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Integration made easy
Warehouse management and control plus(WM+)FastTrak
WM+
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Founded in 1987, Glen Road Systems, Inc. has spent more than twenty years positioning
itself as a premier distribution center system integrator. Solutions are designed withthe pervasive belief that a warehouse system is only as good as it is reliable and
supportable. As a result, GRSIs top priority is to design systems for which it can offer
superior support. Novel, value added features and a large install base in diverse
warehouses has molded GRSIs core software offering, FastTrak
WM+, into an
essential tool for optimizing warehouse operation and automation.
Glen Road Systems, Inc.
GRSI
401 East Elm St., Suite 100
Conshohocken, PA 19428
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Clients for life...
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FastTrak WM+ overview
System architecture
Warehouse management plus (WM+)
Warehouse management system (WMS)
Warehouse control system (WCS)
FastTrak tools
Order management system (OMS)
Packaging integration (PI)
Contents
Inform
Automate Coordinate
Integrate
Manage
FastTrak
WM+is the solution to:
Warehouse and distribution operations
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GRSIFastTrak
WM+GRSI FastTrak WM+ (warehouse management plus) consists of a WMS and WCS. It is software for inventory management,
warehouse automation, and system control from receiving to shipping. Automated equipment and computer-aided manual
transactions are handled in a coordinated manner aimed at optimizing the full warehouse with regard to accuracy, efficiency,
throughput, and resource utilization. The FastTrak WM+ is one suite of software controlling what heretofore might have been
separately controlled subsystems. The result is exceptional stability, minimal interruption, and superior end-to-end, ongoingsupport for the entire warehouse process. The FastTrak WM+ is composed of two modules that work together in various
combinations.
Warehouse execution suite(WES)
Warehouse control system (WCS)
WCS coordinates, controls, automates, and monitors
material handling equipment and fulfillment methods. Th
Fast
Trak WCS includes support for conveyor sorting androuting; automated storage and retrieval systems (AS/RS
in-motion inventory; print and apply; in-motion manifestin
wireless, voice, and laser picking; pick/put-to-light; and
RFID. Graphical user interfaces display real-time materia
flow, messages, and performance metrics. Transactiona
detail is logged for inquiries, reports, and audits.
Order management system (OMS)
OMS organizes orders for efficient and accurate picking
combining both operator and automation-based fulfillmen
methods. Features such as waveless picking, waving,
batching, and cartonization are standard mechanisms
used to optimize the fulfillment process. The FastTrak
OMS has a full range of inventory management features
control putaway, storage, and pick location replenishmen
Additionally, a wide range of methods for resource
optimization are included. Targeted resources include
automation equipment, material handlers, storage media
and diverse warehouse vehicle types.
Packaging integration (PI)
PI encompasses last-100-feet (L1F) operations such
as packaging, literature and packing list insertion, sealing
weighing, labeling, manifesting, and sorting. It combines
and automates all subsystems, packaging equipment, an
material handling equipment from any supplier into a sing
unified process. The result is minimally attended, cost
effective, and accurate processing of orders.
Warehouse management plus
(WM+)WM+ interfaces and facilitates communication between
enterprise software (ERP), warehouse management
systems (WMS), shipping systems, and equipment.
Single-point host communication simplifies design andimplementation, performs with exceptional stability and
reliability, and lends itself to superior support.
Warehouse management
system (WMS)WMS seamlessly controls and integrates receiving,
putaway, storage, inventory management and planning,
picking, replenishing, and order check-out. The FastTrak
WMS utilizes light, bar code, voice-directed, and RF
picking and putting technologies. It coordinates and directs
resources and equipment including carousels, pick carts,
A-frames, PPTL modules, storage media, automated
guided vehicles, and other AS/RS. It tracks the movement
of inventory throughout the entire distribution center from
receiving to shipping. The FastTrak WMS also incorporates
slotting, cartonization, and vast reporting, diagnostics, and
optimization tools to view operator efficiency and error
troubleshooting messages.
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Warehouse fulfillment center
Resources Voice and RF assisted operators
Pick/put-to-light activities
Conveyor routing and sorting
Automated storage and retrieval equipment (AS/RS)
Automated packaging equipment
Specialized vehicles and static storage
Electrical controls
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System architecture
Single-point connectivity
Ethernet backbone
Receiving
Putaway
Picking
Replenishment
Robots
Conveyors
AS/RS
Carousels
Scanners/camera
Scales
Sorters
Packing/shipping
Manifesting
Batching/waving
Cartonization
Host systems:
SAP
Oracle
JD Edwards
RedPrairie
Infor
Manhattan
HighJump
Legacy
More...
ERP/WMS
FastTrak
WM+
Equipment - WCS - WEInventory - WMS
Electrical controls
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Human machine interfaces
Dashboard displays
E-mail/browser alerts
RF handhelds
Diagnostics and reporting
Picking: light, voice,
RF, and paper
Robots
Print and apply
Document insertion
Packaging systems
HOST
Information
Platforms:
Windows
Unix IBM, RISC, or AS/400
Mainframe
PLCs
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Warehouse management plus (WM+)
Shipping systems
Conveyors andsorters
Packaging systems
Pick/put-to-light systems
Scanners and camera
Printerapplicators
Scales and dimensioners
Data collection andintegration
System interfaces
Computer networks
AS/RS, robots,and carousels
Inventory
FastTrak
WM+
Automated pick systems such as storage and retrieval, high speed item sorters, and pick/put-to-light, involve large capital
investments and are central to the function of many modern fulfillment centers. The automation equipment must be operated
at peak performance and utilization in order to satisfy financial expectations. Special software tools and methodology are
required to achieve these goals in a fashion that is integrated seamlessly into to the overall warehouse operation. These
include coordinated order management, inventory management, and device control. FastTrak WM+ provides the total solutionFurthermore, it provides the basis for comprehensive single-source warehouse operations support without artificial and
confusing divisions of responsibility amongst suppliers.
GRSI 24x7 support Single-point contact for support
Rapid response
Remote assistance
Maximum up-time
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Why WM+
Efficient distribution centers need a tightly managed and integrated system
from receiving to order shipment
FastTrak WM+Buffering
Automatic andmanual packaging
Conveyor routing
and tracking
Print and applylabeling
Shipping sortation
Manifesting
Ordshipm
Receiving
Inventory management
Picking/putting
Typical software solutions fail to utilize and manage equipment made by various manufacturers with multiple pieces of softwa
running independently. WM+ is the tool for complete warehouse integration. There is no finger-pointing. GRSI takes full24x7x365 responsibility for the functionality, throughput, and uptime of its systems. GRSI writes a meticulously crafted functio
specification document for every client detailing the entire systems processes, messages, layouts, communications, data
transfers, screen shots, and more.
FastTrak WM+ is an extremely flexible software suite that manages all warehouse processes, subsystems, and equipment w
complete visibility. The benefits of an integrated and streamlined system include:
- Increased throughput - Quick troubleshooting and support times
- Expandable and upgradable - Less operator training
- Decreased bottlenecks - Equipment runs at its full potential
- No finger-pointing - Maximize system uptime
Integration made easyTM
Last-100-foot (L1FTM) packaging system
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Warehouse management system (WMS)
ERP/WMS integrationFastTrak WMS interfaces to many ERP systems using
single-port connectivity. Some ERP systems include:
SAP
Sage
Epicor
Oracle
JD Edwards
FastTrak WMS also enhances the functionality, speed, and
system controls of existing WMS systems. It interfaces
to numerous WMS systems via single-port connectivity
including:
RedPrairie Accellos
Infor
Manhattan
FastTrak WMS and the ERP communicate order, inventory,
and customer data through seamless integration.
Equipment AS/RS and
goods-to-man specializationSoftware AND hardware integration is essential. FastTrakWMS coordinates and controls all material handling
equipment from any supplier into one cohesive unit. It
allocates the necessary resources for optimal throughput
performance. The software can interface to pick/put-to-
light modules, voice picking, and RF devices. It is the
ideal software to manage AS/RS, in-motion inventory, and
goods-to-man operations. Its ability to control carousels,
unit loaders, sorting transfer vehicles (STV), automatic
guided vehicles (AGV), vertical lift modules (VLM), and
other AS/RS greatly improve stock organization and
inventory flow.
