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Labor Challenges in Warehousing and How Automation Solves Them

Labor Challenges in Warehousing and How Automation Solves Them

The warehousing and distribution industry is at a crossroads. Customer expectations for faster, more accurate order fulfillment are rising, yet many organizations face significant labor challenges that threaten productivity, accuracy, and profitability. From labor shortages to rising costs, the pressure on warehouse operations has never been greater. Fortunately, automation offers a proven path forward. Automation not only addresses today’s workforce issues but also positions warehouses for sustainable growth.

The Labor Problem in Warehousing

Warehousing has long relied heavily on people power. Picking, packing, shipping, and inventory control are labor-intensive tasks that require large workforces. But the industry is running into critical obstacles:

1. Workforce Shortages

The demand for warehouse workers far outpaces supply. According to industry reports, turnover rates in warehousing can reach 40 percent or more. Recruiting and retaining skilled labor is becoming increasingly difficult, particularly as e-commerce continues to expand.

2. Rising Labor Costs

As demand grows, wages are rising. Add in overtime, training, and high turnover, and labor becomes one of the largest cost centers in any distribution operation.

3. High Turnover and Training Demands

Warehousing is physically demanding, with long shifts and repetitive tasks that can lead to burnout. Training new workers is costly and time-consuming, often pulling resources away from day-to-day operations.

4. Operational Inefficiencies

Even with a strong workforce, labor-based processes create inefficiencies. Studies show that warehouse pickers spend up to 60 percent of their time simply walking between aisles, which adds no value to the business.

How Automation Solves Labor Challenges

While labor challenges are real and growing, automation is helping warehouses overcome these barriers. By implementing intelligent systems and material handling automation, companies can reduce dependence on manual labor, streamline operations, and create a more resilient supply chain.

1. Reducing Labor Dependence

Automated solutions such as robotic picking, conveyor systems, and goods-to-person technology eliminate the need for workers to walk miles each day to pick orders. Instead, automation brings the goods directly to the worker or, in some cases, removes the worker from the process entirely. This reduces reliance on large labor pools and allows companies to do more with fewer people.

2. Lowering Costs

By minimizing manual tasks, automation significantly cuts labor expenses. For example, automated picking and packing systems can process orders faster and more accurately than human workers, reducing the need for overtime and temporary staff during peak seasons.

3. Increasing Productivity

Automation not only fills labor gaps but also boosts overall output. Robots and automated systems can run around the clock without fatigue, ensuring steady throughput and faster order fulfillment. This directly translates into greater customer satisfaction and competitive advantage.

4. Improving Worker Retention

By taking on repetitive, physically demanding, or unsafe tasks, automation improves working conditions for warehouse staff. Employees can focus on higher-value responsibilities such as quality control, equipment oversight, or customer service support, leading to more meaningful work and higher retention.

5. Scalability for Growth

Labor availability can limit a company’s ability to scale. Automation provides flexibility and scalability, allowing warehouses to handle higher volumes without scrambling to hire seasonal or temporary labor. This is especially valuable in industries with seasonal spikes like retail or consumer goods.

Real-World Results

At Ascent Warehouse Logistics, we have seen firsthand how automation transforms operations. Our clients have reduced labor costs, improved picking accuracy, and boosted throughput without needing to dramatically increase headcount. By combining warehouse management software (WMS) with advanced material handling systems, we help businesses overcome the labor gap while delivering exceptional ROI.

The Path Forward with AscentWL

Labor challenges in warehousing are not going away anytime soon. In fact, as e-commerce demand continues to grow, these challenges may intensify. The good news is that automation offers a powerful solution that reduces costs, increases accuracy, and creates more resilient operations.
At AscentWL, we design, develop, and implement automation strategies tailored to each client’s unique environment. From software-driven insights to fully integrated warehouse systems, we provide the tools that help businesses not just keep up, but lead the way. Ready to solve your labor challenges with automation? Contact AscentWL today to learn more.

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Blog Warehouse Management System

Why Data Matters: Using Analytics to Optimize Warehouse Operations

Why Data Matters: Using Analytics to Optimize Warehouse Operations

In today’s fast-paced supply chain environment, efficiency is no longer just about moving goods quickly. It is about making smart, data-driven decisions that optimize every aspect of warehouse operations. From inventory control to order fulfillment, analytics provides the visibility and insights warehouses need to reduce costs, improve accuracy, and stay competitive. At Ascent Warehouse Logistics, we believe data is not just information, it is the foundation for smarter warehousing.

The Growing Importance of Warehouse Data

Modern warehouses generate enormous amounts of data every day. Every order, every scan, and every shipment adds to a digital trail that can reveal valuable insights about performance. Unfortunately, too many organizations fail to leverage this information effectively.

