DESIGN AND IMPLEMENTATION OF A MICRO-COMPUTER BASED
BAR CODING DATA COLLECTION SYSTEM FOR IMPROVING
WAREHOUSE INFORMATION HANDLING AND COST CONTROL j I
A Thesis Presented to
The Faculty of the College of Engineering and Technology
Ohio University
In Partial Fulfillment
of the Requirements for the Degree
Master of Science
by
Tuan Sun Cheok
November, 1990 ACKNOWLEDGEMENT
This thesis is dedicated to my family, especially to my father Mr. Kim Pong Cheok and mother Ah Guat Tee, in gratitude for their financial support and encouragement. I would like to thank them from the deepest of my heart for their love and support throughout the years. To my wife Poh Geok YU, I give my deepest gratitude for her caring and encouragement. Her caring and love in the most delightful atmosphere is my most beautiful experience.
I wish to express my deepest appreciation to my thesis director Prof. E. Ralph Sims and committee Dr. James Fales for their guidance, cooperation and dedication throughout this project. I highly appreciate Dr. Fales for introducing me to this thesis topic and his availability for help made it a very delightful and educational experience.
I also wish to thank the other members of my committee,
Dr. Donald Scheck and Prof. Ralph Smith for their invaluable criticism. TABLE OF CONTENTS
Page
CHAPTER ONE: INTRODUCTION 1
1.1 Background and Statement of Problem 1
1.2 Statement of Purpose 2
CHAPTER TWO: LITERATURE REVIEW . 4
2.1 Bar Coding Applications 4
2.2 Importance of Bar Coding 6
2.3 Advantages of Using Bar Coding Data Collection System ...... 7
CHAPTER THREE: CONCEPTUAL DESIGN . . 9
3.1 System Objectives .... 9
3.2 Analysis of Warehouse Information Handling 10
3.3 System Operational Requirements. 12
CHAPTER FOUR: DETAIL DESIGN AND DEVELOPMENT 14
4.1 System Overview .... 14
4.2 System Specification 14
4.2.1 Portable Data Terminal .. 15
4.2.2 Bar Code Labels 17
4.2.3 Printing 18
4.2.4 Symbology 19
4.2.5 Communication Software. . 19
4.2.6 Micro-computer and Relational Database Software .. ... 20
4.3 System Development 20
4.3.1 Identification of Required Data .. 24
4.3.2 System Design of an Application Program . 27 4.3.3 Preparation of a Database Management System ·. .. 29
CHAPTER FIVE: SYSTEM OPERATION . 33
5.1 Application Program Operation .. 33
5.2 Database Management System Operation and Options ...... 43
5.2.1 Data Entry Screens . 46
5.2.2 Quick Reports 48
5.2.3 Custom Reports. 48
5.2.4 Forms and Labels . 53
CHAPTER SIX: SYSTEM IMPLEMENTATION . 55
6.1 System Preliminary Tests .. 55
6.2 System Implementation and Validation 56
CHAPTER SEVEN: CONCLUSION AND RECOMMENDATION 61
6.1 Conclusion 61
6.2 Recommendation 62
REFERENCES. 64
APPENDIX A: APPLICATION PROGRAM FLOW CHARTS. 67
APPENDIX B: APPLICATION PROGRAM LISTING. 78
APPENDIX C: !BARSOFT REPORTS ..... 93
APPENDIX D: !BARSOFT DATA ENTRY SCREEN 113
APPENDIX E: BAR CODE LABELS GENERATED BY !BARSOFT. 137 LIST OF FIGURES
Page Figure 3-1 Warehouse Data Flow Diagram 11
Figure 4-1 Warehouse Inbound Operational Flow Chart 22
Figure 4-2 Warehouse Outbound Operational Flow Chart. . 23
Figure 4-3 Bar Code Label on Product. 26
Figure 4-4 Database Operational Flow. 32
Figure 5.1 System Operational Flow. 34
Figure 5.2 PDT's Starting Screen . 35
Figure 5.3 PDT's Configuration Screen 35
Figure 5.4 PDT's Date/Time Setup Screen 35
Figure 5.5 PDT's Password Entering Screen 35
Figure 5.6 PDT's Confirmation for Deleting Data File Screen 35
Figure 5.7 PDT's Selection for Scanning Cant. Code and Location Screen 35
Figure 5.8 PDT's Scan In/Outbound Screen 36
Figure 5.9 PDT's Scan Barcoded Badge Screen 36
Figure 5.10 PDT's Scan Company's Barcode Screen 36
Figure 5.11 PDT's Entering Order Number Screen 36
Figure 5.12 PDT's Entering Number of Pallets Screen 36
Figure 5.13 PDT's Scan Product's Label Screen 36
Figure 5.14 PDT's Entering Product's Weight Screen 37
Figure 5.15 PDT's Scan Cont. Code Screen . 37
Figure 5.16 PDT's Scan Warehouse Location Screen 37
Figure 5.17 !Barsoft Main Menu. 45
Figure 6.1 Bar Coding Template (Front Page). 58
Figure 6-2 Bar Coding Template (Back Page) 59 1 CHAPTER ONE
INTRODUCTION
Warehousing has always been considered an important function of manufacturing storage and marketing distribution. The significance of warehousing lies in having the right product in the right place at the right time for both the manufacturers and consumers. As warehousing has become more competitive, there have been increasing needs for warehouses to have better material control systems. One way for improving the warehouse material control system is to implement bar coding technology in the warehouse. Bar coding is one type of automatic identifications which provides precise and timely support of the data requirements for management information systems. In the warehousing environment, bar coding can help track inventory promptly and record material movement accurately. Therefore, the flow paths of the material can be controlled as soon as the material is received. Material can also be tracked as it flows from receiving to storage, and storage to shipping.
1.1 Background and statement of Problem The selected warehouse at Parkersburg, West Virginia represents a typical pUblic warehouse with its service contracted out to a variety of end users. The end users include major companies like Shell Chemical, Dupont, General 2
Electric and corning. The warehouse has more than 700,000 square feet of storage areas which are subdivided into eight separate warehouses. Most of the products are stored on stackable pallets with the dimension of 40 inches by 48 inches. The pallets weigh from 700 to 2,500 pounds and are stacked three levels high. When a truckload of pallets arrives at the warehouse, the pallets are randomly assigned to any available space in a predetermined warehouse location
(contracted by the end user). The information on product ID, lot number, unit number, and warehouse location are manually recorded on a warehouse movement sheet/report. These manually recorded information sheets are susceptible to human errors.
Because the recorded information is transferred from one person to another, substitution errors, transposition errors or other information loss may occur. Due to these errors, the warehouse is occasionally unable to keep accurate records of the storage location of some products. In addition, the warehouse company spends time and labor just searching for misplaced products. If products cannot be located, the warehouse company has to pay for the misplaced products.
1.2 statement of Purpose
The purpose of this investigation is to design and implement a micro-computer based bar coding data collection system for a selected pUblic warehouse in Parkersburg, West
Virginia in order to improve the warehouse information 3 handling. This proposed system will allow the company to better manage the material or inventory by using the bar coding device to begin tracking the material as soon as it is received. The proposed system will not only simplify the warehouse data collection task but also provides more accurate information for the company. In addition, information based on personnel attendance, and time in use of equipment/machinery can also be collected by the system. ThUS, the warehouse management personnel can exercise better cost control in the warehouse and improve warehouse productivity and efficiency. 4 CHAPTER TWO
LITERATURE REVIEW
2.1 Bar Coding Applications
Bar coding is one type of automatic identification which has been widely implemented in many industries. The initial
implementation of bar coding system was to facilitate the
tasks at the supermarket checkout counter. At the checkout
counter, the product's bar code is read by the laser scanner
underneath the checkout counter and the encoded information is
transmitted to the computer, which searches the product code
in the database to locate the price for the item. While the
information is transmitted back to the checkout terminal, the
quantity shown in the supermarket on hand inventory account
for the particular item is reduced by one, and the item's
price is automatically entered into the sales account. The
system may also be capable of automatically reordering the
particular product if the inventory level drops to a pre
established reorder point (Harmon and Adam 1989). It is
because of these benefits that bar coding systems are not only
widely implemented in supermarkets but also in retail
department stores. Bar coding data collection is rapidly replacing the
keyboard for collecting production data or traCking work-in
process, labor and resource allocation (Abdian, 1987). The
automotive industry has adopted code 39 as the standard bar 5 code for the industry. Code 39 is used not only in automobile assembly plants, but also in manufacturing plants for parts and materials suppliers. By adopting the same bar code standard, companies can communicate with each other through the same network and exchange information by using the
Electronic Data Interchange (EDI) format (Czaplicki, 1987). EDl is the computer-to-computer exchange between organizations of business transaction data in a standard format and is used primarily to improve data interchange among industries. Due to these communication links, bar coding technology has also been considered as the basic tool for implementing Just-In
Time (JIT) methodology by supplying most of the data needed for Material Resource Planning (MRP) and other Computer
Integrated Manufacturing (ClM) systems (Narasimhan and Koza,
1985) . Bar coding technology can playa major role in today's warehousing and distribution centers. In this application, bar code identification can serve as a key for product identification, sortation, storage and retrieval (Knill,
1985) . In an automated distribution center, the bar code is used mainly for identifying and sorting items on the conveyor system. In some distribution centers, bar codes are read in order to transmit instructions to an automated storage and retrieval system which stores the items in pre-assigned areas
(Fuchs 1988). When the items need to be retrieved, the worker 6 can just scan the printed bar coded requisitions, thus causing
the automated storage and retrieval system to retrieve the required items from their assigned locations and send them to a predetermined destination.
2.3 Importance of Bar Coding
Computerized systems are now in widespread use in government, health care, manUfacturing, and offices. Despite the advancement in automation, the input of data or information into the computer continues to require
considerable human effort and time. This has been true in any operation where data input could not be standardized.
Therefore, the need for automatic, fast and accurate means of data input is becoming a necessity (Ettorre, 1987). Bar coding data collection systems require minimum human
intervention or effort because the systems can read or accept
data from a source and convert it into an appropriate
electronic form which can then be received and acted upon by
computers and processors to meet a desired purpose. Bar
coding data collection systems are the most widely used and
most popular automatic identification methodology. Bar coding
offers several advantages: Accuracy of information input. Bar coding minimizes
error; the error rate is one in over 3 million characters
(Allais, 1984). Timely data collection and transmission. Bar coding has 7
the capability of performing real time input of large
masses of information at electronic circuitry speeds.
Data compression. Bar code data is encoded, thus more
data can be "packed" into a smaller space which
facilitates information handling.
Reduced paper work and labor costs. Direct data entry by
bar coding eliminate handling of paper work.
2.4 Advantages of Using Bar Coding Data Collection System
The applications of automatic identification systems are limited only by the human's imagination of how these systems can be applied (Fales, 1989). Bar coding system is one type of Automatic Identification. Each type of automatic identification system has it own unique application and purpose. Bar coding data collection systems are widely implemented, due to the fact that they offer many advantages over other systems. Bar coding system can:
provide high accuracy compared other automatic
identification systems (Palmer, 1989)
read codes at various distances, from contact to several
feet away, and over a wide range of scanning speeds.
utilize both hand held and fixed scanners.
be favorably compared in cost to other automatic
identification systems, since the materials and operating
costs are very low (Palmer, 1989).
have self-checking features, so data collected from the 8
scanner can be directly verified (Palmer, 1989).
operate in conjunction with keyed input and other
equipments such as weighing scales, cash registers, etc.
require very minimum training and skills in its use
(Grieco, 1989).
be generally based on some standardization.
According to one study (Palmer, 1989), a skilled typist would take 10 seconds to manually enter a 20 character data fields, as compared with a bar coding system which would take only 4 seconds to perform the same task. Moreover, the substitution error rate for manually entering data would be high when compared with bar coding system. 9
CHAPTER THREE
CONCEPTUAL DESIGN
The conceptual design for the micro-computer based bar coding data collection system for a warehouse includes the formulation of the statement of need and development of the system requirements. A concise statement of need and detailed system requirements insure a better focus in the upcoming detail design and development process.
3.1 System Objectives
The main objective of this investigation is to design, develop and implement a micro-computer based bar coding data collection system for warehouse information handling and cost control in a selected public warehouse at Parkersburg, West
Virginia. Based on the preliminary analysis and informal interviews conducted in the warehouse, a bar coding data collection system was selected as one of the tools which could help the company improve productivity and efficiency. Using the bar coding data collection system implies that bar coding devices must be integrated into the system. Identification of appropriate bar coding devices must be first considered. It is not the intention of this investigation to select the optimum bar coding devices or computers. Rather, the objective is to identify the selected pUblic warehouse needs and use the currently available bar coding devices in the 10 Center for Automatic Identification Education and Research in the College of Engineering and Technology at Ohio University for designing a low-cost system to fulfill the company's needs.
