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Mobile fulfillment workstations supported with Smart Order Fulfillment Technology (SOFT™) offer the following features to be considered as specific business needs dictate:

Basic Functionality

• Mechanical configuration to efficiently operate in the required stock storage area (size, maneuverability, reach, accessible height)
• Customized design for material to be handled and for pick-zone aisles.
• Support item validation by scanning the item’s UPC or the source location.
• Support light-directed putting (and containers pushers as an option).
• Operate as nodes of an R/F (802.11b/g) network.
• Continuously optimize its operation, in real-time, based on pending work, job priority, and current vehicle location.
• Support real-time exception handling.
• Can provide the selector with two-way communication from any side of the workstation: voice, large or small monitors (standard CRT or touch-screen), lights and confirm buttons, carton pushers, keyboard and/or mouse, scanner.
• Powered by rechargeable batteries, capable of 10 or more hours of continuous operation between charges.

Interface with Host System

• Originally designed to operate as an independent module interfacing with a host system. In this mode, the host system performs order allocation and the fulfillment workstations receive orders as the locations from where to pick the items.
• Also may support an operation where the fulfillment system manages the inventory within the serviced pick zone(s), performing order allocation within the zone(s). This mode allows the fulfillment system to further improve the system productivity. Under these conditions, the fulfillment workstations receive orders as the SKUs required for the orders.
• Can report executed transactions back to the host system in real-time or as a batch process.

Dynamic List of Orders to Process

• Does not require a finite number of cut-off times through the day for order release from the host to the fulfillment system.
• Addition, deletion, and modification of orders in the list of orders to process are allowed at any time during the day.
• Selection of the best order to start next in a workstation is based, first, on order priority, and then, on current workstation location.

Adaptive Features

• Display to the selector the list of all pending jobs for the orders currently in the workstation, in an optimized suggested sequence, based on the current workstation location.
• Allow the selector to modify the suggested job sequence and re-optimizes the future jobs based on the selector’s decision.
• Allow the selector to relocate his workstation at any time and re-optimizes the future jobs based on the selector’s action.
• Allow the selector to scan any container not in the workstation and respond displaying all the pending transactions for the scanned container. Then, the selector can decide if he wants to process the container with his workstation, send the container to other zone, or leave it where it is.

Picking Path

• Support user-defined picking paths independent of location IDs.
• Allow easy addition and deletion of pick locations without re-labeling locations.
• Support picking from multiple pick zones with containers passing from zone to zone

Cartonization

• Supports cartonization
  • As defined by the host system
  • As decided by the selector
  • As calculated by the fulfillment system

Virtual Batching

• Support endless loops as picking paths. Such loops do not have a beginning or an end.
• Allow selectors to add new containers to his workstation and to release containers from his workstation at any point of the picking loop.
• Allows selector to increase the order batch size beyond the number of cells in the workstation.

Reports

• A variety of reports available through the monitor in the workstation, that allows the selector to make better-informed decisions. Some of the report capabilities include:
  • Order status.
  • Container status.
  • Selector productivity.
  • Other custom required reports.

Long Aisles and/or Few Order Line-Items

• Support multi-step picking (i.e. pre-picking).

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Clustering or “batching” orders to be picked together is one of the most intuitive ways to improve productivity in a distribution center. Piece sorters (tilt tray sorters, Bombay sorters, cross belts sorters) take this clustering to the extreme of allowing hundreds, if not thousands, of orders to be picked together.

Piece sorters are an expensive capital investment. Also, they often become the main component of the process, determining the pace at which the distribution center operates. Regretfully, when combined with order batching, the productivity and capacity of sorters is erratic. There are periods of high utilization where the sorter operates almost at full capacity followed by valleys of very low efficiency. The sorter, as the main component dictating facility workflow, causes the erratic or cyclic efficiency to cascade to the other areas of the process as well as diminish the overall capacity of the distribution center.