Without analytics, decision-making often relies on guesswork or outdated methods. Managers may not know where bottlenecks occur, how much labor is truly needed, or whether inventory is aligned with customer demand. This lack of visibility leads to wasted time, higher costs, and missed opportunities.

Key Areas Where Analytics Delivers Value

Analytics helps warehouses move beyond reactive problem-solving and toward proactive, strategic decision-making. Here are some of the most impactful areas where data makes a difference:

Inventory Accuracy

Accurate inventory is the backbone of warehouse operations. With analytics, businesses can track inventory levels in real time, identify discrepancies quickly, and reduce costly stockouts or overstock situations. By analyzing demand patterns, warehouses can also optimize replenishment strategies, ensuring the right products are available when needed.

Labor Productivity

Labor is often the largest cost in a warehouse. Analytics provides visibility into how workers spend their time, helping managers pinpoint inefficiencies. For example, if reports show that pickers spend too much time traveling between aisles, managers can redesign layouts or adopt goods-to-person automation to reduce travel time. Data also helps forecast labor needs more accurately, reducing overtime and improving scheduling.

Order Fulfillment Performance

Speed and accuracy are critical for customer satisfaction. Analytics provides insights into picking accuracy, shipping times, and order cycle times. By identifying trends and problem areas, warehouses can take corrective actions that improve fulfillment rates and reduce costly errors.

Space Utilization

Every square foot in a warehouse matters. Analytics tools highlight how space is being used and where improvements can be made. Whether it is reconfiguring racking systems or reorganizing inventory placement, data-driven space optimization improves storage availability and reduces congestion.

Operational Costs

Analytics tracks the true costs of operations, from labor to transportation to inventory carrying costs. By having a detailed view of expenses, managers can make smarter decisions about where to invest in automation, where to cut costs, and how to maximize ROI.

Turning Data into Action

Collecting data is only the first step. The real power lies in turning that data into actionable insights. This is where AscentWL’s expertise comes in. Our solutions integrate warehouse management software (WMS), warehouse execution systems (WES), and warehouse control systems (WCS) to provide a comprehensive view of performance.

We help businesses not just gather data, but understand it. Our reporting and analytics tools give managers real-time dashboards and detailed reports that highlight trends, pinpoint issues, and guide decision-making. Whether it is reallocating labor, redesigning workflows, or investing in automation, our clients use analytics to make smarter, faster, and more profitable decisions.

Building the Future of Warehousing

Warehouses that embrace analytics gain a competitive edge. Instead of reacting to problems after they occur, they proactively optimize operations and prepare for growth. Analytics provides clarity, reduces uncertainty, and ensures resources are being used in the most effective way possible.

At Ascent Warehouse Logistics, we design solutions that put data to work for your business. By combining advanced software platforms with proven operational expertise, we help you transform raw information into measurable results.

How AscentWL Turns Data into Results

In an industry where margins are tight and customer expectations are high, data is one of the most valuable assets a warehouse can have. Analytics empowers leaders to cut costs, improve accuracy, and enhance efficiency in every part of the operation.
Ready to put your data to work? Contact AscentWL to learn how we can help you leverage analytics to optimize warehouse operations and achieve exceptional ROI.

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Blog Warehouse Management System

5 Signs It’s Time to Upgrade Your Warehouse Management System

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5 Signs It’s Time to Upgrade Your Warehouse Management System

A warehouse management system (WMS) is the foundation of efficient distribution and manufacturing operations. It directs inventory, guides workflows, and ensures products move smoothly from receiving to shipping. However, not all WMS platforms are created equal, and even the best systems eventually reach a point where they no longer meet the demands of a growing business.

At Ascent Warehouse Logistics, we have seen how the right WMS can transform accuracy, labor efficiency, and throughput. We have also seen the challenges companies face when they try to push outdated systems beyond their limits. Here are five clear signs that it may be time for your organization to consider an upgrade.

5 Warning Signs Your WMS Can No Longer Keep Up

1. Inventory Accuracy is Slipping

If your inventory accuracy consistently falls below 99.5 percent, it is a red flag that your WMS is not keeping pace with operational demands. Inaccurate inventory leads to missed shipments, delayed orders, and costly rework. Modern WMS platforms track inventory by location in real time and manage replenishments across multiple location types such as pick faces, overstock, and dynamic locations. The result is stronger visibility, higher customer satisfaction, and reduced carrying costs.

