WAREHOUSING Lucent Technologies Network Products Group, Mesquite, Texas
A new generation of RF terminals and bar code scanners, tied into new warehouse software, enables Lucent associates to pick and putaway items at higher levels of performance.
By Staff -- Modern Materials Handling, 2/1/1999
To continue support of rapid growth and to maximize the investment already made in its Dallas, Texas facility, Lucent Technologies upgraded its Mesquite facility. By overlaying a software system and associated equipment on top of the existing warehousing infrastructure, Lucent positioned itself for flexibility and the ability to adapt to future changes. With a warehouse management system (WMS), the installation of newer radio frequency data communication (RFDC) terminals, and bar coding equipment, Lucent has made great strides in its productivity.Overtime hours decreased by two-thirds and workers can process 2,000-3,000 picking transactions per day, versus a previous 1,800 on their best day. Gone is a congested receiving dock. Meanwhile, software-driven location management has improved storage space utilization by 20-30%.
Lucent now makes better use of its 100,000 sq ft warehouse. Receipt-to-factory floor lead-times declined by about 50%, while inventory data accuracy averages at least 95%.
The WMS manages warehouse operations that include 4,000 high-stack, or rack, locations, 30 rows of shelving with 45,600 locations, and a conveyor system to move materials in a storeroom holding 30,000 individual components.
Double handling is eliminated in receiving with a one-stage process directed by the WMS. The dock supervisor schedules delivery times for carriers. Bulk receiving lanes are used for staging bulk product and interworks that are palletized or shrink-wrapped. Crossdocking has greatly improved with the help of the WMS. Most crossdocked items are "dock to shop'' materials. Typically, 1,300 cartons-or about 10% of all cartons received weekly-are crossdocked.
The WMS also enables Lucent to queue picking requests pending putaway of goods, to allocate inventory still in staging, and to track materials throughout the entire warehouse.
Additionally, a modification to the WMS software provides the capability to accept on-line, Kan-ban replenishment orders.
With 42 RF terminals and real-time operation and communication, there's more flexibility to assign tasks to workers too. Work detail records can be changed quickly so a picker's tour is organized more efficiently. Implementation of the RF and WMS systems has improved putaway efficiency by 50%.
The conversion from Lucent's homegrown warehouse system to the commercial WMS package was extremely successful. The company will continue to improve and upgrade its operations to utilize all of the functionality that the system provides.
Product distributed: Power systems and components
Warehouse management system:
HK Systems 414-860-6635
Radio frequency data communication system:
Teklogix Inc. 606-371-6006
Conveyors: Buschman 800-347-9100
Bar code scanners: Teklogix 606-371-6006
Narrow-aisle order picking trucks: Raymond 607-656-2311
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