3.2 Analysis of Warehouse Information Handling
The main functions of the selected public warehouse can be described as:
1. Receiving the products from a source
2. Storing the products until they are needed
3. Selecting the products when they are required
4. Shipping the products to the final destination
Usually, an inbound truckload arrives at the warehouse with a document called a bill of lading/packing slip (Figure
3.1). Once the warehouse supervisor has verified that the correct goods have been received at the dock, a warehouse forklift operator is assigned to "put-away" the goods in the designated warehouse location. In the existing warehouse information system, all pertinent information must be recorded manually on the warehouse movement sheet which is then transferred to the warehouse office for entering into the warehouse inventory system. For outbound activity, a customer sends an order to the warehouse office where it is matched with the available products. Based on the availability of the products, the warehouse will generate a picking list for order selection 11
Ii 11 or l~ciin, / Pac king s1i p
r 1 I ~ ~rthouse ~ovtmtnt • thett Pr04yct heti.,tcl I Storte!
r 2.1 "" Up~ttd receiving recori Product Infert.
.,~rthoY$t1" i"'1tnto~ \". -
Updattd. order ~c}\tdult IT orci.r ILoed. I inv,nt. rill ~ PicJdn, Conrirmction [ ~ lord, r ,n I r~ I 4.8 """ Ortlt%" - S t 1ee1 ion 1+------.--1 I S ~Ii i? i n3 '- Ordtr Ordtr tilltd Jill of J~din1 / P.c1dng 51i, 1
Cusfointr 1/ Ace. rec,ival>!1 ~hippin~ I ctst. I
Invoice
Figure 3-1 Warehouse Data Flow Diagram 12
and shipping. The warehouse inventory system is then updated
accordingly. Even though the warehouse functions are not
complicated, they involve human handling of information.
Details such as what products and quantities, when the products are received, who received the products, and where the products are stored must be properly recorded. These data
are all required for accounting purposes as well as for warehouse inventory control.
3.3 System Operational Requirements
The following operational requirements were developed to
provide guidelines for the detailed design and development of
the bar coding data collection system. The objective was to
provide an improvement to the warehouse information handling
and cost control. The following system requirements must be
fulfilled in the design and development process.
1. The system should be configured on a micro-computer which
can interface with a portable data terminal (PDT) and
generate essential reports.
2. The system should be capable of collecting accurate data
in the warehouse by means of using the portable data
terminal.
3. The portable data terminal should be rugged enough to be
used in the warehouse environment. It also should be
easy to handle and carry so that it would not interfere
with warehouse operation. 13 4. The portable data terminal should be programmable in a
user friendly manner and should allow the operator to easily interact with the system.
5. The portable data terminal programming code should be structured so that system modifications can be easily accomplished.
6. The portable data terminal should be capable of receiving warehouse transaction information in alphanumeric format.
7 • All the warehouse transaction information should be transferred to the micro computer and stored in a database. The hard disk in the computer should have sufficient space to store several years of warehouse transaction information.
8. The database should allow a user to manipulate and view the warehouse transaction information easily.
9 • The system should be capable of generating warehouse
movement reports, employee's productivity reports, employee's shift reports, and warehouse material handling
cost reports. 10. The system should allow the user to obtain hard copy
printouts of reports or transaction data. 11. The system should be capable of printing bar code labels for warehouse locations, employee identification cards
and product labels. 14
CHAPTER FOUR
DETAIL DESIGN AND DEVELOPMENT
The detail design and development phase began with the transformation of the statement of need, the system requirements, and the conceptual ideas. In order to clarify the development steps, this chapter starts with an overview of the proposed micro-computer based bar coding data collection system followed by a description of the hardware and software which has been used in the system. This will be followed by a detailed discussion of the system integration and development for the selected public warehouse in Parkersburg,
West Virginia.
4.1 System Overview
The micro-computer based bar coding data collection system consists of two sub-systems. One is bar coding system which includes the portable data terminal, bar code labels, printing, symbology, and the communication software. The second subsystem is a micro-computer and a relational database for managing collected data and generating reports. 4.2 System Specification The preparation of specifications is part of detail design and development. In order to determine the system specifications, it is necessary to look at the requirements of the portable data terminal, bar code labels, printing, 15 symbology, and the communication software.
4.2.1 Portable Data Terminal
The portable data terminal selected for this investigation was the MARS ELECTRONIC LASER SCAN TERMINAL, MEQ
300 series produced by Mars Electronics International, West
Chester, Pennsylvania. The portable data terminal functions as a remote data collection unit and bar code symbol reader for the system. Information can be transferred in or out of the portable data terminal in three different ways:
1. Automatically by scanning - The portable data terminal is
capable of reading and automatically discriminating between eight major bar code symbologies; code 39, upe,
interleaved 2 of 5, codabar, code 128, code 11, code 93,
and EAN.
2. Manually through the keypad - Information may be manually entered through the portable data terminal's keypad. The
user may also enter additional information, such as
product quantity and location pertaining to the scanned
item. 3 . Upload and download information through the communication port Data files and programs can be uploaded or
downloaded from a computer to the portable data terminal
through its RS-232 port. The MEQ 300 portable data terminal is a programmable unit. Application programs can be written to allow the 16 collected data to be stored, processed, and transmitted. The MEQ 300 portable data terminal consists of a terminal, laser scanner, decoder, memory, battery pack, and MEQ-BASIC interpreter operating system.
The terminal contains a microprocessor, display, and an alphanumeric keypad. The microprocessor executes the code of the MEQ-BASIC interpreter operating system. The liquid crystal display (LCD) provides the operator with visual feedback by issuing prompts and warning messages while the keypad enables the user to respond to the prompt messages on the LCD and to enter information manually.
The scanner uses two different light emitting sources.
First, a high intensity Light Emitting Diode (LED) emits a visible spot of red light which is used to aim the scanner at the targeted bar code label. The second light source is a laser diode emitting invisible infrared light at 780 nanometers wavelength. This light is moved in a back and forth sweeping motion at a rate of 32 scans per second. In order to read a bar code, the scanner must be operated in distance from a minimum 1 inch to a maximum of 13 inches away from the bar coded label. The decoder is part of portable data terminal. The decoder processes the electrical signals (given off by the scanner) and uses a decode algorithm to translate them into human or computer readable data. The memory in the terminal stores the collected data and 17 the application program. The minimum requirement of memory needed to perform the data collection task in the investigation is 128 kilobytes RAM memory. However, if extra memory is needed, the MEQ 300 portable data terminal memory can be expanded to 512 kilobytes RAM memory.
A battery pack with a rechargeable battery supplies DC power to the portable data terminal. A fUlly charged battery pack provides the power necessary to operate the MEQ 300 portable data terminal for up to eight hours. Under normal operating conditions, the battery supplies power to retain the data present in the portable data terminal's RAM memory. In order to protect the data when the battery in not in place, the portable data terminal also contains an internal rechargeable backup battery. The backup battery is maintained by the battery pack and activated when the battery pack is removed. The backup battery is capable of maintaining the stored data in RAM memory for approximately two weeks.
The MEQ-BASIC interpreter operating system is resident, unchangeable firmware in the MEQ 300. The operating system controls the MEQ 300 primary operating functions.
4.2.2 Bar Code Labels Three types of bar code labels can be printed for use in this system. Bar code for an employee badges, bar code product 1D labels (if the incoming material does not have bar code product ID label affixed to the pallet), and bar code 18 labels for warehouse location can all be printed. In addition, the system designer has created a bar coded template to represent the in/outbound activity, customer ID, and pallet's container code which are currently used in the selected pUblic warehouse.
4.2.3 Printing
There are a number of on-site printing devices to print bar code labels. Depending on the print quality of the label produced and where the bar code label will be used, the bar code label can be produced either on-site or off-site. A dot-matrix printer was selected as the printing device for this investigation because it is an inexpensive way of printing acceptable bar code labels on-site. The dot matrix printer also offers flexibility with respect to label size, character size, orientation, and bar code formats.
The dot-matrix printer is connected to the micro-computer and the label generated through the database software on demand. In order for the MEQ 300 portable data terminal to read the bar code symbol, the minimum bar width printed from the dot matrix printer must not be smaller than 0.0075 inches
(7.5 mils) and it can not be greater than 0.055 inches (55 mils). The bar code label should have a print contrast ratio of at least 75 percent. (The print contrast ratio is a measurement of the ratio of the reflectivities between the bars and spaces of a bar code symbol.) The print contrast 19 ratio is calculated as: Print contrast ratio = (R1 - RO)/Rl where: Rl is the reflectance of the light background RO is the reflectance of the dark bars
4.2.4 Symbology Code 39 is the symbology that was used for bar code printing in this investigation. Code 39 was selected for its ability to support alphanumeric characters. It is capable of being printed in variable length, and thus is most appropriate for the warehouse application. The code is a self-checking code which minimizes the substitution error rate and is widely supported by many industry standards. In addition, Code 39 was selected since bar code labels printed in Code 39 were already attached to some of the products received at the selected pUblic warehouse in Parkersburg, West Virginia.
4.2.5 Communication Software Communication software is needed for the system in order to transfer programs or data files from the portable data terminal to the micro-computer and vice-versa. The communication software selected for the bar coding data collection system was MEQ-COMM, MARS ELECTRONICS COMMUNICATIONS SOFTWARE specifically designed.to support the
MEQ 300 portable data terminal. The MEQ 300 portable data 20 terminal can be connected to a computer with a RS-232 cable and the MEQ-COMM software. This connection allows the user to download or upload programs and files between the portable data terminal and computer.
MEQ-COMM communication software has other special features such as automatic changing of communication parameters for the portable data terminal to match the micro computer and a debugging feature which assists the user in tracing program mistakes or errors.
4.2.6 Micro-computer and Relational Database Software
The bar coding data collection system requires an IBM compatible computer. Minimum requirements include 256
Kilobytes of RAM memory, one 360 Kilobyte floppy drive, a 20 megabyte hard drive and DOS 2.0 or higher. One RS-232 serial port (RS-232) is needed for communication with the portable data terminal and a parallel port is used for a dot matrix printer.
The database software selected for use is a universal relational database software called !BARSOFT, a product of
ASAP Inc., (Santa Cruz, CA). !BARSOFT was selected for its capability to print user-defined bar code labels, transmit collected bar code information into database, and manipulate data into management reports for analysis and decisions.
4.3 System Development 21
After defining the detailed requirements for the system, the next major task was to integrate the software and hardware in order to develop a prototype. The integration process required an in-depth understanding of the warehouse information flow. This information flow was carefully investigated to ensure that all the data needed for the system was properly identified and described in detail.
The warehouse inbound activities start with a daily truck dock schedule (Figure 4.1). By knowing the products to be received the warehouse manager/supervisor can assign the "put away" warehouse location ahead of time. When a truck arrives, products are received and verified. Following verification a forklift operator "puts-away" the products. All the pertinent information regarding the products on that particular truckload are recorded on the warehouse movement sheet by the forklift operator. This warehouse movement sheet contains the following information: order number, customer name, product type, lot numbers , unit numbers, container code, product weight, date, time, forklift operator name, supervisor name and warehouse 22
ScJI.duI. rtetl'Jinf ~ai 1~ truck docx seJ'le~,,&1.
Product and ~u~"t i t~to t. receiv.cl
~tcei\linf I ~ectivinf I u t - l v a ~ put-lva~ roeation assi,ntLent
u.rt~loust lDoutlfltnt shett
Product and ~u~nt i t'j receivtc, loc~fion assl!ntcl
Und~tt V4( t t,oust loe~tion ! invtntor~ s1~t'-lS
~rthouse invtntor~ report
Uarthous t invent. ttl'ot't ~------iidentiries 1tlt product I location inro.
Figure 4-1 Warehouse Inbound Operational Flow Chart 23
I.Qrt~tOus, Out~ounc ~ctivit~
Greiff' receiv,. Picking List
~tc~ ord.r Orda,.. Ho., 'Ii tJ\ product a lvaiJaJ.J. ~uantit, in(o.j invlftt \1,., lIIar,houst location
Ordar stltctioft
Product I ~uantlt'J Picxin, PicklC! ordtr cOnrirNtlon ril tc
Ii II or J.din1/ ;icxing sli?
Pro2uct and ~.ily trucx quantit~ to cocx schtdule 1>, loaded
S~d pping
Figure 4-2 Warehouse Outbound Operational Flow Chart 24 storage location.
At the end of a shift, the warehouse manager/supervisor returns the warehouse movement sheets to the warehouse office where the data are manually entered into the IBM mainframe computer. Only after the data is entered can the warehouse inventory reports be generated. These reports contain the storage location of each type of product and the date when it was received.