2. Labor Costs Are Rising Faster Than Revenue

Warehousing is labor-intensive, and labor costs continue to increase with mandated wage hikes and rising healthcare expenses. If your labor costs are growing disproportionately to revenue and order volume, it is time to evaluate whether your WMS is directing work efficiently. A modern system can guide operators through optimized picking paths, integrate with automation, and reduce wasted movement. These capabilities can cut labor costs by 25 to 50 percent without sacrificing accuracy or throughput.

3. Customer Expectations Are Outpacing Your Capabilities

Today’s customers expect speed, flexibility, and precision. If your warehouse struggles to keep up with e-commerce order profiles, omnichannel fulfillment, or just-in-time delivery, your WMS may be holding you back. Modern platforms support order profiling, batch and cluster picking, zone picking, and seamless integration with automation technologies such as voice picking, pick to light, carousels, and autonomous mobile robots. These capabilities are critical for meeting modern fulfillment requirements without overburdening staff.

4. Integration with Enterprise Systems Is Limited

A WMS must integrate seamlessly with ERP, order management, and other enterprise systems. If your current platform creates isolated silos of data, requires manual workarounds, or struggles to interface with automation hardware, the inefficiencies will compound over time. Best-of-breed WMS solutions not only integrate with ERP but also provide warehouse control and execution capabilities in a single system, eliminating the need for multiple vendors and layers of software.

5. Expansion Feels Risky or Unattainable

If launching a new product line or opening a new distribution center feels overwhelming because of system limitations, your WMS is no longer serving as a growth enabler. A modern WMS should give you the confidence to expand with scalability built in. Whether you are adding users, zones, or new workflows, the right system scales with your business and allows you to deploy new operations quickly and effectively.

Strengthening Your Future with Ascent

Recognizing these signs is the first step toward building a stronger warehouse operation. Upgrading to a modern WMS is not just about fixing problems. It is about unlocking opportunities for growth, reducing business risk, and ensuring you are prepared for the demands of tomorrow’s supply chain.

At Ascent Warehouse Logistics, we deliver WMS solutions that improve accuracy, optimize labor, and integrate with advanced automation. Our proven track record of successful implementations provides the confidence that your investment will deliver measurable results.
If you see any of these five signs in your warehouse, it may be time to evaluate your next step. Contact AscentWL to learn how our solutions can help you achieve higher accuracy, lower costs, and a stronger competitive position.

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Blog Warehouse Management System

The Essential Guide to ERP vs WMS for Modern Warehouses

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The Essential Guide to ERP vs WMS for Modern Warehouses

In today’s fast-moving supply chain world, software is the backbone of efficiency. Two of the most widely used systems are Enterprise Resource Planning (ERP) and Warehouse Management Systems (WMS). While the acronyms are familiar, the differences between these platforms are often misunderstood. Many businesses mistakenly believe an ERP can fully manage warehouse operations, only to discover the limitations once accuracy issues, labor costs, or order delays start to pile up.

At Ascent Warehouse Logistics, we’ve seen firsthand how important it is to know the distinction between ERP and WMS solutions. Understanding where each one excels will help you decide which system best supports your business goals.

What is ERP?

Enterprise Resource Planning (ERP) systems are designed to integrate and streamline an organization’s core business processes. Think of ERP as the central nervous system for the enterprise. Common ERP modules include:

  • Finance and accounting
  • Human resources
  • Procurement
  • Customer relationship management (CRM)
  • Manufacturing planning

ERP systems provide visibility across the organization, helping leaders make better decisions and align business functions. They are powerful tools for managing the “big picture” of operations. However, when it comes to the granular, real-time needs of warehouse execution, ERP systems often fall short.

What is WMS?

A Warehouse Management System (WMS) is built specifically to optimize the day-to-day operations inside warehouses and distribution centers. Rather than focusing on high-level business processes, a WMS zooms in on inventory movement and order fulfillment. Core functions include:

  • Receiving and putaway
  • Inventory location management
  • Picking, replenishment, and packing
  • Shipping and manifesting
  • Real-time inventory accuracy

Where ERP systems tend to track data at a summary level, WMS systems are engineered to direct warehouse staff, automate workflows, and ensure that every product is in the right place at the right time. This operational focus drives measurable gains in productivity, accuracy, and cost control.

ERP vs. WMS: Key Differences

Although ERP and WMS platforms share the goal of improving efficiency and reducing costs, they approach the problem from different perspectives.

Functionality: ERP handles enterprise-wide processes, while WMS focuses on warehouse execution.

Complexity: ERP implementations are broad and often complex, requiring significant time and investment. WMS systems, on the other hand, are more specialized and user-friendly for warehouse teams.

Accuracy: A WMS can achieve 99.5%+ inventory and order accuracy, reducing costly errors that ERPs are not built to manage at the same level.

