ZR Z R Data Systems, Inc.

office (513) 698-8800
fax (513) 698-8805
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info@zrdata.com


JBSS

Client Description

John B. Sanfilippo & Son, Inc (JBSS) engages in the processing, packaging, marketing, and distribution of shelled and in-shell nuts in the United States. Its product line includes peanuts, almonds, Brazil nuts, pecans, pistachios, filberts, cashews, English walnuts, black walnuts, pine nuts, and macadamia nuts. The company offers its nut products in a various styles and seasonings, including natural, blanched, oil roasted, dry roasted, unsalted, honey roasted, butter toffee, praline, and cinnamon toasted. In addition, the company offers peanut butter; candy and confections; natural snacks, trail mixes, and chocolate and yogurt coated products; baking ingredients, including chocolate chips, peanut butter chips, and flaked coconut; bulk food products; corn snacks, sunflower seeds, party mixes, sesame sticks, and other sesame snack products; and various toppings for ice cream and yogurt. It sells its products to wholesalers, grocery chains, mass merchandisers, drug store chains, convenience stores, membership clubs, bakeries, ice cream and candy manufacturers, other food and snack processors, hospitals, schools, universities, airlines, restaurants, and food service franchises. The company markets its products through a network of independent brokers and independent distributors and suppliers. John B. Sanfilippo & Son was founded in 1959 and is headquartered in Elk Grove Village, Illinois.

Need

JBSS is condensing four regional distribution centers into one centralized 1,000,000 sq. foot distribution and manufacturing facility and needs a warehouse management system powerful enough to manage it all. The system has to be able to integrate with their two three level high picking modules and their automated conveyor system.

The System

Receiving

The Inbound Order Receipt process manages the receipt of a single inbound order's items into the warehouse. An inbound order can correspond to a vendor PO (PO), transfer order (TR), Distribution order (DO), or Work Order (WO,WC).

Directed Put Away

The Directed Put-away process manages the movement of inventory items from the user's equipment into their optimal, system-determined storage locations.

Using item-specific put-away rules to pre-determine the put-away location for each item on the user's equipment, users are directed to storage locations using an optimum flow sequence to minimize travel.

A movement transaction is generated for each item quantity moved from the user's equipment or LPN to the specified location and LPN (if applicable). The specific movement transaction is based on the process, which initiated the Directed Put-away process. When the user's equipment is empty, the user is returned back to the process, which initiated the Directed Put-away process.

LP Put-away

The LP Putaway process manages the movement of items between locations within the warehouse. License plates (LPN) are identified to the system in parallel with the movement of the LP from the location to the user's equipment.

When the user's equipment reaches a user-determined capacity, or when there are no more items to be moved, the user is directed to put away the items on their equipment.

Request an Item

The Request an Item process allows a user to create or modify a directed move task to move a specified quantity of an item to a specified location. This process can be utilized to initiate the movement of materials to a production location within the warehouse, or to manually initiate the replenishment of materials to forward pick locations.

Picking

The Wave Picking process manages the fulfillment, or picking, of a logical grouping of order-related items within the warehouse.

Based on the logical grouping ("wave") created within Advantage Fulfillment Optimizer, the process determines the optimal pick location associated to each item on the wave and then directs the user to pick a specific aggregated item quantity from each location in parallel with moving the product to the user's equipment.

When the user's equipment has reached a user-determined capacity, or when there are no more items to pick on the wave, the system will direct the user to deliver the product to the destination location associated with each order on the user's equipment.

Palletizer Loop

The Palletizer Loop process manages the assignment of ‘label picked’ cases to a pallet (LP).

A display screen will show user the pallet type and pallet size that should be used for given order.

Label Confirm

A Label can be confirmed using two methods.  The normal method will be for a ‘Confirmation’ to be sent to WA from the conveyor system.  This is non-RF based and is part of the interface between the conveyor system and the WMS.  The RF Label Confirm process will allow user to manually confirm the label in the situation where the conveyor ‘Confirmation’ did not take place.  E.G.  The conveyor couldn’t scan a certain barcode.

Loading

The Loading process manages the movement of staged inventory within the warehouse.

Based on a specified order or load ID (i.e., "pick ID"), the system directs the user to move a specific LPN in parallel with moving the product to the user's equipment.

When the user's equipment reaches a user-determined capacity, or when there are no more LPs to be moved, the system will direct the user to deliver the product to the door location associated with the Pick ID on the user's equipment.

Unload/Unpick

The Unload/Unpick process manages the movement of staged and loaded inventory from allocated to an order, back to storage.

Based on a specified LPN, Item, and quantity, the product is moved to the user's equipment.

When the user's equipment reaches a user-determined capacity, or when there are no more items to be unloaded/unpicked, the user is directed to put away the items on their equipment

Shipping

The Shipping process manages the shipment of items from the warehouse. Based on a specified load ID the system collects the carrier, pro number, and seal number associated to the shipment. For each order on the shipment, the system generates order/item/line-specific shipment transactions in parallel with removing the associated inventory from the warehouse.

Print LP Label

The Print LP Label process allows the printing of the JBSS LP Label to a selected printer.

Change Pickable Flag

JBSS will use a ‘Pickable\Unpickable’ flag to determine if a pallet can be picked onto an order.  The pallet can be moved within the warehouse regardless of this flag.

The pickable FLAG will usually be changed from the interface with the HOST.  QAD will send down a record to switch from YES to NO, and vice-versa.  This WebWise screen can also be used to flip the flag.  Note: No transactions are sent to the HOST.

The user will be able to bring up a list of LPs by LP, Item, or Location.  They can then inline edit the pickable FLAG.

 

 

 

 

 

 

 

 

 


Outcome

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Quick Facts

Industry: Snack Foods Manufacturing and Distribution

Headquartered: Elk Grove Village, Ill.

Key Processes: Label Picking, Pick Module Replenishment, Palletizer Loop, Lot-tracked Inventory.

Warehouse Size:

Warehouse Floor Personnel: