Release Notes – WDLS 3.2

Featured Enhancements

Transaction Number Expansion

Transaction volumes throughout the client base have gone through dramatic increases over the past few years. New fulfillment customers have pushed order volumes. More granular inventory movement and tracking has increased the number of inventory adjustments. Parcel based receiving has increased tally volumes. Manufacturing operations have increased volumes of part requisitions. After reviewing options, it was decided to expand the size of our transaction number from 7 to 9 digits.

This is a significant change that will affect over 200 files and will require data mapping during the installation. It not only impacts WDLS, but also any labels and EDI processes. It would be best to also put energy into data purging prior to the implementation.

Purging Historical Data

The purge process was reviewed and modified to prepare for this release. The modifications exist for the 3.2 release and were retrofit to the 3.1 release to facilitate purging history before conversion. The archiving capabilities were removed as they lead to too much inefficiency. Archiving can be achieved by retaining a copy of the data on-line in another environment or on tape.

The purge process was re-written to be as efficient as possible. It uses a cutoff to determine transaction numbers and very quickly eliminates everything prior to those cutoffs. It then works backwards from current balances to calculate opening adjustments. Opening balance adjustments are written so that activity nets out correctly. This means that all accounts should be verified to be in balance prior to the purge. Afterwards they will be. Numerous other non-transactional purge processes were added to ensure system cleanup. Many of these can be performed after operations are allowed to continue. Performance and minimization of downtime were the primary focus of the re-work we did.

Inventory Management

Inventory Model

Over time, WDLS has been enhanced to support many different inventory models - located or non-located, lotted or non-lotted, shelf life with expiration, serialized, and internally license plated. Set up became increasingly complex as specific system functionality was required for specific inventory models. An exit was established that allows specification of the model for an account. Additional logic was added throughout the system to ensure the appropriate function is being used based upon the specified model.

In some instances, we were able to overload the logic based upon the functional request. For instance, if you are instructed to pick an amount of a specific item, we will display the appropriate panel and execute the appropriate logic based upon the model. In other instances, we were able to add tests to block execution if an inappropriate function was requested, such as a non-serial one-sided adjustment on a serialized account.

Item Based Order Clean-up

Depending on account setup and operations practices, an operator may be directed or have latitude to pick an alternate lot or an alternate location. When RF is used in the warehouse, this information is captured during the picking scan. Once the order is completely picked, the details of the order are updated, and the original stock commitments are released. On a large order this could take a while. In this release we have improved upon the cleanup timing and once the item is picked, we can perform the cleanup logic for that item. This releases stock commitments sooner and releases committed inventory for other operations.

License Plate Inventory

A license plate model of managing inventory was incorporated throughout the system, from receipt, movement, picking, and shipping, through physical inventory. The license plate model allows warehouse operations to assign an internal unique license label to a pallet or case of product during receiving. The license plate number is then scanned for warehouse operations including piece picking from the license plate. This allows for counting and movement efficiencies as well as more granular tracking of inventory.

Scan Character Check

In some industries where bar coding is used extensively on labeling, prefix characters are placed on the front of the bar code value to identify what is being scanned. For instance, in automotive AIAG labels, the part number has a "P" prefix, and the quantity has a "Q" prefix. A table was added that allows definition of prefixes during scanning operations. Currently for items and lots, the file is checked by our matching logic and if a prefix is in use for the account, the logic will strip the prefix as one of the matching steps it performs. These values can be set differently for each account as necessary.

Additionally, this utility allows you to define a substring of the scan value. If a customer's label lists the item on the product label but prefixes it with a three-character country of origin code, you can define the utility to look for the item beginning in the fourth position.

Shelf Life and Product Expiration

New formats continue to abound in the whacky world of lot code dates. With this release we have added the ability to do lot transformations during identification and to add editing for future production dates and expired products. The lot transformation uses an exit point to name logic that should be executed for take the lot data that was entered (scanned from packaging) and record it in the way you want to track it internally.

The new editing capabilities use shelf-life definition to determine the lot format, verify a valid date can be extracted from the lot, and test to see if that date represents a future date of production - i.e. I'm going to build this next week - or if the lot expires. This validation was added to receiving and lot creation processes. It also was introduced to the physical count process. During counting we can also alert the operator to expired products. In addition, we also now support a shelf-life of over 999 days.

Validation and transformation logic can now be used to address specialized customer requirements. An exit point called LOTCHECK was added to the system. This exit point will inspect the lot captured at point of entry. The logic can perform a transform or validate the lot to ensure that it describes an appropriate date or meets other custom requirements.