Labor Impact: By directing tasks and integrating with automation, WMS reduces reliance on manual entry and lowers labor costs by 25–50% in many cases.

Scalability: ERPs are excellent for enterprise growth, but WMS offers the operational scalability warehouses need when SKU counts, order volumes, or customer expectations increase.

Which One Do You Need?

The choice between ERP and WMS depends on your priorities:

  • If you need enterprise-wide visibility across finance, HR, and manufacturing, ERP is essential.
  • If your challenges center around fulfillment accuracy, warehouse productivity, and labor costs, a WMS is the right fit.
  • In many cases, the two systems work best together. ERP provides strategic oversight, while WMS delivers operational execution.

Why Choose a Best-of-Breed WMS

Many ERP vendors offer warehouse modules, but they often lack the depth of functionality required in complex distribution or manufacturing environments. A best-of-breed WMS, like the solutions provided by AscentWL, goes beyond basic inventory tracking. Our platform integrates seamlessly with ERP systems while delivering the real-time control and automation capabilities warehouses need to thrive.

With AscentWL, businesses gain:

  • Higher accuracy and throughput
  • Reduced labor costs and dwell time
  • Optimized use of space
  • Confidence to scale and expand operations

Ascent to Smarter Warehousing

ERPs and WMS platforms are not interchangeable. Each plays a distinct role in supporting modern supply chains. By understanding the difference, you can invest in the right system, or combination of systems, to improve both business visibility and warehouse execution.

At Ascent Warehouse Logistics, we design and implement warehouse automation software that delivers measurable results. From standalone WMS to integrated solutions with ERP, we help businesses achieve greater accuracy, productivity, and efficiency.
Is your warehouse ready to take the next step? Contact us today to explore how the right WMS can transform your operations.

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Warehouse Management System

Warehouse Integration and Automation Decisions

Warehouse Integration and Automation Decisions

Those tasked with preparing for the future of automation don’t have an easy path in front of them. Nevertheless, the innovation that developing robotic machines produce can be exciting. There are opportunities to grow and streamline many types of businesses. With streamlined control, disparate software challenges and maintenance hassles can fade away.

Selecting Vendors

One of the best decisions a material environment can make is choosing vendors with the proper knowledge and perspective. In selecting vendors, it is important to try to choose ones who have a proactive, big-picture view. The temptation is to choose vendors whose expertise is deep in one area. Expertise about one piece of machinery, or a line of machines, can feel extremely valuable. However, this is often a short-term solution that provides limited long-term value. Expertise with the controls of only one line of machines fails to assist much in a long-term strategy.

Vendors with Long-Term Foresight

Failing to choose vendors who hold an eagle-eye view of logistics, warehouses, and the drift toward automation and robotics has consequences. Without foresight, a COO can end up trying to reassess and renovate their software and machinery situation every few years. Expanding possibilities for robotic integration should be the priority.

Having a ten or fifteen-year perspective and level of proactivity saves effort. A long-term decision is to value and implement an agnostic software solution. A comprehensive WCS can ensure a business is not limited by past investments to old machinery and the associated software. Old software that is unlinked will hold back the possibilities for streamlining and automation. Warehouse operations, distribution centers, and large corporations with warehouses that plan for the future will reap the benefits.

Selecting Groups Who Understand Business Strategy and Technology

In business, having great vision and a clear direction are invaluable skills. Warehousing and logistics are no different. On a large and small scale, focusing on growth and optimization is invaluable. When each item, package, or pallet flows toward its ultimate destination sooner, the streams of small actions add up.

To help create a current of efficiency, vendors who speak the languages of logistics, technology and business make the best partners. When a vendor understands overall operations, the need to constantly explain dissipates. Operators won’t need to brainstorm workarounds resulting from vendors’ lack of understanding. Cobbling together solutions isn’t necessary. Solutions providers who think long-term and are already acquainted with your pain points help operators develop and execute a strategy for proactive, long-term success with fewer adjustments.

Selecting Appropriate Machinery

Choose machinery with the future in mind. For each specific task, the appropriate, best-fit machine makes a world of difference. If an AS/RS serves the objectives better, settling for three carousels is not worthwhile. Creating a future-focused plan hospitable to robotics, and prioritizing machinery that fits within that plan, can pay off.

The Utility of Robotics

One area where robotic solutions are advancing rapidly is for clearly defined tasks. Having robots complete simple, discrete tasks can be wise. The machines ceding tasks to robotic machines at present are conveyors. While conveyors bolted to the floor provide limited movement of goods, agile robots will prove useful for movement-based tasks. It is easy to imagine that by using sensors, they become capable of more efficient movement. By multiplying this agility beyond the limited movement of conveyors, much more efficiency becomes possible.

