Zebra® Material FlowReplenishment 3.0

A New Standard in Lean Manufacturing

Zebra’s world class replenishment execution system is taking lean to a new level with its new Material Flow Replenishment 3.0 system. Zebra’s new Material Flow 3.0 is a robust web-based solution packed with new features to help you optimize your entire replenishment process. Designed to support and automate lean replenishment techniques, Material Flow Replenishment still provides the same superior functionality that eliminates the need for manual and labor intensive processes by delivering real-time data from the factory floor to internal and external supply to help you quickly respond to changes in inventory, production status and customer requests. In addition, manufacturing operations can centrally manage and control supplier collaboration, internal supply and facility-wide communication across multiple facilities or within a single location.

Beyond the core functionality of Material Flow, the new 3.0 version offers more replenishment trigger methods and new and improved reporting and communication tools.

• NEW Broadcast triggers: Using input from other systems and hardware, customers can call parts automatically without human initiation. Replenishment calls can be made based on usage derived from the BOM and the assembly’s position on the line.

• NEW Dual trigger (button) electronic Kanban: This model allows full visibility and control of the Kanban loop. One trigger is used on the consumption end acting as a replenishment trigger as well as a Kanban. Another trigger at the Manufacturing end adds full Kanbans back to the loop upon manufacture.

• Part pick and delivery scanning for verification and lot number capture: Our traceability originally designed for a Windows Mobile handheld scanner extends to the MRT as well, allowing material handlers with an MRT and a wedge scanner to scan part numbers to verify the pick and delivery process as well as capture vendor and lot information from a barcode.

• NEW “Smart Scanning” eliminates verification problems for vendor label format inconsistencies: Extraneous spaces, dashes or other defined characters can be ignored so that only the part number characters are validated. When vendor labels are cleaned up, smart scanning can be turned off again for exact part number matching.

• NEW Scheduled Calls allow for repetitive calls or tasks to be triggered on a schedule: Whether it is a part call or a task for a Material Handler, if it absolutely happens on a set schedule, users can program the event based on calendar date and time.

• NEW Goods Return Process: It sends multiple “Reverse” part calls when parts need to be removed from the line and taken back to their storage locations.

• NEW Button Changeover process: Allows Wherecall buttons to be quickly reassigned to alternate part routes adding flexibility to the line.

New Material Flow 3.0 Features and Functionality

Multiple Replenishment Trigger Methods

Material Flow 3.0 offers more ways to signal material moves. Wherecall button and barcode scan inputs from Windows Mobile handheld or wedge scanner devices.

Improved Handheld Functionality

• Update specific part information on each rack with a Windows Mobile handheld device when the rack is filled, partially filled or emptied. Also locate each rack utilizing VSS and our locate tags.

• Better control of delivery process through scanning: Traceability comes to Material flow with the ability to record Vendor and Lot numbers on Material Pick or delivery, as well as Part number verification through barcode scanning.

• Messaging on Handheld: Manufacturing messages can now be received and answered on a handheld device.

• Expanded tools for part route configuration and button setup: Button verification and reassignment can now be handled on the floor on-the-fly. No need to copy button and part numbers down and return to a terminal. It can all be done with the handheld application in real time.

• Exception Handling: Exceptions to standard deliveries can now be managed via the handheld interface as well as in the main application.

New and Improved Communication Tools

• Administrator defined “Floor” Messages: Material Handlers can now initiate pre-defined communication back upstream to team leaders or managers.

• Improved Quick messaging and Ad Hoc messaging with voting button responses: Allow team leaders and managers to get documented answers from their workforce without relying on radio traffic.

Enhanced Reporting

• New Deliveries reporting tool makes it easier to get the valuable data that the Flow system generates: It builds in industry experience while still allowing custom flexibility.

“This ‘intelligent’ automated system supports our lean manufacturing processes as we benefi t from real-time inventory consumption and can execute replenishment orders just in time.”

Ralf Vierkotten, Supervisor of Logistics and Material Handling, GETRAG Ford Transmissions

GSA#: GS-35F-0268N

P1041209 (5/11)

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Maximize the Value of ERP Software Investments

The Material Flow solution enhances ERP systems by leveraging their master data repository. The solution returns real-time execution level information back into the ERP system to improve their error proofing capabilities and data accuracy. In addition, Material Flow streamlines the ERP’s demand-driven pull replenishment processes by reducing multiple steps into a single transaction, from start to finish. The solution provides real-time execution information that focuses on delivering the product from external supplier or internal storage to the point-of-use line side with actionable and easy-to-use instructions for plant floor associates.

Reduce Inventory and Increase Floor Space

Material Flow Replenishment automates the inventory replenishment process and reduces inventory holding costs by enabling line-side operators to trigger material requests from their workstation either by pressing the wireless WhereCall RFID button, scanning a barcode or by integrating with a third party system. In turn, material requests are delivered in an optimized priority allowing the requests to be processed rapidly and efficiently, thereby reducing lag time and line stoppages. This allows customers to maintain lower inventory levels at line-side and in remote storage locations.

NEW Report Delivery Tool

This new reporting tool allows users to easily customize and share their own report based on any material delivery business data.

Communication Module

• Administrator defined “Floor” Messages: Material Handlers can now initiate pre-defined communication back upstream to team leaders or managers.

• Improved Quick messaging and Ad Hoc messaging with voting button responses: Allow team leaders and managers to get documented answers from their workforce without relying on radio traffic.