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Building Materials Manufacturer

Mobility Project on SAP ECC

Our customer's Roofing division initiated a project to automate their Warehouse Management processes that are by and large paper based. They settled on their main site in Minnesota as the pilot site for the application roll out. 

No of Warehouse Sites  : 14

No of Fiori Apps : 7         

SAP System : SAP ECC EHP2

No of Pilot Users : 40     

Devices : Zebra VC80 based on Android OS

Application : SAP Fiori powered by Neptune Software

Project Background

 

Our Customer's Roofing division initiated a project to automate their Warehouse Management processes that are by and large paper based. They settled on their main site at Shakopee, Minnesota as the pilot site for the application roll out. 

Propel UX delivered seven SAP Fiori applications that were developed using Neptune Software. The total duration of the project was twelve weeks including design, development and user acceptance testing. Highlights of the project are outlined below.

Transfer Order Confirmation 

  • Picking stock and loading product onto trucks is a core process. The transfer order document contains details on which products needs to be loaded onto trucks. Transfer orders are created with reference to sales order deliveries.

  • The process of issuing transfer order documents and collecting completed transfer order documents is managed from a central location at the warehouse. Forklift operators are handed a transfer order paper document that lists out among other things, the product, bin location and the truck details. After the product is loaded, the drivers would check off each transfer order line to indicate that the line has been picked fully.

  • Each trip to the central location would take 8-10 minutes on an average. The objective of the project was to enable forklift operators to receive their transfer orders on a device and allow them to confirm transfer orders from their device. 

  • The App will initiate a download of a single transfer order when user taps on the tile to access the application.  Locking mechanism ensures no two devices get the same transfer order.

  • Only transfer orders belonging to either the loading queue or the priority queue will be downloaded to device.

  • Transfer Orders belonging to priority queue have precedence over loading queue. Transfer orders within each queue will be assigned to users on a FIFO basis.

  • Shipment details are displayed on the initial page of the App.

  • All transfer orders belonging to the shipment are displayed in the next page.

  • When the user drills down into a transfer order, transfer details like truck details, loading notes and transfer order lines are displayed in the “Transfer Order details” page.

  • The user could confirm pick either by scanning the barcode label or manually confirm the pick.

  • If all transfer order lines are confirmed, saving the transfer order posts the confirmation in SAP. Otherwise, the transfer order is reassigned to its original queue.

  • Saving the transfer order confirmation updates shipment completion status; this in turn triggers printing of bill of lading at the warehouse exit location.

Bin to Bin Transfer

  • Bin to Bin transfers prior to the roll out of the App were done manually and were by and large paper based. This resulted in stock inventory not being up to date. The forklift operators use this App to post Bin to Bin Transfers in real time.

  • Support three types of transfers – ‘Bin to Scrap’, ‘Bin to Bin’ and ‘Production Stage to Bin’.

  • Allows material to be scanned or entered manually.

  • Allows transfer in base unit of measure or in pallets.

  • Displays stock availability by bin location.

  • Checks stock availability at source bin before creation of transfer order.

Bin Inquiry Report

  • The Bin Inquiry report allows forklift operators to query bin stock for a material in real time.

  • Allows selection of a single bin or a range of bins.

  • Reports shows material number and description, bin, total available quantity, blocked stock, last GR date among other fields.

  • Allows users to sort and group by material and bin.

Material Bin Report

  • The Material Bin report allows forklift operators to query material stock in real time

  • Allows users to scan bar code label or to specify material number manually on the selection screen.

  • Report displays storage bin, stock category, available stock, total stock, GR date among other fields.

Record Inventory Count

  • The Record Inventory Count App allows users to record periodic inventory counts and save their results to the database.

  • The salient features of the App are given below:

  • Allows counters to record count for each inventory document line.

  • Inventory document is locked in SAP when count is being performed on the App; this prevents other users from processing the document.

  • Results are saved for every inventory count document line.

Exception Queue

  • This App allows forklift operators to select transfer orders that belong to the exception queue to be confirmed

  • The App allows users to select from a list of available transfer orders that belong to the exception queue. Locking mechanism ensures no two devices get the same transfer order.

  • Only transfer orders belonging to exception queue will be downloaded to device.

  • The forklift operator will select a transfer order from the list.

  • Shipment details for the transfer order are displayed on the initial page of the App.

  • All transfer orders belonging to the shipment are displayed in the next page.

  • When the user drills down into a transfer order, transfer details like Truck details, Loading Notes and Transfer Order lines are displayed in the Transfer Order details page.

  • The user could confirm pick either by scanning the barcode label or confirm the pick manually.

  • If all transfer order lines are confirmed, saving the transfer order posts the confirmation in SAP. Otherwise, the transfer order is reassigned to the exception queue for exception handling.

  • Saving the transfer order confirmation updates shipment status; this in turn triggers printing of bill of lading at the warehouse exit location.

Production Order Confirmation

  • The Production Order Confirmations app allows users to post production order confirmations.

  • Validates material number prior to posting production order confirmations. Validation can be performed with bar code scan or manually.

  • Order confirmation quantity posted using a Number pad or by scanning the bar code label.

  • Quantities can be confirmed either in base unit of measure or in pallets.

  • App prevents confirmation quantities to exceed total deliverable quantity.

  • App allows users to record custom fields (Shift Number and Shift Team) to be captured and updated in SAP.

  • App retains the production order details for the last processed order to minimize data re-entry.