Addressing these limitations, VAS has developed SOFT&#trade; optimization modules for sorter-based operations. These modules are based on VAS’ proprietary adaptive technology which continuously searches, in real-time, for opportunistic ways to maximize the usage of system resources by adapting to the changing conditions of the operation. This paper is an overview of how this dynamic sorter system optimization is accomplished and the resulting benefits.

The traditional way to operate sorters is using static waves of orders. The size of these batches is normally made as large as possible to take advantage of all sorter resources. As a rule, low efficiency periods happen during wave transition periods.

The SOFT™ optimization modules eliminate, to the point allowed by the system, the dependency on static waves, converting the process to a continuous operation. The SOFT™ sorter optimization module is “rule driven” and the rules are uniquely defined for each application. In creating a continuous process, the sorter work is broken down into small, non-separable “mini-batches”. The mini-batches are then started individually as the “opportunity” arises, and are also completed individually. Normally, product arrival provides the events that start and complete these mini-batches. SOFT™ sorter optimization de-links the selection and delivery of product to the sorter from the sorter induction process itself. As product arrives and is identified at the sorter, the SOFT™ sorter optimization examines the current need for that product. This examination is independent, as far as the rules allow, of the prior selection of the product. The rules for sorter induction normally prioritize arriving product to the completion of any mini-batch that is currently in-process. If no in-process mini-batch requires the product, there are a set of rules that define the initiation of a new mini-batch and its assignment to available sorter resources. These rules are somewhat more complex and also vary by application but for the purpose of this paper suffice it to say that mini-batches are continuously starting and completing asynchronously.

To the extent that waves are eliminated, so are the wave transition periods and the low efficiency valleys. The most immediate benefit of this approach is an increase on the capacity utilization of the sorter that allows an increase in the facility’s capacity to process orders.

VAS engineers have used adaptive technology to increase distribution center capacities for almost 20 years. Completed projects where this technology successfully increased the capacity of the facility include companies like The Gap, HEB Grocery, and Levi Strauss. In order to achieve the desired capacity improvements, the SOFT™ optimization modules have to coordinate, in real-time, the operation of several subsystems of the distribution center. The subsystems requiring coordination in applications can include picking, product delivery, product identification, the sorter itself, packing, and completed order takeaway. The modules include interfaces for these systems that minimize (if not completely eliminate) the required changes to those other systems. Where the current system does not support real-time communications, the modules add the capability to the existing system.

On a project-by-project basis the SOFT™ optimization modules need to be configured for the facility’s mechanical configuration (i.e.: piece sorter mechanical configuration) as well as for the specific business practice requirements of the customer.

Other benefits yielded by the SOFT™ optimization modules may include:

• Reduced sorter inductor idle time
• Reduced picker idle time
• Increased picking productivity
• Reduced packer idle time
• Smoother completion of orders
• Reduced need to stage early totes
• Faster response to last-minute orders

The extent of these side benefits is application-dependent, as it is a function of the mechanical and process restrictions of each specific project.

Piece sorters are an excellent technology to cluster large number of orders to be picked together. They are also very expensive. Optimization of existing sortation equipment is the most economical means of increasing capacity of an existing system. It can also delay the need to construct additional facilities to increase distribution network capacity. In addition, the benefits yielded from these sortation system improvements may be carried forward to future operations reducing their effective cost.

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“Closed-Loop” systems are systems where output information is “fed back” into the input to compensate for variations in the system. Closed loop systems are contrasted to “open loop” systems that do not use feedback to alter operation. Although both closed loop systems and open loop systems have existed for many years, modern computing technology has allowed using closed loops in situations not previously possible. Closed loop systems originated out of “control systems” that required precision for proper operation. There are thousands of articles that describe and distinguish between closed loop and open loop systems. A great example of the difference between a closed loop and an open loop system is seen when comparing automatic and manual transmissions in automobiles. A manual transmission equipped automobile provides no feedback to “change gears” and relies on an external input to change speed or control engine RPM. In automatic transmission equipped automobiles, the transmission has a feedback mechanism that monitors engine speed and automatically compensates to control engine RPM, and thereby compensating for both terrain changes (going up a hill) and driver desired velocity input (the throttle or gas pedal).