Robotics OEM Software

Robotics machines are usually packaged with OEM software. This OEM-supply WCS is limited in many cases. Integrating them into a broad software solution in warehouses on a wider scale can be challenging, yet may produce  quality results.

AMR Robots

Autonomous mobile robots (AMRs) used for transportation have proven to be a great addition to an overall solution for warehouses. They can work with automated storage devices. However, they’re not capable of interfacing to the certain carousels. Two separate WCSs create unneeded steps and clutter in terms of the volume of software needed. The need to manage and maintain that software piles on extra layers of complexity.

The Evolution of Robotics and WCS

As robotics progress beyond AMRs to those capable of more complex tasks, using one comprehensive warehouse control system software will become increasingly important. Presently, robots completing discrete actions or traveling between points don’t need to communicate with other machines often. As the possibilities for robotics develop, an OEM WCS’s limits would become apparent. For example, the possibility of gamifying the warehouse with augmented reality could make warehouse operations more efficient. The control system from a robotics or carousel manufacturer can’t be expected to control the interface to the user. An agnostic, high-level WCS would shine in managing more developed robotics, along with more classic machines like carousels.

OEM WCS Database Concerns

The prohibitive nature of OEM warehouse control systems not having a robust database is a concern. That is especially the case when trying to plan a road map for warehousing or distribution. Typically, the limited database of OEM software will slow down the progression toward the business’s goals in the future. Avoiding decisions or maintenance of systems that will not scale with discrete should be a priority. In fact, by not controlling the machines from a high, informed level and letting them work together, the business is not maximizing its investment in the machines. Nor is software providing a good return on the investment. By controlling through a higher level, more informed warehouse control system software, unprecedented cohesion becomes possible.

A Proactive Modular WCS Software Roadmap

Taking a bird’s eye, long-term view for ten years is key to making the correct decisions for warehouse control system software. Synchronizing the road map between vendors and other partners will help the business advance toward its goals. Crafting an automation roadmap with scalable software that is financially modular is the best option. A comprehensive WCS designed to be modular and priced according to the currently needed modules can make the difference. As needs change, scaling up within the next month should be possible. Growing with modules of software is easier than adapting to new software packages.

Warehouse Control System Software for the Future

The future of robotic integration into the material-handling world is exciting. With foresight and a well-formulated strategy for software and machinery cohesion, efficiency can soar. High-level warehouse control system software can propel businesses further. Businesses relying on many separate WCSs that came with the machinery will need to keep maintaining them. They’ll need to keep dealing with their limitations and the inefficiency of a disjointed web of disparate software. Meanwhile, those using a streamlined WCS solution will do more with less software. They can push warehouse operations further, faster.

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WMS WCS Integrations

Consider Long-Term Business Objectives and Trends When Implementing A WMS Or WCS

Why it’s critical to consider long-term business objectives and trends when implementing a WMS or WCS

It is a mistake to build a WMS or WCS based solely on current product mixes and order velocities. Instead, be sure to consider long-term objectives, as well as industry trends. Heed this cautionary tale: In the past, many distribution centers built their systems to exclusively convey cases.

Now, they are struggling with ‘eaches’ due to e-commerce shifts. Ultimately, the best WMS/WCS design is one that allows the business to adapt to changes and variability within supply chains.

How do WMS/WCS solve for inventory management on a job or project basis?

Inventory management on a project basis is a matter of inventory ownership. Even if most inventory is tied to a specific job or a specific project, there is almost always some inventory that is used in common. This common stock is usually low-valued items such as nuts, bolts, and washers. Even so, it needs to be included in the conversation about integrating a WMS or WCS with an ERP.

What is a typical timeline for an integration to a WMS?

Timelines for WMS integration projects vary. A good ballpark estimate is two to three months from the start of the project cycle to being able to test the integration in a test environment. Three elements are required to begin the project cycle: an understanding of the various roles of the systems being integrated, defined touch points, and defined functionality. Once those three elements are place, it is possible to define the error conditions and how to automatically recover from them. All of this is part of the design effort. Ultimately, the design needs to be put into a test environment, so that the error conditions can be tested to make sure both sides recover. Testing like that takes additional time, but it is worth it in the long run.

Where can we find information about specific WMS/WCS integrations to VLMs or other hardware?

For more information about specific WMS/WCS integrations to VLMs or other hardware, reach out to the hardware manufacturer. Every manufacturer has their own interface, message formats, and other details specific to that interface. Talk to the manufacturer to ensure your integration proceeds as effectively and efficiently as possible.