Kit Quantity Allocated

The quantity allocated calculation that we have used did not cover quantities of an item that will be needed for kit components on future allocated orders. A new calculation was added the will determine this. Currently this is supported on the web item status inquiry.

Kit Pick Comments

Comments were introduced for kitting. The comments are recorded against a specific kit number and will appear on the kit pick sheet. This allows operator instructions to be provided for the kit. The comments are stored in the system comments file as are item comments. An option was added to the w/w standard order panel to maintain the kit comments.

Warehouse Zones

The number of empty locations was added to the W/W Zones panel. This provides a level of measure for how full a zone is, especially when capacity information is not available for the capacity calculation.

Location Activity Enhancement

The location activity panel has taken off and is more frequently being used. We added the F21 key to print the location activity from the inquiry screen like what we have on the item activity panels.

Re-warehousing Report

A new report was added that is intended to assist in finding slot consolidation opportunities. To use this, you must have an accurate location map with location capacities defined. The report runs through locations and identifies any opportunities to combine stock based upon account setup and definition rules.

Pick Face Management

Tools were introduced to help manage pick faces. A filter for empty pick faces was added to the "Work With Pick Line" panel that allows you to filter for/away empty pick faces or show only those that are empty or eligible for re-assignment due to no remaining stock in the warehouse or expected. A pick face extract was also added to the system.

Handle Serials Returned to The Warehouse

Serialized inventory captures or verifies and externally assigned serial number and tracks that serial through all warehouse activity through the point of it shipping out of the facility. During scanning operations, serials are checked to ensure that they are known and active. Logic was added that supports activity when a serial is shipped out, and later returns to the warehouse controlled by a new exit point. If recycling is allowed, the old activity will be mapped to serial with an appended '-01, -02, ...' and the serial will be re-activated.

Reset Lots for A Storer

We've encountered some situations where inventory changes are driven directly by the customer - such as a customer physical inventory that results in adjustments we post from their findings. We exposed a support utility that now can be run by account to reset the lot status and activity dates for the account.

Account Management and Internal Communications

Account Setup Wizards

A capability was added that allows you to define specific system settings and name them. You can run a process to apply those settings to an account. The logic will review the account and look at each setting. If the setting matches the global setting, it will remove any account specific override. If an account specific setting is required, it will set that value for the account. The account wizard definition was added to the security menu.

Product Code Descriptions

Product code descriptions have gained popularity to track different classifications of items. In the future we see the ability to classify items by product code and assign different inventory models to different groups. A new table was introduced to add product code descriptions for an account. A pop-up panel was developed to help in code selection during item maintenance and the w/w panel search filter on product code. Invoice summaries were developed for storage and summary receiving invoices that provide product code summary listings as an alternative to help reduce the page counts of invoices.

Public And Private Events

The data maintenance panels for data elements were modified to support a flag for internal/external designation. This allows the definition of internal events that are filtered in the event history when customers access their transactions on the web. A new panel was also introduced that allows entry of events with comments. A toggle key was added to the event history panel to filter superseded events.

Non-Print Order Comments

The logic that produces bills of lading and the maintenance panels were modified to support internal comments on orders at both the header and detail levels. The maintenance panel allows the user to flag each line of comment as printable or non-print. Order clean-up and other processes can now leave line level breadcrumbs of their activity without muddying up bills and customer web inquiries.

Receiving Enhancements

If no details were received do not allow the posting of a tally. Perform a reasonableness test on the amount during posting and require an override password if it is exceeded. This only applies if an amount was set for the storer. Added support for serial numbers in the tally email process and formats. Improved the logic for matching the reference number for an RF operator during the receiving process to insure this is an active reference number and it is for their account. Ensure the receipt type was entered when auto-creating a tally from dock appointment entry.

Serial Activity Enhancements

Another area gaining a lot of traction is inventory serialization and license plating. In either of these inventory models, the activity becomes much more granular. Refinements to the activity panels continue as user, staging locations, serial relationships are better depicted.

Item Balance Creation

Item balances provide the inventory snapshot used to bill for storage. They also provide starting points for activity reporting to reduce the amount of history that needs to be processed. Logic was added to clean out and prior balances for the account, item, and date when re-generating balances for an item.

Reprint A Bulk Pick

The bulk pick process produces a pick document based upon open orders at the time. Once produced, the status was set to prevent over-picking. If there was ever a need to re-print a bulk pick sheet after shipping, it was restricted. A re-print capability was added to do this.