For warehouse outbound activities, the customer order is matched against the available inventory in the mainframe computer in order to generate a picking list (Figure 4.2). Information on the customer order number, products and/or quantities ordered, and product location in the warehouse must all be specified in the picking list. Any products that are not found, or any substitution of product type must be reflected on the final picking confirmation sheet. with this picking confirmation sheet, the warehouse office is then ready to prepare the bill of lading/packing slip for the outbound shipment.
4.3.1 IDENTIFICATION OF REQUIRED DATA After investigating the warehouse information flow, the next step was to dete ~nine the essential data for the system.
Most of the products arriving at the warehouse already had a label attached to each pallet. The information on the label is presented in two forms; bar code and human readable 25 characters (Figure 4.3). The information encoded in the bar code label are the product unit numbers and lot numbers. This bar coded information is also printed in human readable characters as well as other information which describes the pallet load such as the product type, pallet weight and package number. In addition to the data on the label, other information is needed to identify where the product carne from and where the product will be located in the warehouse. This information includes company name, container code, warehouse location, staging area, date, time, inbound and outbound status. This data may be in bar coded form or human readable form for manual data entry through the portable data terminal's keypad. However, to make the data entry process easier the needed information can be pre-printed in bar code format and arranged on a bar coded template/menu.
There are additional requirements. The warehouse location is a designated space in each warehouse aisle. The operator has to enter the warehouse location when putting away the product and to avoid keying this data, a bar coded warehouse location label was to be placed at each warehouse location. In terms of manually data entering, the order number and pallet weight have to be entered manually through the keypad because of numerous variations. 26
JIII Itt I I I I nun I I" I u f I II I
Figure 4-3 Bar Code Label on Product 27
4.3.2 System design of an Application Program
After the necessary data for the system was identified, an application program was developed for the portable data terminal. The application program was designed specifically to facilitate the data collection tasks in the selected public warehouse. There were two main objectives for this program:
to minimize human errors in recording the information.
to eliminate data reentering tasks in information
transfer.
This was accomplished by customizing the program so that the operator is prompted to scan or manually enter the data into the portable data terminal rather than use the warehouse movement sheet for recording information.
In the data collection process, data integrity and security were the important factors that had to be considered.
In order to ensure that all the collected data is accurate and secured, the application program was written in such a way that only authorized users with correct passwords have access to data file and system time (for tracking of working time and product arrival time) in the scanner system configuration setup. Though the ideal is to scan every bit of information to reduce errors in recording, this is not always possible. Some manual keyboard data entry is required. Occasionally the available bar code labels are not printed within allowable tolerance of the portable data terminal. Furthermore, it is 28 not always cost effective to produce bar codes for all the information. Having considered these factors, the program was developed to allow for both the scanning and manually entering features. An operator not only has the choice of scanning or manually entering at the beginning of the task, he/she can also override the scanning procedures when available bar codes cannot be scanned. Scanning is automatically overridden when an operator tries to scan a bar code eleven times, but can be restored by pressing "" To reduce entering redundant information, the program is capable of enabling an operator to repeat the data collection tasks several times provided that the scanner has been setup initially to allow this option.
The portable data terminal was programmed to accomplish this function by prompting the operator to enter the number of pallets to be stored, and then to use this number as a control for the allowable repetitions of the data gathering transaction. The program will continue to perform the same task as long as the transaction counter is less than the number of pallets. The program is able to detect some of the common errors that may be encountered when the information is entered manually. A special module validates the number of pallets and product weight; thus, if an operator accidentally enters
a letter or the number of digits which are not the same as the
specified field length, the program will reject the input and
prompt the operator to reenter the values. As each data entry 29 record is collected, it is stored in a data file in the portable data terminal. The program saves all information in an ASCII format. The time interval for a forklift operator to handle the pallet load is also computed in the application program and included in the ASCII data file. As a result, warehouse managers can determine which employee handled what products and how much time was spent in handling each product.
Following the data gathering task, the information is uploaded to the micro-computer. The !BARSOFT database software is used to read the data file and update the warehouse inventory database accordingly.
4.3.3 Preparation of a Database Management System
The development of an application for database management system is essential not only for storing and managing the warehouse information, but also as a tool for generating reports for analysis and decision making. such reports will allow managers to exercise better control; thus increasing overall efficiency and productivity. In order to develop the database management application, two factors had to be considered by the system designer; the data structure rules imposed by the database software and the data fields required to generate reports and data entry screens. The data structure rules imposed by the !BARSOFT software requires all data records to have an index item which serves 30 as a "key" for each record, and establishes relationships with the other data items in the record. Each record can have more than one index, which implies that the database may have record(s) within a record for multiple purposes. Identification of the data field is required in order to generate reports for warehouse management. All the information collected in the portable data terminal is transferred/updated into the database system for generating a warehouse movement sheet (report). Because each record requires at least one index item, the lot number is combined with the unit number to be a unique number representing the
index item for one particular record. Information not available from the collected data has to be entered through the data entry screen of the database system. Such information includes the customer ID number, name, address, and contact person. The employee data and the product information are also entered by using the data entry screen. The data entry screen for updating the warehouse inventory is designed for inbound and outbound warehouse activities. The system designer would like to mention that the outbound data collection tasks are not required to enter redundant information, such as container code and pallet weight if the inbound data collection tasks already has provided the information to the database. However, the selected pUblic warehouse in Parkersburg, West Virginia has several months of previously stored pallets with uncompleted 31
records in the database; thus it is necessary at this stage to have the container code and pallet weight enter into the PDT
to update the database. Once all the needed product
information is in the database, the system designer would
recommend the application program to be modified in order to
eliminate the redundant information collecting tasks.
Each data entry screen containing the essential data is
considered as a record for the database. Information
retrieved from a record for a report can be accomplished by
using the index item related to the record. For example,
information needed for a worker productivity report could be
retrieved through the employee's identification numbers (index
item) and/or customer's identification numbers. Therefore,
the database has the capability to generate warehouse movement
sheet/reports, productivity reports, shift reports, warehouse
pickslips, material handling cost control report and warehouse
charges reports on demand (Figure 4-4).
In addition to the above mentioned, other data entry
screens were created for measuring labor or equipment
productivity. For example, they can be used to generate quick
reports for performing cost control calculations in terms of
different material handling operations and labor usages.
Report for calculating the warehouse cube utilization for a
particular product type and the warehouse charges report for
different warehouse customers were also designed. 32
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Figure 4-4 Database Operational Flow 33
CHAPTER FIVE
SYSTEM OPERATION
The following chapter provides a detailed explanation of the operation of the bar coding data collection system. The chapter is divided into two sections. First, the application program operation within the portable data terminal (PDT) is discussed, followed by a discussion of the database management system operation and options. Figure 5-1 depicts the bar coding data collection system's operational flow.
5.1 Application Program Operation
In order to start the application program in the PDT, the operator must press the "on/off" key; then press the "2nd" and the "C" keys simultaneously to interrupt any task in the PDT.
This clears the memory and prepares the PDT for the data collection routine.
The program is activated by pressing the "2nd" and "R" keys simultaneously. A welcome message will appear on the
PDT's screen (Figure 5.2). The operator may then enter "c" for configuring the scanner or "S" for starting the data collection task. Configuration of the PDT is started by entering "C". The program will prompt the operator to input "Y" or "N" for changing the configuration (Figure 5.3). If "Y" 34
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Figure 5.1 System Operational Flow 35
XYZ PUBLIC WAREHOUSE
Figure 5.2 PDT's Starting Screen
WANT TO CHANGE CONFIG. (YIN)
Figure 5.3 PDT's Configuration Screen
SET DATE I TIME (YIN)
Figure 5.4 PDT's DatelTime Setup Screen
PLEASE TYPE IN PASSWORD
Figure 5.5 PDT's Password Entering Screen
DELETE DATA FILE (YIN)
Figure 5.6 PDT's Confirmation for Deleting Data File Screen
SCAN CONT. CODE & LOCATION (YIN)
Figure 5.7 PDT's Selection for Scanning Cont. Code and Location Screen 36
PLEASE SCAN IN / OUT BOUND Figure 5.8 PDT's Scan In/Outbound Screen
PLEASE SCAN YOUR BARCODED BADGE
Figure 5.9 PDT's Scan Barcoded Badge Screen
SCAN COMPANY'S BARCODE
Figure 5.10 PDT's Scan Company's Barcode Screen
PLEASE ENTER ORDER#
Figure 5.11 PDT's Entering Order Number Screen
# OF PALLETS
Figure 5.12 PDT's Entering Number of Pallets Screen
SCAN BARCODE ON THE PRODUCT Figure 5.13 PDT's Scan Product's Label Screen 37
ENTER PRODUCT WEIGHT=
Figure 5.14 PDT's Entering Product's Weight Screen
SCAN CONTAINER CODE
Figure 5.15 PDT's Scan Cont. Code Screen
SCAN WAREHOUSE LOCATION
Figure 5.16 PDT's Scan Warehouse Location Screen 38
is entered, the program will ask the operator whether he/she would like to reset the date and time (Figure 5.4). If "Y" is
entered, the program will request a password to change the
date and time in the PDT (Figure 5.5). The program will only
allow an operator four attempts to enter the correct password, before denying access to make any configuration changes in the
PDT. However, if the password is entered correctly, then the
application program will update the date and time based on the
operator input of "yy/mm/dd" and "hh:mm:ss" respectively.
The program also validates the date and time by checking
their specific format and allowable numerical characters. The
operator is then prompted to enter "Y" or "N" for deleting any
old data file (Figure 5.6). Again, the program will prompt
the operator for another password to delete the old data file
(same as Figure 5. 5) . Similarly, the operator is allowed
three attempts at entering the correct passwords, before
proceeding without deleting an old data file. However, if the
password is entered correctly, the program will erase the data
file (Which called "INVENT") in the PDT. The program will
next prompt the operator to enter "Y" or "N" for scanning
container code and warehouse location (Figure 5.7). If the
operator chooses not to scan this information, the default
manually enters the container code and warehouse location
information. It is important to note that if the operator has
entered "N" or "ENTER" key for all the configuration setups,
it is the same as entering the "s" at the beginning where the 39 operator has chosen to accept the default configuration of the
PDT.
After the above steps, the PDT is ready to perform data collection in the warehouse. The program will prompt the operator to scan the inbound or outbound bar code (Figure 5.8) on the bar coding template (Figure 6.1). The operator is prompted to scan his/her bar coded badge (Figure 5.9). The operator is then prompted to scan the company's bar code
(Figure 5.10) from the bar coding template (Figure 6.1). After that the operator is prompted to enter the order number
(Figure 5.11). Since the order number is not encoded in bar code, the operator has to manually enter the order number through the PDT's keypad. After the order number is entered, the operator is asked to verify the correctness of the input data. Once this is done, the program will prompt the operator to enter the number of pallets (in two digit format) as shown in Figure 5.12. The number of pallets is used as a control in the program to keep track of how many times the program has to perform the same task. (For example, if an operator has manually entered 25 pallets at this screen, the program will initially prompt the operator to scan the in/outbound, employee's bar coded badge, company ID, and then manually enter the order number. After that the program will go through a routine 25 time for prompting the operator to scan/manually enter the product's bar coded label, product's weight, container code, and warehouse location). After the 40 operator has verified that the number of pallets is correct by entering "Y" or "ENTER" key, the next screen prompts the operator to scan the product's bar coded label on the pallet
(Figure 5.13). The product's lot number and unit number are encoded on the bar code label. If the operator realizes that the number of pallets was entered incorrectly after the verification process mentioned above, the operator may press the "2nd" and the "c" keys simultaneously to interrupt the data collection task. This key combination allows the operator to re-enter the number of pallets again or to enter the number of pallets or the remaining pallets from a new truck load of pallets. All the previous collected information will not be affected by this interrupting task. Next, the program will prompt the operator to enter the pallet's weight
(Figure 5.14) in pounds. For consistency purposes the pallet weight is a four digit number. If the pallet's weight is below 1000 pounds, the operator must inserts leading zeros to make a four digit number. The program checks the consistency and validity of the number of pallets and product's weight.
If the operator accidentally enters a letter or the number of digits entered is not the same as the specified length, the program rejects the information and prompts the operator to re-enter the data again. For flexibility purposes, the program is designed to recall the last product weight entered. If the next pallet to be scanned has the same pallet weight, the operator may enter 41 "s" to retrieve the previously entered product weight. This will facilitate the data collection process so that if several pallets have the same weight, it will not be necessary for the operator to enter the weight for each pallet.
