WMS Implementation Genesco

Slide1: 

Barb Bankson - Inventory Control / Quality Manager WMS IMPLEMENTATION AND OPERATION

Slide2: 

Journey’s Journey’s Kidz Jarman/Underground Station Genesco is a premier life-style focused marketer of branded footwear and accessories.

BUSINESS NEEDS - Current: 

BUSINESS NEEDS - Current Growth of Journey’s, increasing SKU count, planned store growth Multiple warehouses Product mix change – More accessory items All warehouse processes were paper/manual Inventory discrepancies

BUSINESS NEEDS - Future: 

Capacity for five years’ growth Consolidate warehouses Real time inventory transactions - Improve Inventory/Shipment accuracy Tools for planning and scheduling Improve deliveries to retail stores and store receiving process/accuracy Reduce unit costs BUSINESS NEEDS - Future

WAREHOUSE /WMS: 

WAREHOUSE /WMS Groundbreaking August, 2001 323,000 sq ft Floor space 25,000 sq ft on mezzanine Automated MHE 2.5 miles of conveyor (Fortna - Material Handling System) Warehouse Management System PkMS - Manhattan Associates

WAREHOUSE DESIGN/BASICS: 

WAREHOUSE DESIGN/BASICS 11,300 Forward (Active) pick faces 13,500 Bulk (Reserve) locations ACTIVE and RESERVE locations - ALL Single SKU (Style/Color/Size/Width) All transactions require barcode RF scan - live update of inventory Cubi-scan ALL SKUS at receipt

Slide7: 

Receive large quantities quickly ASN Receiving Slot SKUs to Active Location System Directed Put-away, based on volume. - Fill active location first - Remainder to reserve (Bulk storage) INBOUND Warehouse Processes

Warehouse Processes: 

Warehouse Processes Shipping schedule is Monday - Thursday Routes orders together – Grouped by ‘Ship Via’ Carton Shipping labels printed at time Wave is released to the picking floor Conveyor directs cartons to the zone for picking WAVING / REPLENISHMENT

Warehouse Processes: 

Warehouse Processes Associate scans carton label, directed to location, picks quantity directed, scans SKU barcode,scans carton to confirm the pack PkMS adjusts active location, moves inventory to carton PkMS follows carton and tracks ‘status’ through the DC Packed cartons continue to Taping /manifesting mezzanine PICKING

Warehouse Processes: 

Warehouse Processes 6 manifest stations 2 Quality stations In-line scale Manifest on the Fly TAPING/MANIFESTING

Warehouse Processes: 

Warehouse Processes Diverts cartons to Outbound lanes assigned to Shipment/Load SHIPPING SORTER 14 shipping Dock Doors 10 flow load lanes Cartons are sorted by Ship via, diverted to lane

Warehouse Processes: 

Warehouse Processes 7 LTL lanes Cartons are sorted by ship to for LTL shipments

Systems Integration: 

Systems Integration Host Mainframe PkMS (AS/400) Fortna Plus Servers Inventory Transaction Ship confirms (Invoice) Vendors Purchase Orders ASN Tapping Mezz Shipping Sorter Carton and Picking Divert Instructions Divert Confirms “D” End of Life Item Master, Retail Orders, Purchase Orders, ASNs

HOW DID THIS AFFECT THEDISTRIBUTION ASSOCIATES AND GENESCO ? ? : 

HOW DID THIS AFFECT THE DISTRIBUTION ASSOCIATES AND GENESCO ? ?

CULTURE SHOCK : 

CULTURE SHOCK

? ? LDC and WMS ? ? : 

? ? LDC and WMS ? ? Procedures and processes Inventory Accuracy Real time inventory updates Difference between Active and Reserve - (Location / SKU) Locations based on volume Warehouse configuration Personnel - Training - Technical skills

OPERATIONAL CHALLENGES: 

OPERATIONAL CHALLENGES MULTIPLE / DIVISIONS Start-up LDC while operating three other DCs Kidz – Chapel Hill Journey’s – Murfreesboro Road Jarman/Underground Station – Fayetteville Keep inventory separated physically and systematically - Same SKU -- Different divisions

Slide18: 

SEASONAL Spring/Summer (March – April) Back to School (Mid June – September 1) Holiday (October 15 - December 20) OPERATIONAL CHALLENGES PRODUCT MIX Spring – Sandals – small not in shoe boxes Light weight shoes Accessories – T shirts/shorts/sunglasses/watches Fall/Winter - BIG heavy boots – irregular size boxes Accessories – Bulky hats/ fluffy house slippers, Sweat suits / jackets / caps

OPERATIONAL CHALLENGES: 

OPERATIONAL CHALLENGES Internet / Catalogue Journey’s - November 1st – added Jarman and Kidz RESULT: More SKUS - break down inner-paks Extended life-span of SKUS to cover catalogue dates

WHERE ARE WE TODAY ? : 

WHERE ARE WE TODAY ?

LOCATION CONFIGURATION: 

Forward (Active) pick faces Start-up 11,300 Today 16,500 Bulk (Reserve) locations Startup 13,500 Today 7,250 LOCATION CONFIGURATION SKU Count 14,600 89% capacity Locations Used 6,175 85% capacity November 2004 SERVICE 932 Retail Stores Approximately 1,204 shipments per week 60,000 Pr Shoes/Day Shipped 10,000 – 12,000 cartons per day

CHALLENGES ?: 

CHALLENGES ?

TODAY’S CHALLENGE: 

TODAY’S CHALLENGE SLOTTING Correct size location for the quantity being received based on SKU Profile )

Warehouse Pick Configuration: 

Warehouse Pick Configuration Bin Picking Module (Two levels) Small quantities 24 – 36 Pr depending on volume Slow velocity Second Level is used for small “end of Life” SKUS – Catalogue SKUS Approx. 7,600 locations

Warehouse Pick Configuration: 

Two 3- level pick modules Warehouse Pick Configuration

Warehouse Pick Configuration: 

Carton Flow on Floor Levels of B and C modules Warehouse Pick Configuration 60 – 90 pr (10-12 cs) After initial shipment to stores or PO qty Lower ship qty than Pallet flow Approx 1105 Locations

Warehouse Pick Configuration: 

Warehouse Pick Configuration Each location holds four pallets each SKU 350 - 600 pr. High volume - high velocity New Styles - initial shipment Approx 775 locations Pallet Flow Picking Module

FLOOR PALLET LOCATIONS: 

FLOOR PALLET LOCATIONS Single Pallet Locations Approx. 75 – 100 pr. Lower Pick Quantities Approx 700 locations

Slide29: 

SLOTTING CHALLENGE TOTAL RECEIPT 11,292 units 4 DAYS Shipped Total 8,812 units 78%

Slide30: 

Final Thoughts The Digital world and the Physical world must stay in sync Set processes and procedures must be in place Communication – No changes without group consensus and agreement WMS requires discipline, training, and consequences Flexibility – configurable within parameters Be ready for CHANGE – it WILL happen Be ready for RESISTANCE to Change

Slide31: 

Final Thoughts Plan for the unexpected Murphy is ALIVE And WILL VISIT YOU!

Questions: 

Questions

Thank You: 

Thank You Barb Bankson - Inventory Control / Quality Manager bbankson@genesco.com