Design Specification ‐ WMS - lucasgsantos/BIM GitHub Wiki
Manufacturing Execution System (MES) - Warehouse Management System (WMS) Module Design Specification
1. Introduction
This document provides a comprehensive design specification for the Warehouse Management System (WMS) module of a Manufacturing Execution System (MES), based on industry-leading solutions such as SAP EWM, Oracle WMS, and Manhattan Associates. The WMS module integrates with core MES functionalities to provide real-time inventory control, material tracking, and warehouse optimization for manufacturing operations.
2. Module Overview
2.1. Objectives
- Provide end-to-end visibility of raw materials, WIP, and finished goods
- Optimize inventory accuracy and storage utilization
- Enable paperless material handling with barcode/RFID
- Support automated guided vehicle (AGV) integration
- Ensure GMP/GDP compliance for regulated industries
2.2. Key Features
| Feature |
Description |
| Real-Time Inventory |
Live stock levels by location, batch, and status |
| Material Tracking |
Full traceability from receipt to consumption |
| Warehouse Automation |
Integration with AS/RS, AGVs, and pick-to-light |
| Quality Hold Management |
Quarantine control with electronic approvals |
| ERP/MES Integration |
Synchronization with SAP, Oracle, etc. |
3. Functional Requirements
3.1. Core WMS Functions
3.1.1. Receiving & Putaway
- Inbound Scanning: Barcode/RFID capture of material, lot, and expiry
- Automated Storage Suggestions: Optimized putaway based on FIFO/FEFO
- Cross-Docking Support: Direct transfer to production when applicable
3.1.2. Inventory Management
- Cycle Counting: Scheduled or ad-hoc inventory audits
- Location Management: Bin/rack/zone configuration
- Stock Transfers: Inter-warehouse movements with audit trail
3.1.3. Picking & Issuing
- Wave Picking: Batch orders for efficiency
- Kit Management: Pre-assembled material kits for production
- Material Consumption Recording: Automatic deduction from inventory
3.1.4. Shipping
- Packing Verification: Weight checks and label printing
- Carrier Integration: EDI/API links to FedEx, DHL, etc.
- Bill of Lading Generation: Automated documentation
3.2. Advanced Features
| Feature |
Benefit |
| Slotting Optimization |
Reduces travel time by 20-30% |
| Labor Management |
Tracks picker productivity |
| Cold Chain Monitoring |
Temperature logging for pharma/food |
| Returns Processing |
Handles recalls and non-conforming material |
4. User Interface Specifications
4.1. Primary User Interfaces
4.1.1. Dashboard
- Real-Time KPIs:
- Inventory accuracy (%)
- Picking productivity (lines/hour)
- On-time shipments (%)
- Alerts Panel:
- Stockouts
- Expiring lots
- Quality holds
4.1.2. Receiving Screen
| Field |
Validation |
| PO Number |
Auto-match to ERP |
| Material Barcode |
Verify against item master |
| Quantity |
Compare to expected receipt |
| Condition Code |
Damage/quality assessment |
4.1.3. Picking Screen
- Visual Warehouse Map: Highlights pick locations
- Pick Path Optimization: Smart routing algorithm
- Confirmation Methods: Scan, voice, or RFID
4.2. Mobile Interfaces (RF Guns/Tablets)
| Screen |
Purpose |
| Receiving |
Scan items directly at dock |
| Putaway |
Confirm storage locations |
| Picking |
Guided pick sequences |
| Cycle Count |
Discrepancy recording |
5. Integration Architecture
5.1. System Interfaces
| System |
Integration Method |
Data Exchanged |
| ERP |
IDoc/API |
PO, inventory, BOM |
| MES |
OPC-UA/SQL |
Material issues, WIP status |
| PLC/SCADA |
OPC DA |
Equipment status |
| AGV System |
TCP/IP |
Transport orders |
**5.2. Data Flow Example
graph TD
A[ERP Purchase Order] --> B(WMS Receiving)
B --> C{Quality Approved?}
C -->|Yes| D[Putaway]
C -->|No| E[Quarantine]
D --> F[MES Material Request]
F --> G[Picking]
G --> H[Production Issue]
6. Operational Scenarios
6.1. Normal Workflow
- Receiving: Scan incoming pallet → System auto-assigns location
- Quality Check: Hold if COA missing → Release after approval
- Production Request: MES triggers pick list → AGV delivers to line
- Consumption: Operator scans issue → Inventory auto-updates
6.2. Exception Handling
| Scenario |
System Response |
| Short Shipment |
Flag variance → Create AP debit memo |
| Wrong Material |
Alert supervisor → Initiate return |
| Expired Stock |
Block transactions → Trigger QA review |
7. Compliance & Security
7.1. Regulatory Requirements
- 21 CFR Part 11: Electronic signatures for approvals
- EU GDP: Temperature monitoring for warehouses
- ISO 9001: Audit trails for all transactions
7.2. Access Controls
| Role |
Permissions |
| Warehouse Operator |
Scan transactions only |
| Supervisor |
Overrides and adjustments |
| QA |
Hold/release authority |
| Auditor |
Read-only access to logs |
8. Performance Metrics
| Metric |
Target |
Measurement |
| Receiving Accuracy |
99.9% |
Barcode scans vs expected |
| Picking Error Rate |
<0.1% |
Wrong picks/total picks |
| Inventory Variance |
<0.5% |
System vs physical count |
| Order Fulfillment Time |
<2 hrs |
Request to delivery |
9. Implementation Roadmap
- Phase 1: Basic inventory tracking (3 months)
- Phase 2: Advanced picking & automation (6 months)
- Phase 3: Full ERP/MES integration (9 months)
10. Conclusion
This WMS module design delivers real-time material visibility, process automation, and regulatory compliance while leveraging best practices from leading MES/WMS platforms. The system reduces inventory carrying costs by 15-25% while improving order accuracy to >99.5%.
Approval Signatures:
| Role |
Name |
Date |
| Warehouse Manager |
[ ] |
[ ] |
| IT Systems Owner |
[ ] |
[ ] |
| Quality Assurance |
[ ] |
[ ] |
Document Version: 1.0 | Last Updated: [Date]