After the pallet weight is entered, the program prompts the operator to scan the container code (Figure 5.15) from the bar coding template (Figure 6.1). After this has been verified, the operator proceeds to an assigned warehouse location to store the pallet load. Once the pallet has been stored, the operator scans the warehouse location bar code attached to an envelope (Figure 5.16). The envelope is a permanent item used to keep track of the products which are stored in the particUlar row of warehouse aisle. Since the selected warehouse is presently using painted floor numbers to
indicate warehouse location, the system designer is under the constraint to use a permanent item (an envelope) attaches to the front of the first pallet in each warehouse aisle/bay to represent a warehouse storage location. If the operator encounters no stock in a particUlar row of warehouse aisle or the envelope is missing, the system designer recommends that the warehouse supervisor setup the PDT for manually entering the warehouse location with the PDT's keypad. The MARS PDT scanning range is only 13 inches therefore it is also not possible to use a bar coded tag which to be suspended across
the warehouse aisle to indicate the warehouse location. Even
though using the bar code labeled enveloped is not an 42 effective way of entering a warehouse location, it does provide the warehouse management the opportunity to observe how a bar coding system can operate in the warehouse environment.
When the above tasks are completed, the program will compute the amount of time the forklift truck operator spent handling a particular pallet. The first PDT internal clock time is recorded when the operator scans the product's bar code. The second PDT internal clock time records when the operator scans the warehouse location bar code. The time difference between the start and finish is calculated. The material handling time is the time spent from picking up a pallet at the receiving dock until the pallet is stored in the assigned warehouse location or from the storage location until the pallet is handled to the staging area (a particular shipping dock). The program will perform the material handling time calculation only after the operator responses to the PDT warehouse location prompt for verifying the entered information. If the entered information is incorrect, the operation can enter the information again by pressing any keys, except the "Y" and "ENTER" key on the PDT's keypad.
Once all the pertinent data fields are collected and computed, the data are then written into a data record (ASCII format) in the portable data terminal. If the number of times the task has been repeated in the data collection process is less than the number of pallets entered in the program, the 43 program will repeat the data collection task which begins with scanning the product's bar code. This repetitive data collection task is performed until the program transaction counter matches the number of pallets entered.
5.2 Database Management System Operation and Options
After the data are collected, the PDT is delivered to the office where all the collected data is uploaded to the micro computer using the MEQ-COMM communication software. Once the collected data has been transferred from the PDT to the micro-computer, the operator can employ the database management software. Along the bottom of the screen, functions are predefined by the !BARSOFT database software for special commands corresponding to the micro-computer function keys (Figure 5.17). A dialogue box for operator prompts is displayed across the top of the screen. The operator is asked to enter a password for accessing the database. Once the password is entered, the dialogue box prompts the operator to select a function key (F1, F2, F3, ... , FlO). At this point, the operator must select F9, SYSTEM UTILITY (this is a predefine function by !BARSOFT database software), in order to convert the ASCII file uploaded from the PDT to the !BARSOFT database format. During this process, the operator is asked to choose an ASCII format for the data file. The format uses a comma for the item delimiter and a carriage return for the record delimiter. Items which are not numeric must be place 44 in double quotes.
After the selection is made, the operator is prompted to select the data entry screen onto which the converted data will be transferred. At this point, the screen directory is displayed and the operator selects the WAREHOUSE UPDATE screen. As the file is being transferred, the number of records which have been transferred to the data entry screen is shown in the dialogue box along with the number of errors which occurred during the transfer process. If no errors are detected, the operator knows that the collected data is loaded in the database. The error message number, if any, will provide as a guideline for helping the operator to correct problems. Once the above tasks have been completed, the main menu reappears on the bottom of the screen. The operator can choose to update different data entry screens, generate quiCk reports or custom reports, and print bar code labels. 45
E:ller password:
a5aP t m !E: R R 5 0 F VerSl0n: 6.6 r
(C) 1ge~ AZAP,INC. All R1Chts Reserved 1 HELP 2SCREEN 3 DATA ~OUICr 5CUSTOH 5FORMS/ 7QUERY eBACrUp 9SYSTEH10 EXIT DESIGN ENTRY REPORT REPORT LABELS RESTORE UTILITY SYSTEM
Figure 5.17 !Barsoft Main Menu 46 5.2.1 Data Entry Screens
The data entry function in this database has ten different data entry screens. Each of the data entry screens serves a different purpose:
1. WAREHOUSE UPDATE used for updating the warehouse inventory and location status. It is also used for
gathering information on product lot number , unit number, order number, pallet's weight and the material handling
time for each pallet for the warehouse movement report.
2. PRODUCT INFO - used for entering information on each of
the pallets being handled. Information on the employee who handles the pallet, the time it is handled, the customer, and the quantity on hand are automatically updated simultaneously in this and other screens.
3. CUSTOMER INFO - used for updating customer information, such as customer's name, address, contact person, and
telephone number.
4. EMPLOYEE INFO - used for updating employee data such as employee ID number, name, address, pay rate, shift
number, contact person and emergency phone number.
5. CUSTOMER QUANTITY INFO - used for updating the quantity on hand. The database will increase the total quantity
on hand when a product is received. Similarly, the database will decrease the total quantity on hand when a
product is shipped to customer. 6. WAREHOUSE CHARGES - used for updating the warehouse 47
charges for each customer such as storage charge,
handling charge, and transaction charge. All the
warehouse charges are calculated based on the billing
date.
7. M.H. COST CONTROL - used for productivity measurement.
For each different operation to be performed in the
warehouse, the material handling costs per operation for
a pallet and the throughput material handling costs per
pallet can be computed by using the average hourly costs
for all warehouse operations multiplies with the total
hours per month and divides by the total number of
pallets received.
8 . WAREHOUSE INFO. - used for tracking total number of
pallets in any particular warehouse, the data entry
screen is also used for updating the total number of work
hours per month for all the warehouse operations and
calculating the hours per pallet for the particular
warehouse.
9. WAREHOUSE CUBE UTIL. - used for productivity measurement.
Based on the operator I s input of warehouse dimension, the
obstacles in the warehouse and the number of pallets in
the warehouse, the warehouse cubic utilization ratio will
be computed for the operator.
10. W. ROW BARCODE used for printing bar codes for
warehouse locations specified by the operator.
(Samples of data entry screens are shown in Appendix D.) 48
5.2.2 Quick Reports
In the quick report function, the operator can generate a report of all the data entered into any of the data entry screens. The quiCk report can be directed to the operator's computer display, printer, or a Data Interchange File (DIF).
The quick report module is activated when the operator selects
F4 from the main menu. After the selection is made, the quick report directory is displayed on the computer screen. The quick report directory is a list of all the existing data entry screens mentioned above. For printing a quick report, enter P in response to "Do you want to PRINT or CUSTOMIZE a
Quick Report (P/C)?". After that the system will prompt the operator for the quick report to be printed. The operator may enter the particular quick report number listed on the quick report directory. Next, the system will prompt "Destination -
PRINTER, SCREEN or DIF FILE (P/S/D)?". If the operator selects P, the quick report will be printed at the printer. If the operator selects S, the quick report will be directed to the computer's screen. If the operator selects D, the quick report will be written onto a DIF file. When the quick report has been generated, the main menu will be shown again on the screen.
5.2.3 CUstom Reports The custom report module is also used for generating
reports. The custom report directory is displayed on the 49 screen by selecting F5 on the main menu (refer to Appendix C) .
The operator may select to generate productivity report, warehouse pickslip, shift report, warehouse charges, pallet and hours report, warehouse movement report and material handling cost control report. The following are the description of the purpose for each of the reports:
1. PRODUCTIVITY REPORT - used for providing information on
the employee who handles the product, the customer, the
time the product is received, and the material handling
time. The items included in the report are operator ID,
name, date, product IO, company name, starting time, and
material handling time.
2. WAREHOUSE PICKSLIP - used to generate a picking list for
the available products which may be picked for order
selection and shipping. The important items included in
this report are warehouse location, product type,
container code, lot number, unit number, and weight.
3. SHIFT REPORT - used for providing information on the
different shifts an employee might work in. The items
included in the report are operator IO, name, phone
number and shift number. 4 . WAREHOUSE CHARGES - used for generating the typical
warehouse billing report. The charges are based on
number of days the product is being stored plus the
storage, handling and the transaction charges. The i terns
included in the report are company information, billing 50 date, product 10, weight, date start counting for
charges, number of days computed, storage charge,
handling charge, transaction charge, and total charges.
5. PALLETS AND HOURS - used for providing information on total quantity of products in a particular warehouse, the estimated work hours per month for the warehouse, and the
calculated number of hours per pallet. The items
included in the report are warehouse number, total number
of pallets, total number of work hours per month, and the calculated number of hours per pallet.
6. WAREHOUSE MOVEMENT - used for providing information on
the product received, the date it is received, the
product's weight, the employee who handles the product,
and the storage location. The items included in this
report are order number, customer information, operator
information, lot number, unit number, container code,
weight, warehouse row number, and date.
7. M. H. COST CONTROL - used for providing information on
the material handling costs per pallet for each of the
operations to be performed in the warehouse. The items
included are warehouse number, total pallets handled,
operation type, hours per month, hourly costs, cost per
operation, and the material handling costs per pallet.
(Samples of customer reports are shown on Appendix C.)
When the operator has selected the custom report to be printed, the system will display a report table and prompt the 51 operator to enter a number of printing parameters. The parameters are upper and lower limits, space and page breaks, sort items, totals, counts and averages for the report items.
These parameters in the report table enable the operator to select a subset of data from the database records, so that the custom report will contain only the desired data. By setting the parameters, the operator also has the flexibility to state which items the operator wants to be totalled, counted, and averaged.
When the operator first accesses the report table, the cursor is at the top line, called the "title" line where the DATE field is located.
1. At the DATE field, the operator may specify the date to
be printed on the title line of the report. If a date is
not needed on the report, the operator may ignore this
field by pressing the space bar. If the operator wants
the computer system date printed on the report, the
operator may type SYS DATE in the DATE field for this
purpose. 2. At the DESTINATION field, the operator may type "p" to print the report on the printer, "s" to display the report on the computer's screen, "F" to direct the report
to a disk file, or "0" to direct the report to a DIF
file. 3. At the SUMMARY field, the operator may type "y" to obtain
a summary report. 52
4. At the COPIES field, the operator may specify the number
of copies of report to print.
After the operator has set the number of copies to be printed in the title line mentioned above, the cursor moves to the report table in the lower limit field adjacent to the first data item. However, if the operator wants to use the parameters already predefined by the system designer, the operator may press F9 PRINT REPORT to proceed with the printing of the report. If the operator desires to change the report table's parameters, he or she uses the specific setups: 1. At the LOWER AND UPPER LIMIT parameter field, the
operator can select a subset of the data for that
particular item. The system retrieves all records for
which the parameter field value is greater than or equal
to the lower limit value and all records which are less
than or equal to the upper limit value. For example, if
the warehouse supervisor want to generate a warehouse
pickslip for a particular type of product, the supervisor
can specify the lower limit as KTN-1600 and the upper
limit as KTN-1652 so that all the product types within
this range will be retrieved from the database and listed
on the warehouse pickslip. The user may set a lower
limit, upper limit, both or neither on as many items as
needed. Records will be selected for the report only if
they satisfy all of the range requirements which the
operator has specified. 53
2. At the SORTS parameter field, the operator can specify an
item to be sorted in ascending (A) or descending (D)
order, and the sort priority (1 through 9).
3 • At the BREAK parameter field, the operator can set a
space break, which creates a blank line for each item
change in the report. In order to do so, the operator must type "s" in the BREAK parameter field. If a page break is needed for each item change, the operator must type "p" in the BREAK parameter field. The operator can also include a "T" in the column next to the "p" or "S". This will cause whatever subtotals, subcounts or
subaverages that are specified in the TOTAL, COUNT or AVG
parameter fields to be printed at the break.
4. At the TOTAL, COUNT OR AVG parameter fields, the operator
can request in each field a subtotal (8), grand total (G)
or both (B) to be printed when a break occurs. A custom
report can include any number or combination of totals,
counts or averages.
Once the operator has set the report table parameters, the
operator can press F9 to generate the report.
I ! 5.2.4 Forms and Labels The FORMS & LABELS function is used for printing bar code
labels. The FORMS & LABELS directory is displayed by pressing
F6 on the main menu (refer to appendix E). There are three
labels listed in the directory. The first is the product 54 label, the second is the employee ID label, and the third is the warehouse location label. Following is a brief discussion of each of the labels.
1. PRODUCT LABEL - used to print the label for replacing the
missing label or damaged label on the product. The
information on the label includes the product 1D number,
lot number, unit number, customer information, and the
bar coded product ID number.
2. EMPLOYEE ID. LABEL - used to print the bar code label for
the employee badge. The information on the label
includes the employee's name and a bar coded employee ID
number.
3. W. LOCATION LABEL - used to print the bar coded warehouse
row location. The information on the label includes the
warehouse row location number printed in human readable
and the bar code format.
(Samples of bar code label are shown in Appendix E.)
When the operator has selected the label to be printed, the label table will be displayed on the screen for setting the printing parameters. The operator may use the label table to set upper and lower limits for each item field, to select a limited record set for printing or to establish sort items.
The label table is identical to the report table described above, except that the operator cannot set breaks, totals, counts, or averages for printing labels. 55
CHAPTER SIX
SYSTEM IMPLEMENTATION
6.1 System Preliminary Tests
In designing the system, the system designer used dummy data as preliminary tests for checking and debugging each sub system. The PDT was scanned bar coded labels generated from the !BARSOFT software. The collected dummy data from the PDT was uploaded to the computer and then loaded into a word processing software to check the format on the data file.
Even though there were several ASCII formats available, only the format which uses a comma as the data delimiter and a carriage return as the record delimiter was compatible with the !BARSOFT file importing format. After an ASCII data file format was selected, the !BARSOFT data entry screen was used to update the actual database information.
In addition to updating the database, other data entry screen information was also checked for correctness and consistency in terms of how the data field would effect other posting data field. For example, a total quantity on hand data field had to be increased or decreased by one depending on whether the product was for inbound or outbound. All the calculations to be performed in the data entry screens and custom reports were checked for accuracy and correctness by comparing with manual calculations.
When the result of the system was satisfactory in the lab 56 setting, the designer used the equipment in the selected public warehouse and tested the system with real data in the warehouse environment. Based on the feedback from warehouse managers and employees, selected features in the application program and the !BARSOFT reports were changed to meet identified needs. Following these preliminary tests, the system was ready to test for implementation and validation in the selected public warehouse.
6.2 System Implementation and Validation
The pilot test was conducted at the office of the s e i eotied publ i c warehouse in Parkersburg, West Virginia.
Equipment and software used in the pilot test were borrowed from the Center for Automatic Identification Education and
Research in the College of Engineering and Technology at Ohio
University.
The ! BARSOFT database and the MEQ-COMM communication software were installed on an IBM PC compatible computer. The
MEQ-BASIC application program was then downloaded from the hard disk to the portable data terminal. After configurating the portable data terminal, it was ready to perform data collection in the warehouse. In the storage and receiving areas, the PDT data was collected in a selected warehouse storage area (warehouse #8) where all the pallet loads already had affixed bar code labels. In order to simplify the data collection task, the 57 warehouse management personnel selected four batches of pallet
loads and arbitrarily assigned them with four different order
numbers. The first batch had 6 pallet loads, the second batch had 4 pallet loads, the third batch had 22 pallet loads and
the last one had 8 pallet loads. Once these assignments were
completed, the warehouse personnel started the data collection by scanning the operator's bar coded badge and the company's bar code. The in or out bound status was also arbitrarily
assigned by scanning the bar code on the template (Figure
6.1). Other information scanned from the template was the
container code and the warehouse staging areas (Figure 6.2).
Since the primary purpose was to demonstrate how the scanning
routine could be performed, the system designer chose to input
the staging area as a warehouse location when the portable
data terminal prompted to scan the warehouse location bar
code. By doing so, the group of people who participated in
this "pilot test" did not have to follow a forklift truck to
a warehouse location in order to scan a particular warehouse
location bar code. There were also some instances when the
system designer purposely tried to override the application
program by pUlling the trigger eleven times. The portable
data terminal responded by prompting manual entering of the
information. After completing the data collection task, the portable
data terminal was returned to the warehouse office where the
data file was uploaded to the computer. By using the database Bar Coding Template
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01 00 59
Warehouse Staging Areas
ST 1 ST 5
ST 2 ST 6
ST 3 ST 7 ji I hI ,'I: ., I: I'; , w ... I -sr:-
ST 4 ST 8
Figure 6-2 Bar Coding Template (Back Page) 60 system, the management personnel were able to generate custom reports (including the warehouse movement sheet) based on the data just collected from the warehouse. In addition the designer demonstrated how the database could be used for generating reports on worker productivity, quantities on hand, pick-list, warehouse charges, and warehouse cubic utilization was demonstrated.
In terms of system validation, the previous recorded warehouse movement sheets with the collected data were compared with the data collected from the "pilot testing". As was anticipated, the collected data with the portable data scanner was absolutely correct. This strongly suggested to the warehouse management personnel that the bar coding data collection system was not only a feasible way for eliminating human errors in warehouse data collection but also a tool for facilitating information handling and cost control. 61
CHAPTER SEVEN
CONCLUSION AND RECOMMENDATION
7.1 Conclusion
This investigation was initiated to design and implement a micro-computer based bar coding data collection for improving information handling and cost control for a selected public warehouse in Parkersburg, West Virginia. Even though bar coding data collection is not the only technology which could have been implemented to improve the warehouse information handling, it is certainly one proven technology which can be implemented without a major investment in software and hardware.
By implementating and validating the bar coding data collection system for the selected publ i.c warehouse, the system designer fulfilled the requirements stated in conceptual design. It was found that the bar coding data collection system simplified the warehouse data collection tasks, provided more accurate information, and allowed better cost control capabilities in the warehouse. In addition to enhancing the warehouse information handling, it was agreed that overall warehouse productivity and efficiency would also be improved. The result of this investigation suggests that using a micro-computer based bar coding data collection system for improving warehouse information handling and cost control is an effective technology which a pUblic warehouse company 62 can implement to gain a competitive business advantage at a nominal cost.
7.2 Recommendation
While this investigation was limited to the design and implementation of a functional micro-computer based bar coding data collection system, there is opportunity for future investigation. Some ideas for future investigation may include the following:
If real time information is a necessity for the data collection system, a future investigation should study the possibility of connecting a radio frequency device to the portable data terminal so that the scanned data can be transferred in real time to the base radio frequency device which is connected to the personal computer or host computer. The goal would be to investigate the most economical way to upgrade the portable data terminal to perform radio frequency data collection task. By using the radio frequency technology, the operator could virtually eliminate any human intervention in handling the data, and thus the information flow would be better than the system designed in this investigation. Another option is to study the feasibility of applying a two dimension bar code, so that one code would have all pertinent information such as company name, product ID number, product type, product description, unit number and lot number. 63 with this arrangement, the operator could collect all the relevant data with one scan on the product label. 64
REFERENCES
Abdian, Geoffrey. "Bar Code System Improves Tracking of Work-In-Process, Labor and Resource Allocation." Industrial Engineering September 1987: 32-36.
Adams, Russ. "Portables: Data on the Go." Automatic I.D. News December 1989: 30+.
Adams, Russ. "Scanners." Automatic I.D. News January 1990: 25+.
Adams, Russ. "Bar Codes Go Two Dimensional; the Portable Data Base Arrives." Automatic I.D. News May 1990: 1+.
Allais, David. Bar Code Symbology Lynnwood, WA: INTERMEC Corp., 1984.
"Automatic I.D. Delivers the Data for Warehouse Efficiency." Modern Materials Handling Spring 1986: 77-80.
Baker, Eugene F. Industry Shows Its stripes. New York: American Management Association Membership Publications Divisions, 1985.
Burke, Harry E. Handbook of Bar Coding Systems. New York: Van Nostrand Reinhold, 1984.
Burke, Harry E. Automating Management Information Systems: Principles of Barcode Applications. New York: Van Nostrand Reinhold, 1990.
Bushnell, Richard D. Jr. Getting started with Bar Codes: A Systematic Guide. Arlington, MA: Cutter Information Corp., 1986.
Buys, Clifford R. "EDI and Productivity in Manufacturing." Production & Inventory Management Review January 1990: 34-36.
"Carolina Mirror Reflects Bar Code Benefits in Warehousing." Automatic I.D. News November 1989: 1+.
Collings, Sarah. "Bar Coding: A Hot Manufacturing strategy." Manufacturing Engineering August 1989: 55 58.
Culp, Richard T., Roberta J. Galehouse, and Jack D. Harpool. System Analysis and Design Projects. st. Louis, MO: Time Mirror/Mosby College Publishing, 1987. 65 Czaplicki, David J. "Organizations Support Expanded Use of Automatic Identification for A variety of Industries." Industrial Engineering September 1987: 39+.
Demars, Norman A. "Computer Voice Data Entry for Warehouse Receiving Improves Customer Service." Industrial Engineering May 1988: 26+.
Oraxler, Dave. "An RF/ID Primer." 10 Systems June 1990: 36+.
Elliott, Barry J. "EDI." Production & Inventory Management April 1990: 50-52.
Ernst & Whinney and Cleveland Consulting Associates. Warehouse Accounting and Control: Guidelines for Distribution and Financial Managers. Oak Brook, NJ: National Council of Physical Distribution Management and National Association of Accountants, 1985. Ettorre, John J. "Auto. ID Takes Off in Transport... Transportation & Distribution October 1987: 22-24. Fales, James F. Automatic Identification Class IT 454. Ohio University, Spring 1989. Frey, Stephen L. Warehouse Operations: A Handbook. Beaverton, OR: MIA Press, 1983. Fuchs, Jerome H. The Prentice Hall Illustrated Handbook of Advanced Manufacturing Methods. Englewood Cliff, NJ: Prentice Hall, 1988. Gozzo, Michael W., Peter L. Grieco, and C.J. Long. Behind Bars. Palm Beach Garden, FL: PT Publications, 1989.
Hakanson, William P. "The Bar Code Is Key to Automatic Identification." Transport Topics 31 July 1989: 23. Harmon, Craig K and Russ Adams. Reading Between the Lines. Peterborough, NH: Helmers PUblishing, Inc., 1989. Johnson, Thomas. "Managing Costs: An Outmoded Philosophy." Manufacturing Engineering May 1989: 42-46. Kii, Shirley. "Seventh Annual 10 Equipment Buyers Guide." Industrial Engineering September 1989: 51-64. Knill, Bernie. "Automatic Identification: New Building Block of Productivity." Material Handling Engineering November 1985: A2+. 66
Koza, Russell C. and Seetharama L. Narasimhan. "Automatic Identification Systems Serve as Integrators in the Factory of the Future." Industrial Engineering February 1985: 58+.
Malone, Robert. "Bar Code Industry Looks for a Standard." Managing Automation December 1988: 38-40.
Maraschiello, Bill. "Real Time Data Entry: Now's the Time." Handling & Shipping Management October 1986: 60+.
Forger, Gary., ed. "A Course-in-Print: Bar Code Systems Basics." Modern Materials Handling. September 1989: 51 64.
Moore, Bert. "Comparing Apples, Oranges, Pears and Grapes." Production & Inventory Management May 1990: 28+.
Moskal, Brian S. "Trucking looks to the Sky for its Future." Transportation & Distribution April 1989: T14+.
Nelson, Gene A. "Finding Your Way Through the Labyrinth of Electronic Data Interchange." Production & Inventory Management July 1990: 28+.
Palmer, Roger C. The Bar Code Book. Peterborough, NH: Helmers Publishing, Inc., 1989.
Parshall, Michael R. "Four Success stories - Bar Codes Made Them Happen." Modern Materials Handling March 1986: 66 69.
Payne, Robert. "Take Advantage of EDI." Transportation & Distribution August 1989: 56.
"RF Systems are Combining Best of Both Worlds." Handling & Shipping Management May 1987: 41-42.
Rupp, Loralee Butler and Sahney. "Henry Ford Hospital IEs Improve Scheduling, Inventory, Communications. " Industrial Engineering October 1988: 58+.
Shah, Pravin P. Cost Control and Information Systems. New York: McGraw-Hill Book Company, 1981.
Smith, Jerry and James Tompkins. The Warehouse Manaqement Handbook. New York: McGraw-Hill Book Company, 1988. APPENDIX A: APPLICATION PROGRAM FLOW CHARTS 67
~tart
PrtSS the ·on/orr· it, to t,.rn on the scanner
1rtJs the -'n.- k.~ .nc the ·c· xt, siaultaneousl, to inttrrypf in, t~sk iA t}•• sc.nntr
P~tSS ·'n4- xe~ and -g- letf) si~lt.nfousl, to run t ht 4. ~a collection pr01:~
YEt HO Ir -:- is tn~trt~
NO 68
Pro"ft to Access en .r denl'. p.sswords IJtss.gt
~ft passwords coW\ter
Setup dAte ~n4 t 1~ ror tht scanner 69
PrOlTlpt to enter p.sswords
NO Set p.sswords counter
YES 70
:.t rI~9 FCt.:! to Nr.ual1y .------.. enter w.rehou$' container cOd. I loc.tion
rrf
Prompt to r.. rHJ.II~ tnt tr the inrOZ'Ntion 71
Prompt to Anal'll' Inter ('lIN) ~r coci. tor veri'';Ii nt wr cocie
NO
Prollpt to tnt t r ('iItt> (or IItri(';Iin, wr cocie
Prompt to Nnu~ll~ enftr intorNtion
YES
Prollpt to Nnual1~ enter the inro~1ion 72
Pr-ompt to enftr (Y/H) ror v.rir~in, order IUUft.b.rs
NO
Prompt to Y£S enttr ('{IN) ror 1Jtrir~inf set counter numbtr of p;11et
Y£~ NO 73
Analyzi wr co.il
Pro.pi to tnttr (YIN) (or IJtrirljin, ~r coct inrorNfioft
Prol\pt to enter (Y/H) ror vtrirljin, wtlght
yrs
NO Pr:mpt to Inter product's weight Nn\lil !I 74
•
Pro",t to tnter (YIN) ror "erir~ini ~r cocit
Prollpt to r.anuall~ enter cont. code 75
'~.pt t. tnt.,. (YIN) tor vtri(~in, co"f. C04.
tntfr P~mpt to ".:"f ~..oU S, tnttr (YIN) loc.tlon t sr IJtri('ilng Nnu~ll~ ,,~rfhoust loc.tioR
yrs 76
PrQ~pt to tn,.r (Y/H) (or "'tJ"ir~inf wr CQdl
':-orapt to tnttr warthol.U t location eoda Nnu~ll~
'- 77
~lctlla1t tM tlipS'. tiM tor tM Optritor'1 task
y[S HO
HO
NO APPENDIX B: APPLICATION PROGRAM LISTING 10' 20' ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 78 30' •• •• 40' •• INTRO: THIS PROGRAM WAS DESIGNED TO COlLECT INBOUND AND •• SO' •• OUTBOUND WAREHOUSE lliFORMATION BY USING TIlE MARS 60' •• ELECTRONICS LASERSCANTERMIN'AL, MEQ300 SERIES. ••*. 70' •• THE INFORMATION TO BECOllECTED BY TIlE MEQ 300 •• 80' •• SCANNER WILL CONSIST OF PRODUCT ID NUMBERS, •• 90' •• LOT NUMBERS, UNITNUMBERS, CONTAINER CODES, •• 100' •• WEIGHTS, WAREHOUSE LOCA nONS, OPERATORNAME, •• 110' •• INBOUNDIOUTBOUND STATUS, CUSTOMER ID NUMBERS, •• 120' •• ORDER NUMBERS, DATE OF ARRIVAL, TIMEWHEN TIlE •• 130' •• OPERATORS START WORK..J}1G ON THE PRODUCT, TIME •• 140' •• WHEN THE OPERATORS FINISH WORKING ON TIlE PRODUCf. •• 150' •• THE MEQ 300 SCArmER IS CAPABLE OF READIN'G AND •• 160' •• AUTOMA TICALLY 01SCRIMINATING DIFFERENT BAR CODE •• 170' •• SYMBOLOGIES SUCH AS CODE 11,CODE 39, CODE 93, •• 180' •• CODE 128, INTERLEAVED 2 OF 5, UPC-A I UPC-E, •• 182' •• EA.t'l-8/ EAN-13, AND CODABAR. HOWEVER, IF TIlE 184' •• BARCODES ARE NOT SC~'lNABLE, TIllS PROGRAM HAS .*•• 186' •• AN OVERRIDE MODULE WHICH WILL PROMPT TIlE USER •• 188' •• TO &T\ffER THE INFO~\1A nON MANUALLY TIlROUGH 11IE 190' •• MEQ 300 SCANNER'S KEYPAD. WHEN DATA HAVE BEEN ••.* 192' •• COLLECfED, THE OPERATOR MAY UPLOAD ras DATA •• 194' •• TO MICRO-COMPUTER BYCONNECTING THE RS-232 •• 196' •• PORTON TIlE SCA~1'JER TO THE RS-232 PORTON THE •• 198' •• COMPUTER. •• 200' •• •• 202' •• PURPOSE: DESIGN AND L\1PLEMENTAnON OF A MlCRO.coMPUTER •• 204' •• BARCODING DATA COLLECTION SYSTEM FOR IMPROVING •• 206' •• WAREHOUSE INFOR..\1AnON SYSTEM. •• 208' •• •• 210' •• PROGRAJ.\iMED BY: TUAN SUN CHEOK •• 212' •• OHIO UNIVERSITY •• 214' •• mDUSTRIAL'" SYST&\1S ENGINEERING DEPARTMENT •• 216' •• ATHE.1\1S, OHIO 45701 •• 218' •• U.S.A. •• 220' •• •• 222' •• DATE: MAY 9,1990 •• 224' •• •• 22S' •••*.*••**••**.******.***••••••••••••***••••••••••••••••*••••••••••••••••***.*••••• 226' 227 DIM SYSSET(lO),SYSPRM(lO) 'OOTIALlZE SYS. PARA\fETERS de VARIABLES 228 DIM BCODES·64,QS·255 229 DL\1 PIDS·16,LOTNOS·9.lJNITNOS·3,CTCODES·3,LOCATS·6,OPNAMES·9,STATUSS·3 230 DL"f COMPIDS.8,ORDNOS* 1O,SDATES *8,SlL\1ES·S,F1LVlES· 8,SFMS·145 232' 234' SET SYS. PARA.~ETER DECODE TO DEFAULT 236' 240 FOR 1=1 TO 10 250 SYSSET(I)=SYSP~\1(I) 260 NEXTI 262' 264' DEFINE RLE FO~\1AT TO BE SAVED IN xscn 266' 270 SFMS="Cl,C16,C3,C9,C3,C3,C3,C3,C2,N5.0,C2,C6,C3,C9,C3,C3,C3 tC8,C3,CIO,C3tC8,C3,C8tC3,C8,C2~l\jS.2,Cl,N3.0" 272' 274' DE~'"E FILE ~'UMBER AND FILE LENGTH TO BE USED 276' 280 SF=5 290 SLEN=145 292' 294' IF 'f~rvENT" FILE OOES NOT EXIST THEN CREATE rna "INVENT' FILE 296' 300 ONERR GOTO 320 310 OPEN "INVENt AS NSF: ONERR G010 SUBERR : GOTO 330 79 320 OPEN "INVENT' AS NSF LEN=SLEN : RESUME NEXT 330 BCLEN=16 340 KEYBOAR1)::l 342' 344' WITIALIZE ERROR SUBROUTINE 346' 350 GOSUB IERR 360 ONERR GOTO SUBERR 370 ONBAR GOSUB GETCODE 372' 314' SET DEUMITERS TO BE USED IN xscn FILE 376' 380 CRS--cHR$(13) 390 LFS=CHRS(lO) 400 TS--eHRS(34)+CHRS(44)+CHRS(34) 410 ACS--cHRS(34)+CHRS(44) 420 CAS--cHR$(44)+CHRS(34) 430 AS=CHRS(34) 440 CS=CHR$(44) 445 CRLFS--eRS+LFS 446' 447' DETER.\1IJ\TE THE PRESENT STATE OF MODE SEITING ON THE SCAA'NER 448' FOR DATA COMMUNICATION PURPOSES 449' 450 MEQMODE=PEEK(40961) 460 MEQBAUD=MEQMODE Al'ID 15 470 MEQSTATS=(MEQMODE AND 112)/16 480 IF MEQSTATS=O OR MEQSTATS=2 11I~~ MEQSTATS=MEQSTATS+l 490 MODE MEQBAUD..\1EQSTATS 492' 494' SET SYSTEM PARAMETERS TO DISABLE SCANNER, POWER OOWNTL\iER TO 90 SEC 496' AND orssa PARAMETERS REMAIN TIlE SAME FOR AUTO-DISCRIMINATrNG OTHER 498' BAR CODE SYMBOLOGIES 499' 500 SYSPA~MS 1,90,5,255,3,14,5,0 505' 510DIS=" XYZ 520 025=" WAREHOUSE " 530 CT=l 540 COL=16 542' 544' DISPLA Y MESSAGE ON TIlE SCANNER'S SCREEN 546' 550 GOSUB DISPLAY 560 FNO=O 562' 564' WAIT FOR THE USER TO KEY-IN A LETTER ON TIIE KEYPAD 566' 570 ISETS=INKEYS 572' 574' IF NOTIlING IS BEING ENTER TIlEN CONTl1'iUE TO WAIT 576' 580 IF ISETS=,tn TIIEN GOTO 570 582' 584' IF "S" IS BEING ENTER THE.~ STARTTHE DATA COLLECI10N PROGRAM 586' 590 IF ISETS="S" THE.'l GOTO 1230 592' 594' IF fie" IS BEING &\lTER THE.'I STARTTHE CONFIGURATION SETUP ROUTINE 596' 600 IF ISETS="C" THEN GOTO 630 610 GOTO 570 620 ' 622' PROMPT TIlE USER FOR CONFIR.WNG CHOICE 624' 80 630 OlS="WANT 1'0 CHANGE " 640 02$=" CONFIG. (YIN) " 650 COL=16 : GOSUB OISPLA Y 652' 654' ONLY ACCEPT ONE LEITER INPUT FROM TIlE KEYPAD 656' 660 INPUTS NKEYBOARO,"E",I,ANSS 670 IF ANSS="" THE.""J GOTO 630 680 IF ANSS(1:1)<>"Y" THEN GOTO 1230 690 C2=1 700 C'T=1 710 FG=O 720 VOPTS="YN" 722' 724' IF TIlE ANSWER IS "V" THEN PROMPT TIlE USER TO SETUPDATEfI1ME 726' 730 Dl$="SET DATE I TIME " 740 02$=" (YIN) 750 COL=16 760 GOSUB DISPLAY 770 I!'1PUTS IKEYBOARD,"E",I,ANSS 780 ANS=INSTR(l,VOPTS,ANSS) 782' 784' BASED ON USER SELECTION THEN PERFORM rna TASK ACCORDINGLY 786' 790 IF ~'lS=O mEN SIGNAL 3 : GOTO 730 800 IF ANS.::1 mEN GOTO 830 810 IF AJ~S=2 TI-lEN GOTO 890 820 GOTO 730 830 FG=l 832' 834' SET PASSWORD FOR ACCESSING THE DATEffL\1E SETUP 836' 840 PWKEYlS="123" 850 GOTO 960 860 FG=O 862' 866' GOTO SUBROUTINE SETUP DATE AND TL\1E 868' 870 GOSUB SEmATE 880 GOSUB SE111ME 882' 884' PROMPT TIlE USER TO ERASE OLD DATA FILE IN THE SC~'-INER 886' 890 DlS="DELETE DATA FILE" 900 D15=" (YIN) 910 COL=16 920 GOSUB DISPLAY 930 Cl=l 940 Thc1'UTS NKEYBOARD,"E",IJ1'1>S 950 IF mPSo"y" TII~'J GOTO 1140 952' 954' PROMPTTO E~TER PASSWORD FOR ERASING ANY OLD DATA FILE 956' 960 01$=" PLEASE TYPE IN " 970 015=" PASSWORD " 980 COL=13 990 GOSUB DISPLAY 992' 994' SET PASSWORD FOR ERAS~G ANY OLD DATA FILE 996' 1000 PWKEY2S="321" 1010 INPUTS MKEYBOARD,"E",3.P\VS 1020 IF PWS=PWKEY2S AND FG~ mEN GOSUB DELFILE:GOTO 1140 81 1030 IF PWS=PWKEYl$ AND FG=1 TIlEN GOTO 860 1032' 1034' ALLOWTHREETIMES TO TRY TO GAIN ACCESS FOR ERASING DATA FILE 1036' OTIlERWISE,PROMPT ACCESS DENIED MESSAGE 1038' 1040 IF FG=l AND C2>3 THEN GOTO 510 1050 C2=C2+1 1060 DIS=" ACCESS DENIED" 1070 D2S=" TRY AGAIN " 1080 COL=17 1090 Cf=I000 1100 GOSUB DISPLAY 1110 IF FG=l TIIEN Goro 960 1120 IF FG=O TI1EJ'lCl=Cl+ 1 1122' 1124' ALLOWTHREE TIMES TO TRY TO GAIN ACCESS FOR SEITIN'G UP DATAf11ME 1126' 1130 IF Cl>3 THEN GOTO510 ELSE GOTO 890 1140 FCL--O 1142' 1144' PROMPT THE USERTO CHOOSE SCA~1NG CONTAINER CODE AND WAREHOUSE 1146' LOCATION, OR MANUALLY ENTER THESE CODES FROM THE KEYPAD 1148' 1150 DlS="SCAN CONT. CODE" 1160 D2S:="&LOCATION (YIN) " l170COL=16 1180 GOSUB DISPLA Y 1190 ~rpUTS 'KEYBOARD,"E",I,ANSS 1192' 1194' SET A FLAG IF TIIE USER HAVESELECTED NOT TO SCAN TIlE CODES 1196' 1200 IF AJ"lSS(1:1)=··~ llIEN FCL=l ELSE FCL--O 1202' 1204' ONCE THE USER HAVESELECTED "YIN" TIIEN REl1JRN TO THE MAIN PROGRAM 12~' 1210 IF ANSS(l:l)::"Y" OR ANSS(l:l)="N" THEN GOTO 1230 ELSE GOTO 1140 1220 ' 1222' rns ~AIN PROGRAM CONTL\TUE AND PROMPT THE USER TO SC~"i INBOUND OR 1224' OUTBOUND BAR CODE ON THE BAR CODE Tlli\1PLATE 1226' 123001S=" PLEASE SCAN .. 