FEATURE AUTOMATED WAREHOUSING WMS versus WCS
Warehouse management systems (WMS) and warehouse control systems (WCS)... They both have their role to play, but which is right for your distribution centre operations? Chris Castaldi of W&H Systems offers some insight
W
arehouse management systems (WMS) are used in many distribution
centres and warehouses to run operations like picking, put away, and receiving. Similarly, to manage automated material handling equipment, warehouse control systems (WCS) are employed. However, while both have a role to play in distribution operations, modern system designs have distorted the difference between the two, making it more difficult to choose the best system. Typically a WMS controls the movement and storage of materials within a warehouse and processes the associated transactions. It focuses on demand, planning, financials and linking to the extended supply chain. A WCS acts as the ‘traffic controller’ within the DC, directing the real time activities, ensuring everything is running smoothly while maximising the efficiency of the material handling subsystems.
WHICH IS BEST FOR MY OPERATIONS? While the lines between a WMS and WCS continue to blur, they each have their own functionality that is required in a warehouse to work together. Systems integrators need to look at finding the right balance so that each customer’s business requirements are reached. The WCS was introduced in the 1990s in response to the need for real time control of material handling equipment. They can be used stand alone or in conjunction with a WMS, which sends the WCS order information that is then sent to pickers and packers in a timely and efficient pattern of waves. However, WCSs have grown to take over many roles traditionally allotted to WMSs, and can be used on their own in many fulfillment warehouses. Slotting, replenishing, receiving and many aspects of inventory management can now be handled by most stand alone WCSs, reducing the need for redundant and expensive systems in smaller operations. Next generation warehouse control systems have expanded in functionality, such as providing advanced wave and pallet build planning and generating real time views of distribution centre performance. They drive continuous
12 NOVEMBER 2014 | AUTOMATION
operational improvement with unfettered visibility into warehouse operations, delivering actionable intelligence to perfect fulfillment operations. The WCS orchestrates material and
information flow to order fulfillment technology and material handling equipment, providing real time operations intelligence into warehousing processes. Key capabilities include relieving a customer host computer of managing a real time material handling automation interface (maximising system throughput and performance while utilising the most efficient methods for pallet, case and item routing), and intelligent wave release, allowing the grouping of orders by common functionality to make order fulfillment as efficient as possible and to minimise bottlenecks.
that gap between business systems and distribution centre subsystems. The WCS continually monitors systems in order to direct and coordinate specific tasks based on real-time operational data.
Above: Chris Castaldi, director of business development, W&H Systems
Below: WMSs and WCSs have a role in distribution operations, however, modern system designs have distorted the difference between the two
HOW IT WORKS As a stand alone software application, a WCS can be configured to communicate with virtually any material handling systems, equipment and processes. However, when it comes to breaking down that big wave into packets of work, assigning picking tasks through the facility’s voice recognition system and directing the packing stations (activities normally associated with a WMS) the WCS is firmly in control. The WCS is closer to the action so that
proximity to real time events puts it in a better position to dynamically determine which parts to pick and release to the sorter. If a WCS is going to make decisions about what to pick and release, better that it speaks directly to the voice system, the sorter, the packing stations and the shipping sorters than a WMS. For example, in highly automated DCs
with complex order profiles, WCSs often direct order fulfillment operations. The WCS can reassign orders, such as changing who to ship to and the shipping method. Since the WCS monitors events in real time, it can automatically react to events that in the past required manual intervention. The WCS is perfect for resource
WHAT ABOUT ERP SYSTEMS? Often, companies invest in ERP systems and a WMS, thinking that they have what they need to be able to visualise what is being done on the warehouse floor in real time. On the warehouse floor, decisions need to be made based on real world transactional data. ERP and WMSs manage enterprise wide operations, but rarely have the capability for direction of complex material handling equipment instantly. On the warehouse floor, technologies
must be flexible, agile and responsive in order to command all the systems that do the work, such as picking and packing systems, RFID, conveyors and sortation etc. A Warehouse Control System fills
management, such as labour. It orchestrates fulfillment operations to get the lowest cost per case for shipment. To do this, the WCS balances the workload across equipment to eliminate peaks and valleys, creating a steady flow of work from picking to the conveyor and sortation system to packing stations. If a company has a spike in demand, the WCS can look to see if there is enough stock in a particular pick location, and if not, it can order replenishment stock to fill demand and eliminate out of stocks. WCS or WMS? Which then is the best approach? Since most of the variable cost in a typical DC is associated with order processing, efficiency gains received from using a WCS or WMS go right to the bottom line. Companies need to decide the goals of their warehouse and what processes and equipment are used, then determine which system is best - whether it be a WMS or a WCS.
W&H Systems
www.whsystems.com T: +1 201 933 7840
Enter 203 /AUTOMATION
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