Inventory managementFastTrak WMS inventory management features include
inventory forecasting, allocation, receiving, stocking, che
in, labeling, and tracking. It identifies and allocates inbou
inventory to the required areas of the warehouse and trac
its location. The inventory can be arranged and assigned
by customer specific business rules, lot numbers, weight
dimensions, fragility, cost, and others. This allows produc
to be appropriately distributed to its proper location.
FastTrak WMS utilizes multiple inventory and labor zone
to provide batching, waving, waveless operating, picking
and passing, sequential picking, and replenishing.
Recording and tracking inventory usage is critical for
replenishment. FastTrak WMS identifies and notifies
operators, self-guided robots, AS/RS equipment, and
other in-motion inventory equipment when inventory is
running low. It provides the necessary tools and visibility
identify physical locations of static and in-motion inventor
Replenishment times can vary throughout the day, week
and during peak and non-peak seasons. FastTrak analyz
inventory and resource usage, inventory locations, pickin
requirements, and future workloads to replenish necessa
inventory. FastTrak is highly flexible and customized to
handle customer-specific requirements.
Great Plains
PeopleSoft
Homegrown
Microsoft
and others
HighJump Legacy
Homegrown
and others
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RFIDFastTrak interfaces with RF access points to communicate
information from scanned RF tags throughout the
warehouse. Item and order movement is tracked and
recorded by FastTrak. RFID increases visibility and enables
clients to wirelessly track items.
Picking technologiesFastTrak WMS and OMS work to efficiently manage
various picking technologies including pick-to-light
and RF, paper, and voice picking. FastTrak can batch,
superbatch (batching of single-item orders, which is ideal
for e-commerce solutions), and wave items for maximum
performance. FastTrak also records inventory and
manages replenishment.
KittingFastTrak WMS consolidates items originating from different
areas of the warehouse to fulfill and complete orders. It
releases batches to multiple picking operations to fulfill
these orders in a timely manner.
Returned ordersFastTrak WMS allows returned orders (RMAs) to be
received back into the warehouse and generates the pro
paperwork for the order. Returned items may be designa
to a specific area of the warehouse.
DisplaysFastTrak incorporates user-friendly HMIs, dashboards,
reporting, and troubleshooting tools. Operators can view
the location of orders, error messages, and workflow
data using these screens. Notifications are browser
based and accessible by any PC or cell phone with
Internet connectivity. Management is able to remotely
analyze reporting data to see operator efficiency andperform benchmark comparisons. The error percentages
throughput rates, transactional data, and order informatio
are also available for viewing.
SlottingThe slotting process improves picking productivity,
reduces walk labor, provides space utilization, improves
replenishment, and adjusts for peak and seasonal
demands. It manages multiple locations for the same
SKU and provides lot and serial number controls. It is
an organization tool, which complements replenishment,
picking, and packing. This provides a significant number
of cost-reduction scenarios when integrated with GRSIs
cartonization and shipping programs. Graphic and
history displays, report verifications, SKU history, slot
management, and alerts provide a tool to manage and
grow within the size limitations of each clients distribution
center.
CartonizationFastTrak includes cartonization software that uses SKU
and order data with business rules to make improved
packaging decisions. It examines the dimensions, fragilit
weight, position, and special needs of each item in an ord
and the interaction of items in the order to determine the
orders packaging requirements. The software selects the
best suited packaging available using material inventory
data. Cartonization lowers material and freight costs,
decreases order returns, reduces labor, and increases
throughput.
Scanning the volume of
the order using DimScanT
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Warehouse management system (WMS)
Shipping and manifestingFastTrak WMS works as a middleware that interfaces to
shipping systems, ERPs, or existing WMSs. It records and
communicates order, shipping, cost, tracking, carrier, and
address information between the systems. It connects to
various shipping systems including UPS, FedEx, USPS,
Clippership, DHL, Purolator, Canadian Post, and multi-
carrier software including Logicor, CMS Worldlink, Agile,
Pitney Bowes, and others. GRSI provides a wide range of
manifesting solutions with direct connection to all carriers.
In addition to managing the information flow, FastTrak also
controls all equipment involved with shipping operations
including weighing, calculated void-fill inserting, shipping
label printing and applying, and carrier sorting.