1231 02S=" m/ OUT BOUND" 1232 COL=17 1233 GOSUB DISPLA Y 1234 RETRY=O 'SET FLAG TO CHECK BAR CODE GOOD OR BAD 1235 GOSUB GETCODE 'GOTO SUBROUTINE GETCODE TO ~'1AL YZE BAR CODE 1236 IF RETRY=1 THEN GOTO 1230 1237 STATIJSS=BCODES(1:3) 1240 IF STATIJSSo"" THEN GOTO 1340 1242' 1244' IF TIlE SC~'l1'.T£D CODE IS A NULL STRING rn~'l PROMPT TIlE USER TO 1246' MANUALLY ENTER rna CODE 1247' 1248 D1S=" IN I OUT BOU}.!]) " 1249 02S=" &'ITER (1)/(0) .. 1250 COL=15 1260 GOSUB DISPLA Y 1270 VAUOS="10" 1272' 1274' ONLY ACCEPT ONE LEITER ~rpUT FROM THE KEYPAD 1276' 1280 ~llUTS NKEYBOARD,"E",l,IOS 1290 IO=INSTR(l,vALIOS;OS) 1292' 1294' BASED ON THE USER SELECI10N TIiEN ASSIGN ttIN''' OR "our STATUS 82 1296' 1300 IF 10=0 THEN SIGNAL 3 : GOTO 1230 1310 IF 10=1 THENSTA11JS$=" lJ'l" : GOTO 1340 1320 IF 10=2 THEN STATIJS$="OUr:GOTO 1340 1330 GOTO 1230 1332' 1334' PROMPT THE USER TO SCANOPERATOR BARCODED BAOOE, WHICH SHOULD 1336' THE OPERATOR ill NUMBERS 1338' 1340 D1S=,tpLEASE SCAN YOUR" 1350 01$=" BARCODED BADGE .. 1360 COL=17 1370 GOSUB DISPLA Y 1372' 1374' SET A FLAG TO CHECK BARCODEGOOD OR BAD 1376' 1380 RETRY::O 1382' 1384' GOTO SUBROUTINE GETCODE TO ANALYZE BAR CODE 1386' 1390 GOSUB GETCODE 1392' 1394' IF fLAG INDICATES THE BARCODE IS BAD THEN PROMPT FOR MANUALLY 1396' E~ERING THE CODE 1398' 1400 IF RETRY=1 THEN GOTO 1340 1402' 1404' IF TIlE BAR CODE IS ACCEPTABLE THEN ASSIGN COLLECTED CODE TO OPNAJvlES 14()s' 14100PNAMES=BCODES(l:9) 1412' 1414' PROMPT THE USER TO SCANCUSTOMER 10 NUMBER ON TIlE BARCODE TEMPLATE 1416' 1420 DIS:" SCANCOMPANY'S"
1430 D2S=" BARCODE ,t 1440 COL=16 1450 GOSUB DISPLA Y 1460 RETRY::Q 1464' 146S' GOTOSUBROUTINE GETCODE TO ANALYZE BAR CODE 1466' 1470 GOSUB GETCOOE 1474' 1475' IF fLAG INDICATES TIlE BARCODE IS BADTIlEN 1476' PROMPT FOR MANUALLY El'ITERING TIlE CODE 14TI' 1480 IF RETRY=1 THENGOTO 1420 1484' 1485' IF BAR CODEIS ACCEPTABLE THEN ASSIGN COLLECTED 1486' BAR CODETO COMPIDS 1487' 1490 COMPIDS=BCODES(l:8) 1494' 1495' PROMPT THE USER TO ~vrER ORDER NUMBERS 1496' 1500 Dl$.=" PLEASE ENTER " 1510 D2S="ORDER' 1520 COL=8 1530 GOSUB DISPLA Y 1540 ~'PUTS NKEYBOARD,"E't,9,ORDERS 1544' 1545' PROMPTTHE USER TO VERIFY THE ORDERNUMBERS 1546' 83 ISSO D1S="ORDERJ="+ORDERS 1560 D2S="CORRECT (YIN) .. 1570 COL=:16 : GOSUB DISPLAY 1580 INPUTS 'KEYBOARD,"E",I,ANSS 1584' 1585' IF mE ENTERED NUMBERS NOT CORRECT THEN lRY AGAIN 1586' 1590 IF AJ~SS<>"Y" THEN GOTO 1500 1600 ORDNOS=ORDERS 1610 015=" 1# of Pallet " 1620 D2S=" ";COL=2 1630GOSUB DISPLAY 1634' 1635' PROMPTTHE USER TO EJVfER NO. OF PALLETS IN A TRUCK LOAD 1636' 1640 INPUTS NKEYBOARO,"E",2,NUMS 1650 ~~S="OI23456789" 1654' 1655' CHECK TIlE ENTERED NUMBERS FOR VAliD INTEGER NUMBERS 1656' 1660 FOR 1=1 TO 2 1670IF NUMS(I:I»="O" AND NUM$(l:I)<="9" TIIEN FLAG=<> ELSE FLAG=1 1680NEXT I 1690IF FLAG=1 TIIEN GOTO 1610 1694' 1695' PROMPTTO VERIFY THE CORRECT NO. OF PALLET 1696' 1700 01$='" PALLET="+NUMS 1710 02S="CORRECf (YIN) " 1720COL=:15 : GOSUB DISPLAY 1730 INPUTS NKEYBOARD,"E",I,ANSS 1734' 1735' IF ENTERED NUMBERS NOT CORRECT 11I~'I lRY AGAIN 1736' 1740 IF ANSS<>"Y" TIIEN GOTO 1610 1744' 1745' SET A COUNTER LOOP BASEDON NO. OF PALLET 1746' 1750COUNTER=VAL(NUMS) 1760J=1 1770 FOR 1=1 TO COLJ1'41ER 1780 D1S=" SCAN BARCODE" 1790 D2S=" ON TIlE PRODUCT' 1794' 1795' PROMPTTO SCAN BAR CODE ON THE PRODUCT 1796' 1800COL=17 : GOSUB DISPLAY 1810RETRY=O 1814' 181S' GOTO SUBROUTINEGETCODE TO ANALYZE BAR CODE 1816' 1820GOSUB GETCODE 1830 IF RETRY=} THEN GOTO 1780 1834' 1835' ASSIGN PRODUCT BAR CODE TO pros 1836· 1840 PIDS=BCODES(1: 16) 1850GOSUB DISPLA Y 1854' 1855' ASSIGN THE FIRST 9 CHARACTERS OF nos TO LOTNOS 1856' AS LOT NUMBERS 1857' 1860 LONOS=PIDS(J ;9) 1864' 1865' ASSIGN THE 10m TILL 12THCHARACTERS OF PIOS TO UNITNOS 84 1866' AS UNITNUMBERS 1867' 1870 UNITNOS=PIDS(10:12) 1874' 1875' ASSIGN THE SCA~ER'S DATE TO SOATES 1876' ASSIGN THE SC~~ER'S TIME TO STIMES 18n' 1880SDATES=DATES 1882 STL\1ES=TIMES 1883 01$=" &~IER PRODUCT" 1884 D2S=" WEIGHT= 1885 COL=lO 1886 GOSUS DISPLAY 'PROMPTTO ELvrER PRODUCT WEIGHT 1887 INPUTS #KEYBOARD,"E",4,PWTS 1888 IF PWTS(1:1)="S" AND PWfS(2:4)=" "lliEN PWTS=PWTPS : GOTO 1900 1889 FOR 1=1 TO 4 1890 IF PWTS(I:n>="o" ~'ID PWTS(I:I)<="9" TIIEl'J FLAG=O ELSE FLAG=1 1891 NEXT I 1892' 1893' IF "S" IS ENTERED TIIEN USE TIlE SAMEWEIGHT ENTERED PREVIOUSLY 1894' ALSO CHECK THE ENTERED CHARACTERS ARE VAUD INTEGER NUMBERS 189S' 1899 IF FLAG=! mEN GOTO 1883 1900 D1$=" WEIGHT= "+PWfS 1901 02S=" CORRECT (YIN) .. 1902 COL=16 1903 GOSUB DISPLAY 'PROMPT TO VERIFY PRODUCT WEIGHT 1904 INPUTS ##KEYBOARD,"E",I,A~SS 1905 IF ANSS<>"y" THENGOTO 1883 'IF NOT CORRECT THEN TRY AGAIN 1906 WTS=PwrS 19(J7 PWTPS=WTS 1908 WT=VAL(WTS) 1910' 1911' IF TIlE FLAG INDICATED TIlE CONTAINER CODE SHOULD BE 1912' MANUALLY ~7ER TH~'I GOTO 2080 1918 IF FCL=1 TH~'I GOTO 2080 1919 D1S=" SCAN CONTAINER" 1920 D2S=" CODE 1930 COL=17 1934' 1935' PROMPT TO SCAN CONTAINER BAR CODE 1936' 1940 GOSUB DISPLAY 1950RETRY::O 1954' 1955' GOTO SUBROUTINE GETCODE TO ANALYZE BAR CODE 1956' 1960 GOSUB GETCODE 1964' 1965' IF NOT CORRECTTHEN TRY AGAIN 1966' PROGRAM IS L'1 rns MA~1JALLY E]\.TTER MODE 1967' 1970 IF RETRY=1 TH~~ GOTO 1919 1974' 1975' ASSIGN THE COLLECTED CODE TO CTCODES 1976' 1980 crCODES=BCODES(l :3) 1990 DIS=" SCAN WAREHOUSE .. 2000 D2S=" LOCAnON .. 2010 COL=17 2014' 201S' PROMPT TO SC~" WAREHOUSE INFOR,.'dATION 2016' 85 2020 GOSUB DISPLA Y 2030 RETRY=<> 2034' 2035' GOTO TO SUBROUTINE GETCODE TO ANALY2E BAR CODE 2036' 2040 GaSUS CETCODE 2043' 2044' rr NOT CORRECTmEN TRY AGAIN 2045' 2050 IF RETRY=I THEN GOTO 1990 2054' 205S' ASSIGN THE COLLECTED CODETO LOCA1'$ 2056' 2060 LOCATS=BCODES(l :6) 2070 GOTO 2340 2074' 2015' rna FOLLOWING MODULE IS DESIGNED FOR USER WHO HAS SELECTED 2076' TO ENTER TIlE CONTAINER CODE AND THE WAREHOUSE LOCATION CODE 2078' TIIROUGH ruE SCA~ER KEYPAD 2079' 2080 Dls="~vrER CONTAL'.cR " 2090 D2.S=" CODE: 2100 COl:=8 2104' 2105' PROMPT TO E.~'TER CONTAINER CODE 21
3600 CKEY:QS=" ft' 3610 WHILEQSo"" 3620 QS=INKEYS 3630 WEND 3640 RE11JRN 3644,'
