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Purchase Inventory System

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					Advanced Tracking System
      for Inventory


 Automated Data Collection and Tracking System
          for Inventory Management




                               Developed by


                 Business By Design

                                Version 5.0




529 Martin Avenue, Rohnert Park, California   707.586.9122   Fax 707.586.3505
                                        TABLE OF CONTENTS

Welcome to the advanced tracking system ___________________________1
  ATS Functions at a Glance:.................................................................................... 1

ATS Inventory Functions __________________________________________2
       Receiving Raw Materials & Label Printing........................................................... 2
       Put-Away............................................................................................................. 2
       Order Pick Scheduling ........................................................................................ 2
       Picking ................................................................................................................ 2
       Kitting .................................................................................................................. 3
       Order Pick Verification ........................................................................................ 3
       Shipping .............................................................................................................. 3
       Locate Function .................................................................................................. 3
       Build Common Kit Function................................................................................. 4
       Take Sample Parts.............................................................................................. 4

Ats manufacturing/finished goods inventory Labeling
functions _______________________________________________________4
       Product Labeling ................................................................................................. 4
       Receive Finished Goods to Warehouse.............................................................. 4

Inventory maintenance functions ___________________________________5
       Setup Inventory Function .................................................................................... 5
       Cycle Counting.................................................................................................... 5
       Physical Inventory ............................................................................................... 5
       Relocate (move function) .................................................................................... 6
       Create Purchase Order Requisition .................................................................... 6
       Print labels .......................................................................................................... 6
       Janus RF Handheld Menu................................................................................... 8
  System architecture ................................................................................................ 9
        Advanced Tracking System for Inventory

WELCOME TO THE ADVANCED TRACKING SYSTEM

        The Advanced Tracking System (ATS) for Inventory is a complete system
        that operates standalone or as a front-end that interfaces with almost any
        company information system. It automates data collection and provides a
        fast and easy place to view critical inventory activity in real time.
        ATS for Inventory is designed to improve customer service, boost
        productivity, and provide accurate management information. The system
        automates time consuming data collection tasks and provides accurate
        inventory status, bar code labeling, put-away, picking and kitting,
        shipping, cycle counting and physical inventory, historical data, and much
        more.
        Data collection is fast and easy. Transactions are captured quickly and
        accurately in real time without handwritten forms and manual keyboard
        entry. Value added work increases dramatically by reducing errors and
        wasted time.



ATS Functions at a Glance:
•   Receiving & Label printing               •   Packaging & Finished Goods
                                                 Labeling
•   Put-Away
                                             •   Build Stock Kit Function
•   Order Pick Scheduling
                                             •   Take Sample Parts
•   Order Picking
                                             •   Setup Inventory
    §   Pick to Pallet – One Person
    §   Pick to Pallet – Two or more         •   Cycle Counting

•   Kitting                                  •   Physical Inventory

•   Picking Verification                     •   Relocate (move function)

•   Shipping                                 •   Create Purchase Order Requisition
                                                 using handheld
    §   Automatically Prints Packing
        Slips & Bill of Lading               •   Bin Location Labeling

    §   Prints SSCC Pallet Labels
•   Locate using Handheld: Parts,
    Orders, Parts - where needed,
    Orders - parts needed
ATS INVENTORY FUNCTIONS

Receiving Raw Materials & Label Printing
     •    Imports purchase orders from                      •   Tracks PO line item receipt
          your host computer system.                            number (for accurate lot
                                                                tracking) of received items.
     •    Prints bar coded labels for items
          received.                                         •   Easily customizable
     •    Prints PO receipt report
     •    Updates host system with
          accurate purchase order receipt
          data.

Put-Away
     •    Random stocking locations -- allows multiple stocking locations per item and multiple
          items per location.
     •    Allows for PO/lot or serial number identification and tracking.
     •    Put-away or receiving function can be configured to display on handheld all partially
          picked orders on-hold and waiting for item (cross docking).


Order Pick Scheduling
     •    Schedules open orders by due date and priority
     •    Allows manual override of schedule
     •    Schedule automatically displayed on picker’s portable RF handheld unit. Operator
          can pick to schedule or pick a different order.