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WMS WCS Integrations

How to Succeed Integrating A WMS Or WCS With An ERP

How to Succeed Integrating A WMS Or WCS With An ERP

Successful integration of a WMS or WCS with an ERP requires knowledge of the process flow and data flow within the operation. Then, it is necessary to identify and understand where the pain points occur. Every warehouse or distribution center has unique challenges. For example, some customize their ERPs to control allocation of inventory.

They might prefer to spread inventory across multiple orders, portioning some to every customer instead of applying an entire shortage to one account. For an ERP to dictate inventory allocation like this it must be integrated with a WMS/WCS so that the information can be shared efficiently and effectively. The ERP needs to tell the Warehouse Management System (WMS)/ Warehouse Control System (WCS) what lot to allocate and pick and pack, and not only the quantity ordered, but also the distribution of that quantity across all of the orders. Understanding the unique role of each component—the ERP, WMS, and WCS—is vital. For instance, if an ERP is the system of record, the integrity of that system must be maintained.

What are the functional requirements that need to be defined with an ERP?

When integrating a Warehouse Management System (WMS) with an ERP, the functional requirements that need to be defined include any touch points between the two systems. These typically include the part master, receipts, orders, and uploads (put-away, pick/pack/ship, adjustments). Note: It is essential to identify the touch points in both directions—from the WMS upstream to the ERP, and from the WMS going downstream to the WMC or other peripherals. For example, if an ERP is the system of record for part number information, no downstream systems should be permitted to edit or create new part numbers. This is a best practice and ensures that the part number and part profile information are maintained in one system, the ERP.

In most cases, an ERP is also the system of record for procurement and order management and order entry. This receipt information is another touch point from ERP to a WMS or WCS. It is “inbound information” about inventory coming into the facility. There is also “outbound information,” which includes sales orders, production orders, and transfer orders, that require the system in a distribution center to pick the inventory and pack/ship it, or in a manufacturing facility, pick the inventory out of the stockroom and deliver it to assembly or the manufacturing floor.

Another important functional requirement to consider is inventory adjustment and deciding which system is the system of record for inventory is key. Some ERP systems can instruct a WMS or WCS to decrement inventory; however, it is more common for the WMS and WCS to be the system of record of where inventory is stored. The ERP system has the aggregate quantity on hand, but the WMS/WCS tracks the inventory at discrete locations and is best-suited for cycle counting, inventory counting, or physical counts.

What are the mechanics of integrating a WMS with ERP?

The basic mechanics of integrating a WMS with an ERP usually include staging tables, webservice, flat files, and other specific methods of integration depending on the ERP (e.g., RFC in SAP or message queues in other systems).

The term “staging tables” refers to database tables that are shared between an ERP and a WMS or WCS. These tables are either in the ERP database or the WMS or WCS database. They are called staging tables because they are not internal tables that the systems would use to process their own business logic and perform their own functions. Imagine a wall between these staging tables and the rest of the respective system. This imaginary wall, which is actually a gatekeeper requiring validation, ensures that a WMS cannot, for instance, directly update data in an ERP table. Likewise, an ERP cannot directly update data in a WMS table. Instead, all updates require a set of staging tables to protect both sides.

Integrating a WMS with an ERP often also requires webservices and flat files. The webservices needed are real-time and implementing them requires a special IT skill set. The flat file data can be in XML format so that it can easily be used in EBI transactions. Having lower-level systems that can create flat files in XML format can be a significant time-saver.

All of these methods of integration depend on the particular ERP being used. For example, most ERPs use remote function calls (RFC) for messaging, but others have their own unique message cues that must be adopted. Even so, the communication piece of integrating a WMS is fairly straightforward. The goal is that once a messages is sent by one system, the other system responds within the timeframe expected and all functions run according to spec.

Of course, not everything runs according to plan 100% of the time. This is especially true in distribution and manufacturing environments where tasks and processes are fast paced with many dependencies. Often, when one process doesn’t work perfectly, there is a domino effect. That is why, as part of the design phase of an integration, it is crucial to consider what could go wrong. In fact, working on error detection and recovery is a key part to any integration effort and usually, more time is spent designing the what-if scenarios than the actual touch points. This time and effort are worthwhile in the long run. Being able to detect and recover from errors in any integration can make the difference between a successful project with happy users and one where the users don’t want to even talk about their experience.

