1 November 2016, Melbourne.

Cadell Trading have selected Navigator WMS with Vocollect Voice to optimise processes in their Preston distribution centre.

Cadell Trading, a member of the Countrywide Food Service network, was established in 1994 with a five person workforce. Today, they have grown to a workforce of over 85 staff with offices in both regional Victoria and Melbourne. Cadell carry a range of dry, frozen and chilled products which are distributed to their customer base of hotels, clubs, schools and restaurants using their own refrigerated truck fleet.

The Solution

Cadell recognised that reducing paperwork in the warehouse would improve the accuracy and reliability of inventory data within Nexus. After evaluating options from other WMS vendors, Cadell engaged RFBS to design and deliver a total warehouse solution which would streamline practices from goods receipt through to despatch.

Cadell installed Navigator WMS, and modules for scan-receiving, replenishment, put away as well as Navigator's voice-directed batch picking application - all tightly integrated with their Nexus ERP system.

Nexus: An Integrated Solution

RFBS worked with ETechnique to build a bi-directional interface into the Nexus ERP system to support Cadell's warehouse processes. The two systems now work together to exchange data to support multiple transaction types in the EDI module:
  • Order Picking: Sales orders can now be exported to Navigator and pick results confirmed automatically once an order is completed.
  • Purchase Order Receipts: Purchase orders are exported to Navigator and received stock is applied agains the purchase order.
  • Inventory Adjustments: Two way inventory adjustments allow cycle count adjustments to be posted to Nexus.

 

Zone Picking with Vocollect Voice

In the Navigator system, paper pick slips are no longer required. Instead, orders are exported from Nexus and appear in Navigator's pick queue in drop sequence. Navigator locates an appropriate pick location for each item on the order and marks this on the electronic pickslip. Sales orders are also split into multiple fragments by zone, allowing the work to be effectively spread across the available staff each night.

When pickers arrive for work, they put on their Vocollect A720 mobile computer and headset and sign on to a delivery run and zone. Navigator automatically assigns work to each picker, ensuring that orders are picked in the correct sequence. The system even has the flexibility to pick multiple orders simultaneously in a single pass through the warehouse (an alternative to Nexus' Consolidated Pickslip).

The picker is directed around the warehouse in bin location order. They listen for the next bin location to visit over their headset and must verify, on arrival, that they have found the correct product. Navigator allows Cadell the flexibility to verify that the item being picked is correct by:
  • Speaking a location check digit (this is a random number printed on the bin location sticker used for items without a barcode)
  • Speaking a carton check digit (the last 3 numbers from the GTIN-14 barcode on the carton if the user must pick more than a carton)
  • Speaking a product check digit (the last 3 numbers from the EAN-13 barcode on the item if the user must pick less than a carton)

Once the item is verified, the system tells the picker how many items to pick (in the appropriate unit of measurement), and the picker confirms how many cartons or items were taken. Finally, the system tells the picker which order needs the stock by speaking the carton identifier (a letter from A to Z), and waiting for the picker to speak the check number off the relevant 'pick marker' label.

Random Weights
When picking random weighted items, including smallgoods and cheese, Navigator allows the user to speak the exact weight off the item ensuring that the customer is invoiced appropriately. 

Labelled Cartons
Navigator allows pickers to print a label for each carton shipped from the warehouse. Information on the label includes the customer's name, assigned delivery run and drop sequence number. This approach allows the delivery driver to efficiently locate cartons relevant to each stop - reducing incorrect deliveries and simplifying the customer's checking process.

Invoicing
The Nexus system is automatically updated with the picked quantities as soon as the order is completed.

Receipting - With Put Away

The system allows workers to use a mobile scanner to receive stock against purchase orders. Each item is scanned and matched against the purchase order to show the expected quantity, and the number of items received so far. The worker can enter the amount received, then record where the stock was placed by scanning either a pallet 'lot number' or the picking bin barcode.

RFBS worked with Cadell to design a new 'receipt to put away' strategy which allows the worker increased speed and flexibility around how items are handled. The worker can now use their scanner to see a list of items to be received, sorted by bin location. The worker can move the pallet to the pick face and scan the location barcode to identify which item is being putaway/received. Once the item barcode is scanned, the system verifies that the item is correct for the bin, and also check the item against the purchase order to verify the correct item has been delivered.

Replenishment

Cadell replenish stock each morning, using Navigator's scanner-driven replenishment function. The system directs workers to fill bin locations in priority sequence, with bins with insufficient stock to fill orders being targeted first, and bins below their minimum level are processed once all other tasks are completed. The system drives stock rotation, with workers directed to take stock from the oldest lot numbered pallets first. The replenisher scans the item and the picking location to confirm stock is always placed in the correct bin.

Cycle Counting

Cadell perform regular cycle count checks on pallets and picking bins in the warehouse. The scanner allows for directed and random bin audits which work in conjunction with an approvals process. This strategy means the warehouse does not need to close down during the counting phase.


Food Service & Navigator


The Navigator WMS includes hundreds of features designed to take the hastle out of running a food service warehouse. Some of these include:
  • Random weighted items. Receive stock directly from vendors including Golden Cockerel, JBS Swift etc by scanning the supplier's carton bacode. Capture random weights as stock is picked.
  • Batch and expiry tracking. Capture batch data during receiving and use this to drive replenishment. Capture information about picked batch numbers to assist in recall management.
  • Zone Picking. Splitting up orders across dry/freezer/chilled zones reduces walking and improves throughput.
  • Voice Picking. Pickers have both hands free to lift and move single items and full cases. Pick quantities can be captured easily, even in the freezer, where pickers do not need to remove their gloves.
  • Scan receiving. Navigator allows you to capture the GTIN and EAN barcodes on stock as it is received. Accurately identify stock inbound against purchase orders.
  • Reporting. Navigator captures statistics on worker productivity in real-time providing instant visibility to the warehouse manager.
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