Picking
     •    Paperless pick with recommended order picking sequence based on system
          generated picking schedule (see above) with operator override feature.
     •    Pick one order -- one picker.
     •    Pick one order -- two or more pickers (system tracks each picker’s items picked).
     •    Pick function includes item location lookup.
     •    Pick options: FIFO, by Lot, by Serial number, and customizable for other user
          definable order.
     •    Pick to pallet feature allows items loaded on pallet to be assigned a serial numbered
          pallet label.
     •    Automatically generates a shortage list of all items picked short. The shortage list
          can be displayed on an RF handheld or as a printed report. Shortage reports on
          total quantity per item or totals per customer.




     BUSINESS BY DESIGN              ADVANCED TRACKING SYSTEM                                    2
Kitting
     •    Kit one order                                     •   Locate a needed part (including
                                                                WIP locations) without exiting
     •    Kit several orders together                           kitting function.
     •    Substitute a different part for a
          specified part – password
          protected for control.


Order Pick Verification
     •    Operator rescans order previously picked – verifies order accuracy prior to shipment.
     •    Allows users to verify and ship a partial order or a complete order.
     •    Picking verification can be done by pallet. Operator scans pallet number and all
          items on pallet.


Shipping
     •    Packing list shows detail by pallet number and includes order summary. Very useful
          for multi-pallet orders.
     •    Packing list includes pallet numbers and weights (if available) plus a list of bundles
          and loose items.
     •    Automatically prints bills of lading.
     •    Prints UCC128 SSCC pallet labels.


Locate Function
     Users can perform the following lookups using a portable handheld RF unit or system
     PC:
     •    Locate Part: Displays all stocking locations and quantities on hand. Also displays
          items received but not put-away and, if desired, partially picked or kitted orders that
          contain the needed part -- helpful when you need parts from a low priority order to fill
          a high priority order.
     •    Locate Order: Displays location of a suspended or staged order.
     •    Part Number - Where Needed: Displays or prints a list of orders on hold waiting for
          part.
     •    Kit (or Order) - Parts Needed: Displays parts and quantities needed to complete
          kitting or picking an order.




     ADVANCED TRACKING S Y S T E M                     BUSINESS BY DESIGN                          3
Build Common Kit Function
     •   Functions as a simple MRP system using inventoried parts as raw materials to make
         commonly needed items, such as assemblies, service part kits, retail displays, etc.
     •   Includes database of common kits and their bills of materials.
     •   Allows operator, using a portable handheld, to scan or enter a kit number and
         quantity of kits needed. System checks inventory for on-hand quantities of parts
         needed and displays number of kits that can be built from available inventory.


Take Sample Parts
     •   Tracks parts taken from inventory for customer samples, engineering prototypes, as
         obsolete, etc. Using a portable handheld, a “reason code” is scanned, along with the
         part number, quantity, and bin location. The system updates inventory and provides
         a report with summaries for each category.



ATS MANUFACTURING/FINISHED GOODS INVENTORY
LABELING FUNCTIONS

Product Labeling
     •   Automated labeling feature prints product labels on-demand for work order items
         being packaged. User simply scans work order and all relevant information is sent
         to printer. User may specify which printer to output labels (convenient when more
         than one printer is used).
     •   Product labels are customizable and can include company logo and/or specific
         graphics using economical blank label stock.
     •   Transfers items packaged from WIP to finished goods.
     •   Automatically generates summary pallet label for both single item pallets and mixed
         item pallets.
     •   User can enter serial number ranges or individual serial number of products
         packaged. User can delete or add serial numbers to a previously entered range.
         Serial numbers are useful to track products returned for repair or for ISO 9000
         product and component part tracking requirements.


Receive Finished Goods to Warehouse
     •   Function transfers goods from manufacturing (WIP) to receiving location in
         warehouse (finished goods).
     •   Automatic lookup feature displays (on RF handheld) all staged orders on-hold
         waiting for received items.
     •   Provides ability to print list of staged orders picked short and on-hold in shipping
         area. Report lists orders and items short.




     ADVANCED TRACKING S Y S T E M                    BUSINESS BY DESIGN                        4
INVENTORY MAINTENANCE FUNCTIONS

Setup Inventory Function
     •   Setup Inventory is a special function used to enter the initial ATS inventory and
         automatically print bar coded labels as needed. This function allows users to scan
         bin locations, enter part numbers, PO numbers, and quantities for each part. Part
         labels are printed as needed and data is entered into the system. The data may be
         exported to the host accounting system to synchronize both systems.