Increase Total Weight on Consignee Volume Report

The total weight on the "Consignee Volume Report" was expanded to support running the report over wider date ranges and to accommodate increased volumes. The report now supports 10 million pounds in its totals.

Increase Chemical Name

To remain compliant with DOT name structures, we increased the hazmat chemical name to support 60 characters.

PRO# Enhancements

In a prior release, we added the ability for the system to automatically generate the next available progressive number based upon the carrier assigned range. When the range is added, the low stock point can be entered. This process was enhanced to send an email when a carrier is running low on their assigned numbers.

A program was introduced that can be placed in the SCCHECK exit to verify a PRO# was assigned to the order.

Work Order Enhancements

Logic was added to tie the work order number to the adjustment transactions when committing inventory to work order releases.

Dock Scheduler

Dock Schedule Enhancements

Options are now supported on Tallys, Orders, and Loads to link directly to the dock scheduler for setting appointments. Linkage to the appointment was expanded to fully support individual transactions, consolidations, and batches. Modifications were made to support shuttles as well as pick up appointments. Modifications were made to performance reporting and new extracts introduced to support on-time and volume analysis. Support was added to the data extracts to restrict the extract by campus and region.

Support was added to cross-pollinate the dock appointment information back to WDLS master bills. An option was added that supports auto-creation of a new order based upon the appointment entry, much as is supported for an inbound shipment. Logic was introduced that can be set to auto-create an appointment for an order based upon a customer supplied shipment time request. Appointment auto- creation can also be set to occur on manual tally and order entry. A filter was added to the appointment event panel to suppress the superseded events for clarity.

The dock schedule rules were re-worked so that those with no remaining trace of timidity can define their own dynamic scheduling rules. Combinatory operators allow you to get as geeky as you want with the rules and their conditions.

Electronic Commerce

Introduce Inbound 850 Purchase Orders

Originally, 850's were treated as another form of shipment request or ASN depending on the Trading Partner. Purchase orders were added to WDLS that allow us to track customer purchase orders and relate inbound receipts back to those purchase orders. The 850-document processing logic has been modified to populate purchase order information. As the process has evolved, handling of purchase order updates and identification of duplicate purchase orders has gone through several iterations.

940 Order Processing Enhancements

The WDLS standard order comment is 60 characters per line, which is accommodated on our standard order forms. The X12 standard supports 80 characters and we have been encountering more of these longer comments. Logic was added to our 940 processing programs to address wrapping these comments into our standard 60-character fields. More addresses are coming in in mixed case. For substitution and matching, upper case is used, but the original customer case is recorded in the address.

Flat File Processing of 940 and 945

The WDLS standard flat file layouts for orders and order shipment confirmations were expanded, documentation updated, stock processing introduced to the system.

Prevent 947's When Shipping from Other Than Available

When an order is shipped from other than available, logic runs that adjust the inventory to available so that it can be committed and shipped. The reason code for this adjustment was changed to "99" and logic was added to block storer triggers from being written for that specific reason code. This eliminates customer confusion when these internal condition changes are made to support processing logic.

Outbound XML

Programming was added to produce outbound XML transactions utilizing the XML message class definitions in WDLS. Prior to this the message classes were used to parse inbound XML. Standard processing routines for 944, 945, and 947 documents were added. Parsing changes were also introduced to allow longer tag names.

Extol Error Email

A utility was added that sends an email alert if an Extol EDI transaction fails to process.

Warehouse Operations

Move Queue Enhancements

The move queue has become a critical communication channel between the CSR and the warehouse associates. In addition to queuing up picks and replenishments and using the move history of completed moves to update orders, directed operator activities like cycle counts load out, physical inventory, and other activities are flowing through the queue. To accurately close the communication loop, all moves must now be accounted for in history, even those that were never done. This has led to a lot of activity in this area.

Events are written for the order when it gets placed in the queue and if it gets deleted. A new option was added to mark a move as not completed and record the reason. This can be used by the order clean up to automate short shipment handling. A capability was added that allows a line to be added to an order after it has been placed on the queue and then push that line to the queue for processing. Over commitment is now allowed for lots when the associate is allowed to pick any lot from the designated location. If a move cannot be complete, a not-picked option was introduced that records the fact that the move was not done in the move history along with the reason.

Order details and moves have been tied together by line number. A new cleanup process was introduced that eliminates this dependency. Move activity is now tied back by item/quantity. This allows for item level cleanup of the order as each item is picked. The pop-up for redirecting a move was changed to only list locations where there are no current stock commitments to prevent redirection to a conflicting location.