Integrating a WCS to an ERP or WMS

A WCS is a warehouse control system, and it can be integrated to an ERP, a WMS, or directly to material handling equipment, such as a VLM, a carousel, or an ASRS. There are some WCS systems that use a standard application programmable interface (API). These systems offer little flexibility in terms of integration and are not as complex as an interface to an ERP might be. In most cases, the WCS integration can be done with direct device control. That means, instead of communicating at a high level to another application, the integration can occur directly to material handling equipment. But since every equipment manufacturer has their own proprietary interface, it is critical to work with the equipment manufacturer to ensure understanding of the entire architecture.

Often the WCS is integrated to control inventory within these devices. For instance, in a vertical carousel, a WCS could manage each bin location, keeping track of what and how many is stored in each of those locations. An ERP is not well-suited for this type of inventory management. A WCS, by contrast, can communicate to the device so that the needed items are brought to the operator, but the WCS can only manage the inventory within that device.

What about inventory that isn’t stored in a device managed by a WCS? This is where the integration between a WCS or WMS and ERP comes into play. Without integration, a WCS or WMS could be managing movement of inventory in certain locations, while the ERP is managing aggregate inventory, without any knowledge of where that inventory exists in real-time. Integration solves that problem by ensuring all of these components work together to optimize workflows and processes.

What Additional Factors May Come into Play When Integrating A WMS Or WCS?

When integrating a WMS or WCS, it is also important to consider additional factors such as replenishment, slotting, and shelf life. In most cases, the replenishment transaction originates within ERP, and then the information is sent from ERP to the WCS. That way, the WCS learns that the inventory is coming and can find the right location to store it. Slotting involves using the WCS or WMS to determine optimal locations to store inventory. The main elements that factor into slotting are capacity, velocity, and dimension. Capacity refers to the number of items that need to be stored. Velocity refers to how long the item is expected to stay in storage. (Items that are picked and shipped quickly should be stored in the most easily-accessible location.) Dimension refers to the dimension of the item being stored, as well as the dimension of the location that’s available to store that item. Shelf life and whether FIFO is a requirement can also factor impact WMS/WCS integrations.

Integrating a WMS or WCS with peripherals

Peripherals are pieces of hardware that are used in the process flow of a distribution center or warehouse. Examples of peripherals include print-and-apply machines, barcode printers, weigh scales, X-ray machines, and devices used for reeled inventory in SMT shops. Each one of these peripherals generally has its own interface. So before integrating a WMS or WCS, it is essential to contact the OEM manufacturer or at least refer to the interface manual to ensure that the proper integration steps are followed. These devices use either a serial connection, an RF232, or a network connection. In today’s warehouse environments, most peripherals are networked; however, there are still some devices that only support serial connections. That is why it is important to know which interface is available and to order the proper equipment and associated kits to support that interface.

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WMS WCS Integrations

What Are the Main Considerations for Implementing A WMS?

What Are the Main Considerations for Implementing A WMS?

Before implementing a WMS, it is critical to consider a few key factors. Most notably, a WMS must be thoughtfully integrated with existing external systems, any WCS already in place, and all other relevant peripheral systems.

What does the word “integration” mean in the warehouse and distribution center environment?

In the warehouse and distribution center environment, the word “integration” refers to communication between systems. Those systems could be software systems, hardware controls, or any other type of peripheral. When integrated successfully, these systems are able to work together using a well-defined language that consists of a specific set of questions and answers. Integrations provide a variety of business benefits. They allow applications from different suppliers to be combined to create the most effective implementation.

What systems do WMS and WCS integrate with and what is the role of each?

WMSs and WCSs can integrate with upstream and downstream external business systems. Most commonly, the external business system they integrate with is an upstream enterprise resource planning (ERP) system; however, in manufacturing environments, there may also be integrations with downstream external systems, such as material requirements planning (MRP) systems, shipping systems, or transportation management systems (TMS).

Generally speaking, an ERP is designed to manage processes across the entire business. It is the system of record for a wide range of processes, including financials, forecasting, procurement, order management, production planning, and resource management. Although highly effective for managing those processes, ERPs are usually not optimal for real-time workflow optimization within a distribution center or stockroom.

A warehouse management system (WMS) is a specialized application used to manage all of the inventory activity within a distribution center or manufacturing facility. Typically, a WMS interfaces with an ERP system, using information from the ERP to manage workflow and optimize processes. It tracks inventory, regardless of where that inventory is stored. For example, a warehouse might have inventory stored in carousels, VLMs, flow racks, and other shelving locations. A WMS can manage inventory in all of these areas and provide a fluent, fluid, and seamless transaction going from one to another. A WMS can also interface downstream, integrating with other systems, such as a TMS.