Cycle Counting
     •   User can cycle count parts in all              •   System directs user to each bin
         departments/locations or one                       location, part number, and PO
         department/location.                               lot number (if tracked) in bin
                                                            location order.
     •   User can cycle count one part to
         quickly adjust a quantity or                   •   Verifies items and quantities are
         change a location.                                 correct/not correct.
     •   Allows definition of cycle count               •    User can terminate cycle count
         codes and frequency                                at any time and update system
                                                            with counts completed.
     •   Last cycle count date is kept for
         each item detail.


Physical Inventory
     •   User can start a directed count                •   Operator can add an item at a
         from any bin location. After first                 location to update system
         bin is scanned, system directs                     database.
         operator in bin location order to
         count each item.                               •   Several users can take physical
                                                            inventory at the same time.
     •   Allows multiple part numbers in
         a location.                                    •   Provides exception reports and
                                                            host update.
     •   Allows multiple bin locations for
         a part number.
     •   Verifies items, quantities, and
         locations are correct/not correct.




     ADVANCED TRACKING S Y S T E M                 BUSINESS BY DESIGN                         5
Relocate (move function)
     •   Moves raw materials or finished goods across stock room or warehouse.
     •   Between stock rooms or warehouses.
     •   Move to replenish dedicated locations, such as a pull slot.
     •   Move within warehouse to temporary storage location.
     •   From one picked order to another picked order. Useful when items are needed to fill
         a hot order.
     •   Unpick an order and return the item to a stocking location.
     •   Can be used for “cross docking” to move items from pallets of finished goods
         received to the warehouse to an order on-hold for the item.


Create Purchase Order Requisition
     •   Operator can build a purchase order requisition using a handheld by simply scanning
         parts to be ordered.
     •   System can look up last order quantity or user can enter quantity to be ordered.
     •   System automatically prints out PO requisitions sorted by vendor (if desired).


Print labels
     •   Bin location labels
     •   Raw material labels
     •   Manufactured part labels
     •   Kit Labels
     •   Finished goods product Labels.
     •   Pallet labels.
     •   UCC 128 SSCC pallet shipping labels.




     ADVANCED TRACKING S Y S T E M                   BUSINESS BY DESIGN                     6
Sample Raw Material Label:




                                                           Logo
                                                           preprint –if
                                                           desired




Sample Bin Label




                   Dept       Aisle   Bay         Shelf




     ADVANCED TRACKING S Y S T E M    BUSINESS BY DESIGN          7
  Portable RF Handheld Menu

  Handheld Menu for Manufacturer of Build to Order & Build to Stock
  Products


                    MAIN MENU                                     LOCATE MENU

               1-RECEIVE & LABEL
               2-LABEL, MFG. PART
               3-PUT-AWAY
               4-PICK WORK ORDER                              1-LOCATE PART
               5-PICK FINISHED GOODS                          2-PART- WHERE NEEDED
               6-BUILD KIT                  Locate Function   3-LOCATE SUSP. ORDER
Main Menu      7-RELOCATE
               8-LOCATE
               5-CREATE PURCH ORDER                           Enter Selection:
               0-CHANGE USER
               M-MORE SELECTIONS

               Enter Selection:


                     More Selections


                  MAIN MENU-CONT.

                1-CYCLE COUNT
                2-PHYSICAL INVENTORY
                3-TAKE SAMPLE PARTS
                4-SETUP INVENTORY              When user selects
                5-RELABEL PURCH PART           [M] "More selections"
                6-RELABEL MFG PART             (above main menu) this
                7-DATE AND TIME                menu is displayed

                Enter Selection:




            ADVANCED TRACKING S Y S T E M           BUSINESS BY DESIGN               8
System architecture

     The Advanced Tracking System was developed in Microsoft Access for
     Windows and can be operated on a local area network or as a stand-alone
     system. It is usually connected to a Novell or Windows NT network as well as
     an Intermec bar code data collection network, consisting of one or more wireless
     radio frequency (RF) gateways, and portable RF linked handheld units with
     built-in laser scanner. The ATS system receives input from several sources:
     your existing information system, directly from scanned or keyed input, and from
     the portable handheld units. The system provides information output to both the
     handheld units and work stations on the network and can export data to your
     existing information system.
     The system is tailored to your company’s needs. This outline provides a brief
     overview of some of the system’s many capabilities. Our programming staff is
     able to make custom modifications and interface the Advanced Tracking System
     to your existing system.




     ADVANCED TRACKING S Y S T E M             BUSINESS BY DESIGN                  9

				
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