The timing of when replenishment location adjustments are written was changed to when the move completes. The location move used to be recorded when the move was placed on the queue, so that stock commitment could be made, and orders placed on the move queue. With real-time quantity and over-commitment allowed, this was changed to only record the adjustments after the operator completes the move. Other refinements to start and completed time were made to improve activity reporting accuracy.

A capability for recording indirect labor was added. These entries post to the move history and are therefore included in the activity and performance reports.

Operator Equipment and Assignment

Setup of building level operators was reviewed. For most operations that are related to a transaction such as a receiver or a bill of lading, the account can be determined from the transaction header. To determine the account for non-transaction related activities, item identification logic was modified to return the account on an item match. If the match results in multiple accounts, the accounts and item descriptions are displayed for the operator for selection of the correct one.

An operator equipment file was introduced. Equipment can now be identified for a building. Based upon setup, the operator can be asked to identify the equipment they are on. Move assignment logic can tap this information to only assign appropriate moves to the operator. Once identified, a checklist can be provided to walk the operator through an inspection. Responses are mandatory and are logged. Settings allow you to set the inspection period by date or shift. Inspections are required based upon the setting. If an inspection was logged withing the inspection period, the operator will not be repromoted.

Map Location Check Digits

The map cross reference file was tapped to maintain location check digits. Using an Exit Point setting, you can specify that a check digit is required for verification. The check digits show as barcode values on the location placards. A simple setup process is used to associate a check digit with a location. If set, the operator must scan the appropriate check digit for the location they were sent to verify they are at the right spot.

Location Auditing Improvements

Added option to mark differences as they are resolved and provided a filter on the work with location audits panel to search for unresolved differences. Support paperless location audits via the move queue. Support loading audits across accounts, but within a location range within a building.

Physical Inventory Auto-increment Tag Counts

A new counting process was introduced that allows recording of a single count inventory using RF equipment. Instead of requiring the inventory to be tagged in advance, the process builds a tag number on the fly during counting. This provides an alternative to the typical worksheet-based or tag-based model, both of which require book extraction before counting can begin.

Trailer Inspection

A trailer inspection process was introduced during this release. Trailer inspection occurs just prior to loading out. Inspection questions can be established that have simple yes or no responses. The questions are either listed on a paper inspection report or on an RF unit. The associate assigned to the inspection task is presented with the questions. Their responses and comments can be recorded along with the associate ID, date, and time of the inspection. If a trailer is rejected by the inspector, a supervisor overrides with comment is required.

Load Out

A standard load out capability was introduced for orders that have order configurations recorded and unique pallet ID's. This would include any order with UCC-128 labeling or that otherwise went through a configuration process. Note that all orders that are picked using RF are inherently configured. The load out process records each label as it is loaded. The operator is alerted if they scan a label not associated with the order or if they are short of any labels prior to completing load out. A load out sheet can be produced that shows the load order.

Order Scan Out (Verification) Enhancements

Several custom scan out programs were written for fulfillment operations that are used at the shipping station. From these, new capabilities were added to our core program. These include a running total of pieces scanned, memory of what was scanned so that if the process is interrupted it can be picked back up from where it left off, and improvements to user feedback when the order does not total out.

Move History Enhancements

More information is logged into the move history than ever, and mining that information has become more common place. Filters were added for document numbers and type to more easily pin all activity that occurred for a specific transaction.

Labor Planning

Labor Planning Enhancements

Process sub-steps were introduced to the labor planner.

Manufacturing Support

Support Requisition Reference Number Re-use

Add logic similar logic to that used on tallies and orders that allows re-use of a requisition reference number if it is over 6 months old.

Requisition Processing Enhancements

Requisition processing is finding its way into more operations. Several modifications have been made to lock down processing and accommodate different warehouse practices such as multiple picks per request, requisition grouping, and double-checking status of a requisition when executing options rather than relying on the w/w panel status.

Yard Management

YMS Yard Check Discrepancy Report

During the yard check process, a list of trailers that were not found is displayed on screen. As part of the process, these will be marked as departed after the yard check is confirmed. The F21 print was added to that panel so that a listing can easily be produced of these trailers.

Trailer Extract

A trailer extract was introduced in this release. It can be restricted by carrier, and you can indicate if you are looking for released, empty, or all active trailers.