FastTrak WMS provides the central software module and
interfaces with 3PL providers, outsource operations, and
distribution networks with warehouses that span multiple
facilities. The software is also highly involved with reverse
logistics management.
ASNFastTrak links orders to advance shipping notices
(ASNs) in the standard EDI format. The ASN contains
order, customer, and shipment information. The ASN is
communicated to appropriate distributors and customers
during the shipment process.
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Warehouse control system (WCS)
Main screenThe WCS main screen is a data-oriented view of
warehouse operations. Users can view the flow of
individual parcels through each subsystem, interactions
between FastTrak and the host system, and transactions
involving automated and computer-aided processes.
Process logsEach action performed by the automation system upon a
container (parcel, tote, package, pallet, etc...) is recorded
Actions might include transfer of a container into a pick
zone or sorting of a package to a shipping lane. The
unique identification of the container, specific location of
the action, action detail, time stamp, and process duratio
are displayed on screen for routine monitoring. This data
also recorded for subsequent reporting and auditing.
Dropdown menusUsers can access configuration, diagnostic, and reporting
tools from the drop down menus on the main screen.
Exception logAny automation process or transactional error that result
in exception handling by a machine or an operator is
recorded. The exception data is displayed on screen to
help in resolution of specific exceptions. In addition, the
on-screen data is used as an aid for identifying trends
that represent reoccurring system performance or data
problems.
Transaction logsRadio frequency scan and voice transactions, as well
as pick/put-to-light transactions are recorded. The data
describing each
transaction is availab
on screen for routine
monitoring and is
also recorded for
subsequent reporting
and auditing.
Buttons, indicators, and
statisticsUsing the buttons on the bottom of the main screen, users
can start, stop, and pause subsystems with the click of a
mouse. The status of each subsystem is displayed using
a three-color code. Underneath the buttons are real-time
performance statistics.
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Tools
Diagnostic and messagingDiagnostic tools allow users to view critical operational d
including communication between FastTrak and PLCs, a
communication between FastTrak and the host system.
Tests can diagnoses issues with digital I/O, serial, and
socket communication.
Browser based messagingCustom notification levels alert users about system
events and errors. Messages with configurable wording
and multilingual support are sent when processes
are completed, started, or stopped; errors occur; or
performance lags behind a set threshold. Notifications a
browser based and accessible remotely by any compute
mobile device with internet connectivity.
ConfigurationUsers can configure key operational characteristics
including timeouts, error count thresholds, and heartbeat
intervals.
Host interfaceFastTrak is able to connect to any ERP or WMS host
operating on any platform. This powerful connection
features configurable source and destination endpoints
using TCP/IP sockets, FTP, shared tables, and remote
function calls.
Monitor system
operations with a PDA
or smartphone!
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Human machine interface(HMI)
HMIs display a graphic warehouse representation that
shows real-time behavior of each subsystem, details abouteach parcel, and process performance. HMIs allow users
to monitor and control operations.
DashboardThe dashboard is a graphic representation of pending
versus processed workload. Users can allocate work by
dragging and dropping tasks to different resources.
Spreadsheet reportingAll process, transaction, and exception log data is availab
as spreadsheet reports. These reports can be used for a
wide range of purposes including operator productivity,
machine performance reliability, audit trails, inventory, an
shipments. Reports are created by stored procedure call
to the FastTrak database from within the spreadsheet
environment. A wide range of standard reports are
available as well as custom reports to meet specific user
requirements.
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Order management system (OMS)
BatchingBatches are designed either to accomplish an immediate
business requirement such as consolidation of priority
shipment orders, or to provide an efficient pick walk path
through a limited region of the warehouse. Batches can
be designed based on custom criteria including shipping
carrier, packaging type, or pick cart/truck capacity.
Super batchesSuper batching is a labor effective method to pick large
quantities of single-piece orders. When items picked
in a super batch reach the outbound process, FastTrak
automatically assigns individual pieces to an outstanding
order using a reverse lookup.
Real-time dataOMS interfaces with the host in a fashion that assures
dynamic order, SKU, and replenishment data is current.
Drill downsThe OMS main screen shows active batches and their
progress. Batches drill down to individual orders and item
Parcel data is accessible by right-clicking any item. Histo
data shows the movement of items from picking to packi
to shipping.