WCS stands for warehouse control system. Unlike a WMS, a WCS cannot manage all storage areas within a distribution center or manufacturing facility. Instead, it can only manage automation. This automation can take many forms, ranging from routing cartons or totes on a conveyor system to material handling equipment, such automated storage retrieval systems (ASRS), vertical carousels, or vertical lift modules (VLMs). A WCS integrates with, communicates with, and controls these various automated material handling components within the overall solution. Any inventory in non-automated storage areas needs to be managed by an independent and separate WMS or ERP.

A WMS/WCS is typically more agile than an ERP. That is because a WMS/WCS has more tools and business logic available to manage and optimize workflows within a distribution center or stockroom. As a result, they are able to make localized improvements with far-reaching benefits for inventory control, customer service, assembly, QA, etc. Generally speaking, a WMS/WCS is also easier to change for adaptation to fluctuating business conditions.

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WMS WCS Integrations

What Are the Current Trends Impacting Supply Chains and Warehouse And Distribution Space?

Current Trends Impacting Supply Chains and Warehouse And Distribution Space

There are three significant trends currently impacting supply chains and warehouse and distribution space. These trends are: the shortage of warehouse and distribution space, labor availability, and accelerating e-commerce growth.

The shortage of warehouse and distribution space

Consumers are increasingly turning to online shopping and research suggests by 2025, an additional 1 billion square feet of warehouse and distribution space will be needed to keep up with this growing demand. But shoppers cannot wait for the build out of infrastructure; they want their orders fulfilled today. That is why more and more distribution center managers and supply chain leaders are working to maximize space in their current facilities. They are reconfiguring layouts to maximize vertical space and increase storage density while also implementing goods-to-person technologies including robotics, autonomous mobile robots (AMRs), and automated storage retrieval systems (ASRS).

Labor availability

The pandemic, competition from Amazon, and changing workforce expectations are all effecting labor availability. As a result, distribution center management and supply chain executives are seeking labor-saving solutions such as automation. In addition, they want to shorten the training time required to get their labor to productive rates sooner.

Accelerating e-commerce growth

Before the pandemic, e-commerce was growing steadily, but somewhat modestly. Then, in May 2020, e-commerce spending skyrocketed $82.5 billion—an increase of 77%. That expansion has continued and now nearly equals what was projected for the next four to six years’ growth combined. This unprecedented growth, coupled with the shortages in warehouse/distribution space and labor, is creating extraordinary challenges for supply chain leadership. Many are considering implementing a warehouse management system (WMS) and/or a warehouse control system (WCS) to meet these challenges.

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Warehouse Management System

What Is The Difference Between WMS, WCS, And WES?

What Is the Difference Between Warehouse Management System (WMS). Warehouse Control System (WCS), and Warehouse Execution System (WES)

A true Warehouse Management System (WMS), when it’s not a bolt-on module, is the foundation for inventory management within a warehouse. It controls all inventory operations, including tracking, expiration date tracking, and numerous other details that an ERP would be hard pressed to keep track of with large scale inventories of 100,000—200,000 items.

A warehouse control system (WCS) is a software package that not only manages some forms of WMS functionality, but also controls automation equipment within that same environment. In other words, a WCS controls, directs, and manages vertical carousels, vertical lift modules (VLMs), horizontal carousels, conveyor systems, sortation systems, autonomous guided vehicles (AGV), automated storage and retrieval systems (ASRS), goods to person (G2P), pick by light, put by light (i.e., put wall), hands free picking, robotic picking, and more.

A WCS interfacing with all these different technologies can sound quite complicated, but the level of complexity depends on the type of automation equipment under control and the capabilities the WCS. In fact, for most horizontal carousels, vertical carousels, and vertical lift modules (VLM), the WCS can be relatively straightforward. Other technological solutions, such as those involving robots, AGVs, and MDR conveyor systems, typically introduce more complexity.

A warehouse execution system (WES) is analogous to a task manager; it will execute on a specific task, but it can do tasks from the WMS and it can do tasks from the WCS. Some call it a “WMS lite.” A WES has some, but not have all, of the capabilities of a WMS.

Our WCS software capabilities interface directly with the underlying PLC-based controls so an extra OEM software system or integration point to communicate to automation PLCs is not required. This eliminates an entire layer of software complexity across a warehouse operation. A WCS can be considered the brains or the intelligence of the automation as opposed to the direct control of equipment. The underlying PLC machine controls execute the decisions dictated by the WCS or WES.

What type of operator training is required for WMS with WCS?

Operators do not need training on the software programs for the automation included in the WCS. From the user perspective, all WCS functioning happens in the background. Maintenance personnel will need to know how to service and maintain the different automated systems, but warehouse operators will only see the end result—e.g., that the carousel has spun and that the light bar is indicating the product that needs to be picked.