picking operation.
LeanWMS supports different picking methods. Depending on the material storage technology, storage form and material unit loading type, you can configure the optimal picking method, such as discrete picking based on minimum path algorithm, zone picking, picking to light, dynamic goods to man Picking, etc.
Depending on the needs of the process, LeanWMS supports a wide range of mobile picking and labeling devices that facilitate the printing of shipping labels at the same time as mobile picking.

==> Line Feeding, e-receipt

LeanWMS can help manufacturing customers properly control line-side material buffer and the production materials supplies. Based on material pull requirements during the production process, LeanWMS plans and organizes production material picking, line delivery, and manage returns and containers recycling.
Where material handover is required, LeanWMS supports RF handheld terminals based material counting, verification and e-signature receipt (e-sig).

==> Automated, unmanned equipment control

When materials are operated with automated, unmanned equipment or systems, such as AGV, automated material storage systems, automated picking systems, etc., LeanWMS’s capabilities and extensive implementation experience in automation, unmanned system drive and controlling can help customers seamlessly integrate them into the material process chain, through direct drive or via WCS interface. In situations where human-machine interoperability is required, LeanWMS will provide a unified operator interface and provide optimized operational procedures based on different system characteristics to maximize the benefits of automated, unmanned systems.

LeanWMS native load-unitized material management capabilities

LeanWMS provides native load-unitized material management capabilities. Material load-unitization management is the main feature of modern material management and the most fundamental element of intelligent logistics. The load-unitized material management capability reflects the fundamental ability of the material management system to meet and adapt to modern logistics management.

LeanWMS’s native (non-alternative) load-unitized material management capabilities enable LeanWMS to easily handle various in-house material management needs of modern manufacturing companies, such as:

• Material management process and material control methods based on load-unitization technology, such as: load-unitization based material storage, line-feeding methods, e-Kanban application, picking and replenishment, line side presentation, etc.
• Material identification based on load-unitization
• Various unit load types: single item unitload, mixed item unitload, kitting material, etc.
• Convenient material load unit operations such as unitload splitting, merging, transferring, labeling, etc.
• Unit load container turnover management

LeanWMS fine-grained material control capabilities

Fine-gained material control is the main characterization requirement of modern logistics, and it is also the biggest challenge for enterprises in the field of modern logistics management. Fine-grained material management not only requires proper management of material attributes, but also requires fine-grained control of materials with attribute differences during logistics execution. In modern manufacturing enterprises, insufficient material control ability may bring serious problems affecting the development of enterprises.
LeanWMS provides the ability to meet the reuirement of fine-grained materials control in modern logistics management, including,

• Material lot attribute management
• Material version control
• Material multi-vendor control
• Multi-ownership management
• Material quality lifecycle management
• Project material management
• Material load-unitization management
• Material life cycle
• Material source attribute, etc.

LeanWMS production material traceability

LeanWMS achieves a “holographic” full traceability of production materials, which not only traces the static source information of the production materials, but also traces the detailed activity trajectory of the materials during the warehousing cycle.
LeanWMS supports off-line material identification. By scanning the barcode, the original material information can be traced back and restored during the production returns or rework, which not only greatly simplifies the return receiving material identification, but also avoids the breakpoint of material traceability information caused by the material production cycle.
For each warehousing operation, LeanWMS collects comprehensive operational information about operator, handling device, execution time, handling material information, execution status etc. Through the LeanWMS Control Center, warehouse manager can not only easily track the realtime status of the operation, analysis the cause of the exceptions, but also obtain analysis data on work efficiency, quality, resource requirements through facet analysis of the operational information, thus support enterprise decision-making and CIP ( Continuous improvement plan).

LeanWMS in-house material visibility

LeanWMS provides full visibility for in-house material management, including raw materials, work in progress, and finished products. Through LeanWMS, managing people can easily get static material inventory information such as current location, unitload, quantity, project attributes, quality and availability status, and other control attribute information.
LeanWMS also makes material execution process visible. Through LeanWMS, material execution status, such as handling stock unit, equipment application, operators, time nodes, execution results, process exceptions can be easily obtained in real time. Therefore, when an abnormal situation occurs, intervention can be immediately carried out according to the exception handling plan.
Risk identification and early warning. LeanWMS can effectively identify and warn the quality defects, expired materials, supply anomalies, and manpower shortages in the plant to support the timely and effective response of the enterprise supply chain system.

LeanWMS integration capabilities

LeanWMS has capability to seamlessly integrate with enterprise management systems and is used in almost all LeanWMS applications. Integration with ERP, MES, APS, BOM, and PLM systems makes LeanWMS an integral part of enterprise management and execution.
Further, LeanFour provides a team of experienced integration experts who can provide integrated implementation services at the external system side when customers need it, such as providing SAP-side implementation services integrated with LeanWMS.