It would be worthwhile to look at some of the articles on closed loop systems that are available on the Internet. Notice the distinctions made between the systems. A particularly interesting one that we found is an article entitled “Closed Loop Systems” written by Bill Inmon, who is universally recognized as the “father of the data warehouse.”

The following two diagrams respectively represent open and closed loop systems. The “Operation” receives input (data) and from that makes a plan or generates an output that may then be observed (data may be collected) but no action is taken on that data. This is like sitting in your car, looking at the road ahead, determining the best gear to select for your manual transmission, and then hitting the gas. In distribution operations the only correction that may be undertaken is upon completion of the current operation.

The next diagram represents a closed loop system. In this situation, the observed results of the current operation are “fed back” to constantly modify the input to create the desired outcome. In this situation the system continuously adapts to changes encountered in the operation. In closed loop systems you may encounter the term “PID” which stands for “Proportional, Integral, and Differential”. This term applies to the feedback function. The feedback function determines the amount and rate of adjustment necessary to create the desired outcome. You have encountered and witnessed the benefits of “PID” controlled closed loops many times. Again from automotive industry, speed or cruise controls on cars include PID feedback.

As the cruise control automatically controls the throttle (gas), the control is not only observing the current speed, it is also monitoring the rate of change of speed (differential velocity) and well as the average speed of the past several seconds (integral of the velocity). The “proportional” element is the difference between the current speed and the desired speed. By creating a feedback function using these values it is possible to detect slight changes in velocity that will create slight changes in the application of the throttle, that allow the cruise control to accurately control the velocity at the desire value and not “oscillate”. A closed loop system can react to the slightest changes that a good human “observer” may not even detect, you can encounter a slight hill, a strong head or tail wind, pulling a trailer, a miss-firing sparkplug, high an low octane fuel, literally any unexpected event and the cruise control just keeps the proper set speed until such time the system is out of range of control.

So how do closed loop systems apply to logistical operations? Typically, or more correctly near universally, open loop techniques are used to control logistical operations. Plans are made and then executed. Feedback is limited to human observation sometimes aided by real-time progress reporting tools. Adjustment to the plan, if possible, is accomplished by supervision re-directing efforts. Distribution and fulfillment operations are nothing more than complex “plants” with complex and unexpected conditions continuously being encountered. Billy is ill and working slower than expected, you had a large order of very few SKUs that was unexpected, someone tipped over a pallet of bolts, today’s order profile was not typical, and on and on. You know the obstacles that face distribution operations. Is it possible to operate in an “open loop fashion”? Certainly—you have been doing it for years. We also drove cars for years without automatic transmissions and speed controls. The real question is what is the benefit of using a closed loop design? Things that you need to consider are: improved productivity by lowered worker idle time, reduced supervision through automatic control of work flow, higher capacity through constant work flow, reduced facility hours through better productivity, and so on. We have installed closed loop systems that have created benefits that paid for the entire system in a matter of months.

VAS is the leader in “closed loop” implementations in the distribution and fulfillment operations arena. As “closed loop” technology moves into distribution and fulfillment operations, there are some that will claim that there is no distinction between open and closed loop system or that they are too complex, impossible to implement, too expensive, or simply that they already provide closed loop systems by claiming that a supervisor closes the loop. You be the judge. We have grown up in real-time dynamically optimized systems. We have made closed loop systems for years in hundreds of differing forms and applications both within and outside our industry.

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The following checklist provides an overview of the “basic functions” available with the MandateIP AWCS. The MandateIP AWCS provides basic features to integrate and control equipment and work processes of a fulfillment or distribution center. An “Adaptive” WMC (AWCS) uses real time or dynamic optimization of the workflow. Dynamically optimized workflow adapts to the changing conditions found in fulfillment operations.