InventoryFastTrak inventory management supports rules-based
putaway, replenishment, and picking. These sophisticate
activities are tailored to optimize the use of complex
automated material handling pick areas and conveyor
routing between them. Tasks are interleaved as appropri
and idle machine time is used for routine counting and re
stocking. FastTrak cartonization breaks multi-carton orde
into a carton fulfillment plan that minimizes pick area visi
for each individual carton of the order. Cartons are releas
to balance workload amongst the pick areas. FastTrak
provides automated post-pick carton consolidation.
Sorting, wave, and waveless
managementFastTrak coordinates wave and waveless picking by
assigning pickers to designated zones of a warehouse.
Picked items from different zones are consolidated into
their respective orders downstream. Waveless picking and
sorting provides a streamlined flow of orders through the
distribution center. Consolidation can be accomplished
using a wide range of high-speed sorting technologies or
pick/put-to-light systems.
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CartonizationCartonization decreases material, labor, and freight, cost with sustainable solutions. Cartonization is designed to analyze
orders and automatically determine their packaging needs based on business rules. For each order, the associated costs,
benefits, and sustainability of all possible packaging options are analyzed to create a cost model. The model compares
the cost of packaging materials, labor, equipment, freight, damage claims, and other related costs from picking to delivery.
These factors and the clients goals guide the cartonization system to make packaging decisions for each order. Using
software to make these important packaging decisions takes the
pressure off operators, improving throughput and consistenc
The cartonization system is able to determine packagin
needs as soon as orders are placed, so picking
and consumables replenishment can be done with
complete packaging foresight. To make these decisions
FastTrak determines and stores essential item information
Basic information is gathered via a dimensioning andweighing system. Additional data, based on busines
rules, is fully customizable for each item. Some of the
data the cartonizaton system analyzes includes:
Dimensions (LxWxH)
Weight
Fragility scale
Business rules
- High-end item
- Priority customer
Inform, automate, coordinate, integrate, and manage
Receiving
Stocking
Picking
Packing
Shipping
Sortation
Packaging automation
Conveyor routing
Advanced shipping notice
RFID
In-motion order fulfillment
In-motion print and apply
In motion manifesting
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Packaging integration (PI)
In-motion packaging systemGRSI integrates all L1FTM functions including product, pack list, and document inserting; scanning and tracking; conveyor
routing; carton closing and taping; shipping label printing, applying, verifying, and manifesting; and shipping carrier sorting
FastTrak coordinates all operations into a streamlined in-motion packaging system.
Cartons with LPN barcodes
Cartons are automatically erected, each with
a unique license plate number (LPN) bar
code. FastTrak uses this unique LPN to track
packages throughout processing.
Cold sea
induction
Carton inductionPicked orders arrive at carton
induction. An operator scans each
orders bar code and scans the
cartons LPN. FastTrak associates the
carton with the order.
Pack list insertion andverification
Dynamic document insertion
Shipping label printing,applying, and verifying
Carton closingand taping
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Void fill and sealingAn operator inserts the proper
amount of void fill. The carton is
conveyed to an automated carton
sealer.
MergeSealed cartons are merged
with cold-seal orders for
shipping operations.
Cold seal lineWhen multi-piece orders arrive at the cold seal line, the operator scans each orders bar code and FastTrak associates the
order with an LPN printed on the cold seal substrate. The order is wrapped in the cold seal substrate and identified by its
LPN during subsequent processing. For single piece orders, the item bar code is scanned and FastTrak uses a reverse
lookup to associate the item with an outstanding order.
Integration made easyTM
Final packaging and shippingSealed orders are conveyed to an in-motion scale andscanner. The order is weighed and its LPN is scanned.
Using the weight, FastTrak generates the appropriate
shipping label and the order is conveyed to a shipping
label printer applicator where the proper label is applied.
FastTrak scans the label to verify the integrity of its conte
and the order is conveyed to a shipping sorter.
In-motion weiging andscanning
Shipping label printing,applying, and verifying
Shipping carrier sorting
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Warehouse management and control plus(WM+)
FastTrak
WM+
Contact us for more information:
610-397-1050
Glen Road Systems, Inc.
401 East Elm Street, Suite 100
Conshohocken, PA 19428
610 397 1050
www.grsinc.com
Integration made easyTM
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