Automated, autonomous system integration capability is another feature of LeanWMS. Based on the native load-unitized material management concept and the material control, scheduling, execution and visualization capabilities provided by LeanWMS, LeanWMS can easily navigate different automation and autonomous material handling systems and maximize the benefits of them. Through in-depth cooperation with such system suppliers and numerous implementation experiences, LeanWMS has obvious advantages in the following types of automation and autonomous system integration applications:

• AGV unmanned warehouse
• Automatic vertical storage system，e.g. Kardex
• Shuttle warehouse
• Automatic forlift navigation system, e.g. VNA auto navigation system
• etc.

Application example 1: Intelligent warehousing process integrated with AVSS (Automatic Vertical Storage System)

In this application case, LeanWMS directly drive Automatic Vertical Storage System for automatic storage and retrieval of the storage bin. Combining AVSS’s automation, high space utilization advantages and LeanWMS’s enhanced professional warehouse management capabilities, as well as a unified RF visualization interface, realise intelligent, accurate and efficient and cost-effective material storage solutions. Under the unified management of LeanWMS, the automatic cabinet unit is also organically integrated into the overall material management and control process of the enterprise.

This integrated LeanWMS application is especially suitable for stock management of manufacturing hardware parts, electronic components, and manufacturing WIP products.

Application example 2: AGV unmanned warehouse application

In this application case, LeanWMS integrates AGV unmanned forklift to achieve unmanned warehouse operations.
 
LeanWMS is responsible for the management and scheduling of the overall warehouse, and coordinates the interoperability between the AGV and the operator. In the AGV operation, LeanWMS sends task instruction to the AGV and monitors the execution status of the AGV, such as task reception, unit load lift, in transportation, placement, etc.
The main processes that executed by AGV include: pallets put-away, replenishment to picking area, picking left-over pallets return, in-house pallets transfer, empty pallet replenishment, etc.
Considering the rigid characteristics of the AGV operation, in this application case, the operation support of the complex business occasions in which the AGV is interoperated with the manual operation is realized, and the business flexibility of the AGV warehouse is highly improved.

Application example 3: VNA (Very Narrow Aisle) forklift automatic navigation control

LeanWMS cooperated with the industry’s leading forklift supplier to implement the first commercial application case of VNA forklift automatic navigation in China. By integrating the VNA forklift automatic addressing system, the VNA forklift is optimized in the movement path during the operation, and to guide the forklift fork automatically reach the working position, Greatly improves the efficiency of the VNA forklift operation. Through business measurement, the operating efficiency can be increased by more than 50% compared to the traditional VNA manual mode.

• The driver does not need to memorize the storage position , no need to manually find the storage location, and can save a lot of working time in the VNA operation.
• When the forklift enters the wrong aisle or the fork is facing to the wrong direction, the forklift can automatically prompt to prevent errors from happening in advance.
• Automatically optimize forward speed and automatically decelerate to the target position
• Real-time communication with LeanWMS system, through LeanWMS job scheduling capacity and process optimization specifically for the VNA business scene which provided by LeanWMS vehicle terminal subsystem, VNA warehousing system operating efficiency and system benefits are greatly extended

LeanWMS Logistics Capability Management (KPI)

Production material execution capability has become one of the most important core competencies that modern manufacturing enterprises rely on for order-based and customized production. With the development of mass customization, intelligent manufacturing production mode and industrial upgrading,
the need for quantitative analysis of the company’s ability to execute materials is becoming more and more urgent. The significance of this is that through the quantitative analysis of the material’s execution ability, it can not only accurately evaluate the operator’s performance, promote the capacity increase without changing the resource input, but also the necessary conditions for the enterprise to accurately evaluate the order delivery capability and lead time.

LeanWMS KPI module is based on the practice of material operation, through the automatic data collection of material operation activities, plus setting of analysis parameters according to different working environment, working conditions and operation types, to obtain reliable analysis results data related human resources, equipment, execution level and resource utilization, which supports the estimation of the execution capability of the enterprise logistics, the matching of the logistics execution capability related to the production plan and the product delivery plan, and the continuous improvement of the logistics capability.

LeanWMS supports international user environment

Designed for international applications, LeanWMS provides a multi-language user interface GUI, including LeanWMS Control Center running on the desktop, RF handheld/vehicle terminal subsystem, and reporting system. The multilingual interface can be instantly switch to any language during operation that users are familiar with. LeanWMS has built-in support for the following languages and can be extended to support any computer-recognizable language with a simple data dictionary definition.

• Simplified Chinese
• English
• German

For more information about LeanWMS, please feel free to contact us.