Manufacturer/Distributors often overlook material synchronization and handling and focus on production processes and equipment. But, when internal material flows are not optimized, the lack of coordination between production and distribution requirements can often reduces the very efficiency of the production equipment. The automation of material tracing, tracking, disposition, storage, and handling systems used in industrial operations can significantly reduce costs, increase productivity, and create a safer, more ergonomic production environment when aligned with other enterprise systems.

    WISE Impacts Waste in Material Handling:

    • Right-Sized Inventory Levels
    • Reduce or Eliminate Delays
    • Eliminate Excess Motion of People
    • Reduce Excess Inventory Moves
    • Cut Unnecessary Worker Activities
    • Adjust Positioning of Inventory
    • Control Transportation of Goods
    • Minimize Transportation Costs
    • Eliminate Overproduction
    • Integrate Quality Checks at the Door
    • Reduce Defects and scrap Rates

    Contact Royal 4 For More Information

Manufacturer/Distributors Often Overlook Material Synchronization.

Some manufacturers don’t consider material handling, but the systems that trace, move, and handle material as it enters, passes through, and departs manufacturing processes, machinery, or fabrication areas can be a critical key to productivity improvements. Many of the same principles that are often applied to manufacturing and distribution can be applied to material movement. Elimination of waste is a key driver of productivity and WISE can have an impact on these elements.


Cycle Time

Like your manufacturing operations, your warehouse has a cycle time too. Calculation of the lapses in time between receipt of an order and delivery to the customer can give you insight as to where you stand competitively. If you can measure and reduce the order cycle time a lot of good things start to happen.

  • DII (Days in Inventory) Begins to go down which reduces carrying costs. Inventory turns go up, reducing obsolete products or materials.
  • WIP (Work in Process) level goes down freeing up cash or operations. Inventory standard cost trend down to reflect efficiencies in your supply chain. Square foot of inventory and WIP locations are reduced making more space available.
  • TCO (Total Cost of Ownership) of Enterprise Inventory and Material Handling systems (% of IT spend) is reduced
  • Cost of Goods Sold (COGS) goes down to reflect lower carrying costs and inventory handling expense

Flow of Materials

Improvement of the flow of materials and information is one way to accomplish all of these interrelated objectives. In materials handling, flow is facilitated by reducing the number of times that product is moved during the process of receiving, storing, picking and shipping. Flow of information is controlled in similar ways, by eliminating opportunities for error in the transmission of data supporting this activity. WISE has user defined location rules, package types, picking rules, shipment procedures, packaging techniques, and all other significant details regarding your operations. WISE then optimizes these tasks for you based on detailed algorithmic rule engines. These extensive WISE functions are available to improve operations by minimizing costs and increasing productivity. More importantly, we have direct customer references for many of the System Requirements specified herein, as well as organizations with similar numbers of users supported by the product.


The Perfect Order

Lean manufacturing professionals define perfection as the complete elimination of waste, so that every activity in the process creates value. In the lean supply chain and warehousing, perfection is identified with “the perfect order” meaning that it is delivered precisely on time (neither early nor late), that it is free of any damage or defect, and that it contains the correct materials that were expected in the end receipt of the order.

Imperfect orders result in unhappy customers, lower levels of productivity, higher costs, and missed opportunities for improvement. In extreme cases, the imperfect order can cause a disaster involving assembly line or distribution disruptions or shutdowns, or a lost customer. Perfect inventories are nearly as important as perfect orders, and neither can be accomplished without the other. In earlier times, shipping and receiving errors were considered to be inevitable. Current information technology enables the best warehouse operators to achieve a shipping accuracy rate above 99.9%. The pull system relies on a very high degree of reliability in parts storage and delivery of replacement parts. As an ever larger percentage of finished products are imported from overseas, effective distribution of replacement parts has become more critical than ever before.

WISE Supply Chain Management

Royal 4 Systems welcomes the opportunity to assist you in your initiative to automate the handling and storage of materials, supplies, assets, and other items in your warehouse and supply chain operations. The purpose of this proposal is to show how WISE can be applied throughout all core warehouse processes, transforming your warehouses from paper, spreadsheets, and older manual system to a contemporary electronic fully paperless environment.

  • Eliminate Waste

    Eliminate wastes that are prevalent in material handling. Many of the same principles that are often applied to manufacturing and manufacturing/distribution can be applied to material movement. Elimination of waste is a key driver of productivity.

  • Right-Sized Inventory Levels:

    By synchronization of materials across the internal supply chain ensures the right product/inventory is in the right place, at the right time, in the actual amount of inventory you need to have on hand.

  • Reduce or Eliminate Delays

    Waiting or Delays: Visibility to inventory status, potential bottlenecks and proper locations can proactively reduce or eliminate these issues.

  • Eliminate Excess Motion

    Excess Motion (of people): Directed activities by WISE scm and end-to-end material controls reduces excess inventory moves and unnecessary worker activities in material handling by being able to adjust the positioning of inventory to where it needs to be.

  • Minimize Transportation Costs

    Transportation (of Goods): Visibility to actual inventory, materials, supplies, and part consumption rates give insight on how to minimize transportation costs both into the facility and out to the supply chain.

  • Control Overproduction

    Overproduction: Support for pull based (Kanban style) production and real-time monitoring reduces over producing parts, or subassemblies when production limits are approached.

  • Prevent Overprocessing

    Over processing: Integrated quality checks at the facility door, ensures that materials, supplies, parts, etc are to specification before they enter the manufacturing, or fabrication, value chain.

  • Contain Defects

    Defects: Integrated quality and containment reduces scrap rates, rework, human error, equipment related quality defects