Each VAS AWCS system is delivered configured to meet the specific needs of the customer. Typically 70% to 90% of the WCS functionality is standard while 10% to 30% would be customized based upon the customer’s requirements.

For some systems, where a full WMS is not needed, the VAS AWCS offers basic WMS modules that may be used to provide WMS functionality.

External System Interfaces

• Host, Sockets, FPT, NFS, Async
• Equipment Control Systems, Conveyance, Sorters, ASRS, Carts, Vehicles etc.
• Worker Interfaces, RF, PTL, Handheld, Voice, Mobile, Wired

Receipt Processing

• ASN/EDI Receipt Processing
• Q/A—inspection management and scheduling
  • User Specified % Of Shipment, Vendor, Random Selection
  • Inbound Weight Check
• Shipment, Vendor and Carton level holds and releases for allocation

Customer Returns Processing

• Batch Hold, Re-sellable, Other Disposition
• Like SKU “Recursive” Sortation For Piece Sorters
• Add To Stock, Write Off

Dynamic Stock Disposition

• Rules For Allocation, Strict FIFO, FIFO prioritization, Emptiest location
• Directed To Putaway
• Directed To Fulfillment (cross dock, cases, pieces)

Inventory and Putaway

• Directed, Random, Slotted, Replenishment
• Multiple Locations Per SKU, Multiple SKUs Per Location
• User Defined Locations (Creation/Deletion -temp & permanent locations)
• Split Case, Full Case, Residual Management, Cartonized/Open Case Flowrack
• Overlap Storage, Retrieval an Cyclic Operations To Reduce Travel
• Container Within A Container Concept, Container Identification By Member Scan

Cyclic Or Cycle Counting

• Random
• Scheduled
• Opportunistic (Continuous Based On Workload) Overlap With S/R Operations
• Re-Checks, Double Checks, Sample Size

Dynamically Optimized Fulfillment

• Dynamic Inventory Allocation
• Waveless Picking, Wave Picking, Overlapping Wave Picking
• Labor Balancing, Within Zone, Between Zones, Between Areas
• Prioritized Continuous Processing, Realtime Acceptance On New Orders
• Optimization Of Piece Sorters, Dynamic Assignment On Item Arrival
• Zone and Zoneless Picking, Realtime Configurable Zones, Pick Paths
• Realtime Optimized Travel, Acceptance Of New Resources
• Worker Interface Independent (Paper, RF, Voice, PTL)
• Synchronized Inter-Zone Operation
• Optimized Order Consolidation, Reduction Of Order Dwell Time

Added Value Services

• “Work” Identifies Required Actions, Functions, Descriptions, Pictures
• Automatic Generation Of Paper Work
• “Work” Attached To Orders, Items
• “Work” Assigned To Stations/Resources
• Work Balancing Between Assigned Resources

Outbound (Shipping) Management

• Shipment Routing, LTL, Shotgun, Priority
• Carton, Order, Shipment Weight
• Outbound QA Management, By User Defined % By Shipment
• Waybill, BOL Generation
• ASN Notification

Reporting System

• Extensive Standard Reports, User Customizable Special “Workstation Views”
• User Defined Custom Reports As Required, Definition Of Data, View, Printed
• Uses Powerful SQL Reporting Language For Data Definitions
• Printed, Screen Reports Ave Separate View Definitions
• Screen Reports Item Tagging, Linkages, Actions

Productivity And Tracking Reporting

• Interfaces To “Office Tools”, Spreadsheets, DB etc.
• AWMS Collects Data, Analysis Done Externally To AWMS
• Automatic Data Aging, Data Cleanup, Data Maintained 31 Days
• User Specified Events
• Log of Individual Events
• Log of Event Counts Over User Specified Periods
• Equipment Error Event And Error Resolution Logging

Worker Authorization, Login–Logout

• Individual Worker Authorization Levels, Restriction Of Unauthorized Action
• Add/Delete/Modify Users
• Configurable Password Aging