Financial Reporting, Invoicing, Accounts Receivable

Recognize Deactivated Task Codes

Pricing models have grown in complexity. New task codes are introduced, but prior ones must be maintained for historical purposes. The logic for entry and auto-charging was modified to check the status of a given task code and only allow recording of active tasks. The work with pop-ups, and maintenance panels were modified as appropriate to support de-activation.

Task Code Maintenance

Block deletion of storer specific task codes if they are referenced. This prevents a situation where a global task remains but has a pricing difference which leads to confusion during research.

A/R Report Totals Expanded

Our customers are making too much money. We had several requests to expand total fields on A/R and revenue reports. The totals were expanded to support up to 1 billion dollars.

Freight Invoice Formatting

Alignment issues were addressed on the overlay version of the invoice.

Storage invoice

A "NC" (No charge) basis type was introduced, to simplify handling of accounts with supplies and packaging materials tracked as order lines.

Miscellaneous A/R Enhancements

Prevent positive credit memos. When an invoice is deleted - adjusted to zero with no payments or credits applied, show the status as 'DL', not 'PD'. Account attributes were added as selection parameters to all A/R reports including registers. Extracts were added for A/R transactions, payments, aging, and sales journals to facilitate interfacing and modeling.

Base Utilities

Date Utilities and Validation

As we migrate system code to newer language capabilities, we can review and improve them. More date formatting options can now be handled, and some inconsistencies such as the handling of midnight in a timestamp as 00:00 not 24:00 were addressed. Additional validation was added to utilities to test date validity before performing the requested transform.

Miscellaneous Utilities

Tools were added for comparing message files and identifying ddifferences in message severity and text. Database tools, date selections, and several pop-ups were modified to support wide-screen (DS4) format.

Business Duration Calculator

A utility was created that used the working hour schedule and schedule exceptions tables to calculate business durations. Begin by, End by, and durations can all be calculated based upon the work schedule. A calculator panel was added to the utility panel that allows for verification of calculations. These calculations are used by the labor planning logic, but also allow you to get a quick calculation of when to start work on a project that will take 15 hours and must be completed by next Thursday by close of business day.

Distance Calculator

Data was purchased and incorporated into Codeworks utilities for validating zip codes for the United States and its provinces. In addition to a complete list of valid codes, the table contains the longitude and latitude of the geographic center of each code. Utilities were developed and included in our base utilities that return a bird’s eye distance between any two codes. This was incorporated into our TBMS application to provide information for possible load consolidations. In that application there is also a table to record over-the-road distances between to zip codes. The over-the-road distance is given if found, otherwise the birds eye distance is shown as an estimate.

PDF Publishing Enhancements

Several enhancements were made to our PDF publishing utilities. The use of PDF files for output has expanded considerably since it was introduced for invoicing. Refinements were made to the storage location of these documents. Generally, PDF files are published under a specified path that ends in a directory for the storer. Storer 100 files would be under DIR0100. As more types of documents were supported, a tree structure under the storer's directory was established. New directories in addition to "Invoices" include "POD", "BOL", "TALLY", and "Report".

As more types of web users were introduced in addition to a single account, storer based user, we added publication paths for carriers, consignees, and added utilities for determining storer path to a specific document for super-users that have access to multiple accounts. To streamline setup, the programming was modified to test for existence of the directory when publishing and if it does not exist, create it. Additional logic was introduced to set authority on the new paths and documents when they are created.

The programming that creates the PDF files was converted to use new system capabilities. Rather than using a graphic document image as a backdrop, logic can handle advanced printer functionality. This allows publication of all output from WDLS as PDF files. This includes forms like the bill of lading or invoices, but also documents with bar codes, and special fonts. The Codeworks publishing utility also supports PDF as an output format which means that any printed output from the system can now be published.

Additional Email File Utility Formats

Additional file formats are now supported on the email file utility supplied by Codeworks. HTML and XLM formats are now supported. These use a shell definition that can be used to wrap the file contents and provide control over formatting. These shells can link back to a local stylesheet stored off your website that can add graphic elements and control color and font information.

User Defined Data Extract Views

When the last iteration of the Global Performance extract was written, a more systemic approach was taken to allow user tailoring of the extract file. This was intended as a model for future data extraction. From the maintenance menu an option was added to define a view of an extract. When that is done, the available columns are presented, columns can be excluded, the sequence set, column heading can be changed, and any column that should have a total identified. The Global Performance Activity extract was the first to take advantage of this capability.

Miscellaneous

RFID Serial numbers Updates

Some minor changes in EPC number construction were modified for compliance. The number types and definition panels were revisited, and help enabled.

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