More than just load building
October 1st 2007

Prior to becoming a business unit of Procter & Gamble, Gillette decided to upgrade the WMS at Reading to the latest version of Swisslog's WarehouseManager WMS

During the upgrade process Gillette requested that Swisslog investigate how improvements could be made to transport planning and order delivery. To meet this requirement the 'LoadBuilder' concept was created and developed.

The solution Although the system enhancement was labelled 'LoadBuilder' it involved all aspects of customer order processing control from the time the order was communicated to the WMS through to the despatch confirmation.

The functionality was delivered in several phases. Phase 1 optimised the transport planning of customer deliveries by applying customer driven pallet build and load stack build rules to each order and sequencing pallet build using product and pallet stackability factors. It has been designed to achieve maximum vertical fill of each load stack in the context of specified trailer configurations thus creating a Load Plan. Each Product can be specified as, 'Top-Only' or 'Non-Stackable', or assigned a stackability factor to be applied when building pick pallets. Each pallet or layer(s) of product are also assigned stackability factors to assist with load stack build.

Phase 2 converted the pallet configurations in each load plan to full pallet retrieval and order picking instructions. The order picking functionality is based on WarehouseManager's 'pick run' concept. A 'pick run' is a sequenced set of pick tasks that creates a licensed pick pallet when completed.

By taking account of pallet configuration and stackability (including weight) WarehouseManager can group and order the pick tasks for each pick run, thereby delivering a pick strategy optimised for creating a stable and stackable pick pallet. These pick pallets have a suggested location within the despatch vehicle/trailer that maximises the use of available storage capacity.Voice picking was progressively implemented during the above development.

LoadBuilder objectives Enhance Transport Planning Provide the transport planning department with a more accurate assessment of pallet stacks associated with each order.

Provide system visibility of these pallet stacks to provide on-screen building of despatch loads.

Through web solution create full internal visibility to maximise truck fill.

Reduce transport costs Optimise the stacking of pallets in each despatch vehicle/trailer.

Improve management of own and subcontract vehicle fleet by matching vehicles to load stacks for each load.

Improve Customer Service Greater system control over pick pallet configurations that are built to a customer's requirements.

Create load stacks that match customer's delivery requirements.

Allows customers under trade terms to achieve a full load every time.

So what made the company decide to chose the LoadBuilder solution? According to Marc Ragot, operations manager UK/Ireland, there were several decisive factors: "The impact of transport 'rate cost inflation' and legislation such as the Working Time Directive created a need for improved control over transport planning. This could be achieved by providing a 'LoadBuilder' module, linked to the site's WMS, that pulled orders for planned loads through the distribution centre rather than the transport department having to make late changes to loads during and following order picking.

The decision to upgrade the site's WMS to Swisslog's WarehouseManager meant that 'LoadBuilder' needed to be an integral feature of the WMS and Swisslog were commissioned to develop the 'LoadBuilder' concept as imagined and specified by the DHL/Exel (which manages Gillette's UK distribution) team and myself. The module creates Load Plans of load stacks and despatch pallets that are system converted to order picking instructions that create stackable pick pallets." What opportunities were there to reduce transport costs? "The transport department had reports that indicated the number of load stacks that each order would create but this data made no allowance for the impact of pick pallet build where a pallet comprises multiple products in layer/case quantities or changes in pallet configuration due to customers' own requirements.

The aim was maximise the number of pick pallets that could be stacked to improve the utilisation of vehicle/trailer capacity.

Maximising the number of cases in a load stack and the storage capacity utilisation in each vehicle were key objectives for the development. All orders would be passed through the 'load assessment' module to determine the number of load stacks for each order. This data would be visible to transport planners so that they could plan loads directly at a WMS workstation and select the best vehicle/trailer for each load." Which benefits has LoadBuilderprovided you with concerningtransport operations? "As anticipated LoadBuilder plus the implementation of voice picking has extended the functionality of the WMS to provide a net reduction in Transport Costs, expressed as Pence/case of over 20%. Also, the ability to order pick to specified load plans has improved picking productivity and reduced the requirement for 'groupage' loads where the carrier has responsibility for out-sorting customer orders as well as delivery." Has the system driven case picking of licensed pick pallets created improvements? "Yes, there has been an improved flow of goods through the DC and productivity has increased. The order picking and marshalling process is more controlled and timely, assisted by the voice picking system that provides targeted instructions at the start of each pick pallet 'Pick Run'." Has Load Builder helped to improve customer serviceability? "There has been Improved control over the presentation of orders. This control has reduced the error rate and created a reduction in claims by customers." The benefits Improved pallet stackability increased the number of cases/stack by up to 35%.

Better utilisation of stack height increases the cases/trailer despatched by up to 36%.

This increased utilisation of vehicle space has given a net reduction in transport cost expressed as Pence/case of 30% for the sites served by Reading's own fleet.

Accurate order stack data for transport planning On-screen assessment of outbound loads System created pick pallets and load stacks Stable pick pallet build and load stack build Pallets and load stacks configured to customer requirements System created load plans from pallet and load stack data Redeced 'non value added' customer claims Outlook The DHL/Exel team and Marc Ragot have commissioned Swisslog to develop the web version of LoadBuilder. This will provide a service to other DCs within the UK and making it accessible to Gillette's customers as a planning aid prior to placing full/half or quarter load orders on UK distribution.

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