364S' START THE CTIMER SUBROUTINE FORSETI1NG COUNTER 3646' 3650 CTL\1ER:IF QS="P llIEN GOSUB CBAR 3660 COUNT=SEC 3670 RETURN 3674' 3675' START TIlE SUBROUTINE FO~\1 FOR ENTER SYSTE\1 DATE AND TL.\1E 3676' 3680 FO~\1:1NTL\1E=O 3690 INPOS=I' 3694' 3695' SET THE OLD SYSTEM DATEITL\1E FOR VARIABLE INSHOWS 3696' 3700 INSHOWS=INMASKS 3710 D2S=" "+INSHOWS 3720 COL=17 3724' 3725' DISPLA Y TIlE OLD SYSTE.\1 DATEITL\1E ONTHE SCA~'NER LCD 3726' 3730 GOSUB DISPLAY 3740 WHILE INPOS<=LEN(INMASKS) 3750 IDXS=il'lKEYS: 3754' 3755' WAIT FOR TIlE USER TO ENTER VAUD U'ITERGER NUMBER Al'lD 3756' LACATE THE CORRECT POSITION TO BE SHOWN ON THE LCD 3757' 37YJ LOCATE 2;NPOS+4 3770 WHILE IDXS<>"" 3772' 3773' IF A VAUD INTEGER NUMBER OR A SKIPCHARACfER HAS 3774' BE&'l ENTERED THEN MOVE TO THE NEXT POSmON 3775' 3780 IF INSTR(l," 1234567890"JDXS) > 1 TI1E.'l INSHOWS(L\'POS:~rpOS)=IDXS : L~1'OS=~roS+l : IF INSHOWS(1N"POS:~"POS)=rNS KIPS THE.'l mPOS=ll\rpOS+ 1 3784' 3785' IF A DELETE KEY HAS BEEN E.~"TERED THEN ~OVE THE rosrnox 3786' TO THE PREVIOUS rosrnox IF TIlE PREVIOUS POsmON IS 3787' A SKIP CHARACfER THEN MOVE TO THE rosrnox BEFORE iliAT 3788' 3790 IF IDXS--eHRS(127) AND mPOS>l TIIEJ'l INPOS=~roS-l : IF U\SHOWS(Th'POS:mPos)=msKlPS THS'l L'WOS=INPOS-l : mSHOWS(INPOS:~l'OS)=L~MASKS(L\roS:~'POS) ELSE INSHOWS(INPOS:INPOS)=INMASKS(L\'POS:~rpoS) 3794' 3795' IF A RETURN' KEY HAS BEE..\J PRESSED 111EN SKIP THE RE.\1AIN 3796' rosrnox AND DISPLAY TIlE CO~1PLETE SYSTS\1 DATEJTL\1E 3797' ON THE SCAl'lNER LCD 3798' 3800 IF IDXS=CHRS(l3) TIIEN ~l'OS=LE~(lNMASKS}+ 1 3810 D2S=" "+INSHOWS 3820 COL=l? 3830 GOSUB DISPLAY 3840 IDXS="" 3850 1NTL\1E=O 3860 WEND 3864' 3865' IF TIlE' CO~NTER LARGER THAN 1000THEN ENDPRORAM 3866' 92 3870 INTIME=INTIME+l:lF INTL\1E>lOOO THEN END,RESUME:INTL\1E--o 3880 WEND 3884' 3885' ASSIGN THE NEW SYSTEM DATEmME TO THE VARIABLE INMASKS 3886' 3890 INMASKS=INSHOWS 3900RETURN 3904' 3905' START11-1E SUBROUTINE ISAVE TO OPEN A DATA ALE CALLED 39~· "mYEiVl' FOR DATA COLLECfION 39m' 3910 ISAVE: 3920 SFO~\1S="C16'1 3930 SFILE=11:SFLEN=17 3940 OPEN "INVEJ'IT" AS Mil LEN=16 3943' 3944' IF ERROR ENCOUNTED THENGOTO TO SUBROU~E SUBERR 3945' 3950 ONERR GOTO SUBERR 39.60 RETURN APPENDIX C: !BARSOFT REPORTS 93
Create, Duplicate, Erase, Modify or Run REPORT? (C/D/E/M/R):
CUSTOM REPORT DIRECTORY
No.' Harne No. Name xo. Name
1 PRODUCTIVITY REPORT 2 WAREHOUSE PICKSLIP 3 SHIFT REPORT ~ WAREHOUSE CHARGES 5 PALLETS AND HOURS 6 WAREHOUSE MOVEMENT 7 M. H. COST CONTROL
1 HELP 2 PAGE ~ PAGE 4NUHBER 5 NAME 6 7 8 9 10 EXIT FORWARD BAC1:W'RD SORT SORT
Custom Report Directory 94
DATE PRINTERISCREEN/FILE/DIF \' 3/FID ) P SUMMARY N COPIES 1
~AREHOUSE MOVEMENT
ITEM NAME LOWER UPPER SORTS BREAK TOTAL COUNT AVG LIMIT LIMIT 1-9 AID PIS T S/G/B S/G/B S/G/B
ORDER NO F P T NAME F P C HAME F P STATUS F P
TYPE LOT NO. t A S T UNIT NO. CONT.CODE 2 A S T NET '«T. BOTH BOTH ROW' NO. 3 A S T DATE OS/21/90 OS/21/90 PRODUCT ID • OPERATOR ID • ) PRESS PgDn KEY TO SE NE PAGE « 1 HELP 2SELECT 3 PAGE 4BLANK 5 TO 6 TO 7 8HODIFY 9PRIHT 10 EXITI FORMULA, LENGTH LINES TIT:';' TABLE REPORT REPORT SA VE
Figure C.2 Warehouse Movement Report Table 95
l.JJAhEHOUSE MOVEMEN1 ORDER NO: N7::'16 OF'EF:ATOf~: : ~:At·JD'( ~JAL TER
CUSTOMER: SHELL CHEMICAL CO. I NSPECTED BY: . _
CARRIER: DATE: TIME: STATUS: OUT
REMAR~~S: _
TYPE LOT NO. UNIT NO. CONT.CODE NET ~JT • ROl.JJ NO. DATE ------_._--_._------t)4MBF1504 (H) 1 870 560 ST8 OS/21/90 (>4MBF 1504 ()O2 870 7:0 5T8 OS/21/90
S Ll b t Q t 211 : 1280 Subcount: '""
04MBF1510 003 870 720 ST8 OS/21/90
Subtotal: 720 SubcoLlnt: 1
04MBF15:1 025 870 7:0 ST8 OS/21/90 04MBF1521 027 870 720 ST8 05/21,"10 04MBF1521 028 870 720 5T8 OS/21/90 04MBF1521 045 870 720 ST8 OS/21/QO 04MBF1521 046 870 720 5T8 OS/21/90 04MBF1521 047 870 720 5T8 OS/21/90 C>4MBF1521 048 870 720 ST8 OS/21/90 04MBF1521 049 870 720 5T8 OS/21/90 C>4l"1BF 1521 050 870 720 5T8 OS/21/90 04MBF1521 051 870 720 ST8 OS/21/90 (l4MBF1521 052 870 720 ST8 OS/21/90 (l4MBF1521 057 870 720 5T8 OS/21/90 04MBF1521 058 870 720 5T8 OS/21/90 04MBF1521 067 870 720 5T8 ()5/21/90 (l4MBF1521 068 870 720 5T8 OS/21/90 04MBF1521 069 870 720 ST8 OS/21/90 04MBF1521 (>70 870 720 5T8 OS/21/90 04MBF1521 073 870 720 5T8 OS/21/90 (>4MBF1521 (>74 870 720 5T8 OS/21/90
SLlbtotal: 13680 Subcount: 19
TOTAL: 15680 ...... COUNT: L':'
Figl..tre C.3.1 Warer101...1Se MoVernerlt Repor·t 96
vJAREHOUSE MOVEMENT OF:DEf.: NO: B3505:? 1 86 OPERATOF: : RAt·lOY WAL TER
CUSTOMER: SHELL CHEMICAL CO. I NSF-'EeTED BY: . _
CARRIER: _ DATE: _ TIME: _ STATUS: IN r..:t 1"1AF:~:.· s: _
TYPE LOT NO. UNIT NO. CONT.CODE NET WT. ROW NO. DATE
01MBLI0:29 092 839 1250 ST5 OS/21/90
Suttot a 1 : 1250 Subc ount r
OlM8f<1029 108 839 1250 ST7 OS/21/90
Subtotal: 1250 SubcoLlnt:
C>lM8VI029 080 870 1250 ST7 OS/21 , 'iO 01""Bkl0~9 091 870 1250 ST7 OS/21/90
Subtotal: 2500 SubcCJunt: 2
04MBA7012 004 839 15(JO ST6 OS/21/90
Subtotal: 1500 Subc ourrt t 1
04MBA7012 002 870 1500 5T5 OS/21/90
Subtotal: 1500 SLlbcount: 1
TOTAL: 8000 COUNT: 6
Warehouse Movement Report 97
WAREHOUSE MOVEMENT CJf·:DEF: NO: 83:-1 1O(JOA5 OFEF:A1 OF: : F:ANDY ~JAL TEF:
CUSTOl"1EG:: SHELL CHE~l I CAL CO. I NSPEC fED BY: .. _ fJ':F:r:: I ER: DATE: TIME: ~ STATUS: OUT
REMAR~S: _
TYPE LOT NO. UNIT NO. CONT.CODE NET WT. ROW NO. DATE
04MBF1521 060 839 720 8001 OS/21/90
Subtotal: 720 SUbCGltnt: 1
(l4MBF1521 059 870 720 8001 OS/21/'70
Subtotal: 720 Subc OLin t : 1
l1LBP1010 029 820 17~O 8467 05/21/90
Subtotal: 1750 5ubcount:
(>0.3 820 2500 8467 05/21/90
Subt. at a l : 2500 SubcQunt:
TOTAL: 5690 COUNT: 4
F'igure C.3.3 Warerl01lse Movernerlt Report 98
WAREHOUSE MOV~MENl OPERATOR : RANDY WALTER
CUSTOMEr·:: SHeLL CHEMICAL. co. INSPECTE~ By: _
CAF:F~.r EF:: . _ DATE: __ . TIME: STATUS: IN
Rl.MAR~S: _
TYPE LOT NO. UNIT NO. CONT.CODE NET l-aJT. F:Ol;J NO. DATE
06LBI<1008 137 8·39 1250 8103 ()5/21/90
Subtotal: 1250 5ubc OLIn t :
06L BJ< 1008 109 870 1250 8103 OS/21/90
Subtatcal: 1250 Subcount:
1)7lBL1535 051 817 1800 8103 OS/21/'J(> O/LBL1535 052 817 1800 8103 OS/21/90
Subtotal: 3600 Subcount: ""'e;
1OLBV1(H)4 053 870 1250 8355 OS/21/90
Subtotal: 1250 SubCOLtnt:
OC""") 1OLBt<1004 ...)4 870 1250 8467 OS/21/90
Subtotc::e.l: 1250 Subcount:
10LBKI012 054 839 1250 8579 OS/21/90
Subtotal: 1250 Subcount:
1OLBt Subtotal: 1250 Subcount: 10TAL: 11100 COUNT: 8 GF:AND TOTAL: 4(1470 GRANO COUNT: 40 Figt.lre C. 3.4 Warehouse Movement Report 99 DATE rRJNTER/Sr:~ PRODUCT1VITY REPORT ITEM NAME LOtNER UPPER SORTS BREAK COUNT TOTAL AVG LIMIT LIMIT 1-9 AID PIS T S/G/B S/G/B S/G/B I OPERATOR ID F P T SHIFT NO F P 'NAME F P DATE PRODUCT 1D PRODUCT FROM START TIME MH TIME GRAND CUSTOMER ID • 1 HELP 2SELECT 3 PAGE 4BLANK 5 TO 6 TO 7 8HODIFY 9PRINT 10 EXIT/ FORMULA LENGTH LINES TITLE TABLE REPORT REPORT SAVE Figt!re C. 4 Pr-oduc t.iv i t.y Repor·t Table 100 rRODUCT!Vl~Y REPORT OPERATOR ID : SHIFT NO : 2 OPERATOR NAME RANDY W'ALTER NOTE: MH TIME IMPLIES MATERIALS HANDLING TIME IN MINUTE3 FOR HANDLING AnD STCRING PALLETS DATE PRODUCT ID PRODUCT FROM START TIME MH TIME 0~/21/90 OtMBi:l0290803 SHELL CHEM1CAL CO. 09: 51: 40 0.43 OS/21/90 01HBKI0290913 SHELL CHEMICAL CO. 09:52:13 0.38 OS/21/90 OtMBK10290923 SHELL CHEMICAL CO. 09:53:58 0.68 OS/21/90 OtMBK10291083 SHELL CHEMICAL CO. 09:53:23 0.46 OS/21/90 O~MBA 70120023 SHELL CHEMICAL CO. 09:~6:09 0.31 OS/21/90 OLtHBA 70 1200~ 3 SHELL CHEMICAL CO. 09:55:43 0.31 OS/21/90 04MBF'150400t3 SHELL CHEMICAL CO. 09:45:01 0.53 OS/21/90 O£+MBF' 1 ~/04002:; SHELL CHEMICAL CO. 09:45:37 0.48 OS/21/90 CLtMBF15100033 SHELL CHEMICAL co. 09:46:4~ 0.30 OS/21/90 04MBF'15210253 SHELL CHEMICAL co. 09 :46: 1e 0.40 OS/21/90 OLtMBF'l5210273 SHELL CHEMICAL co. 09:40:35 0.45 OS/21/90 04MBF 1 5210283 SHELL CHEMICAL CO. 09 : 41 : 10 0.51 OS/21/90 04MBF' 1 ~,2 104 ~/:; SHELL CHEMICAL co. 09:36:45 0.48 OS/21/90 OLtMBF'152104c3 SHELL CHEMICAL co. 09:37:38 0.40 OS/21/90 O~MBF 15210473 SHELL CHEMICAL CO. 09:39:33 0.40 OS/21/90 OLtMBF 15210483 SHELL CHEMICAL co. 09:40:05 0.36 OS/21/90 04MBF15210493 SHELL CHEMICAL co. 09:42:50 0.33 OS/21/90 0t+MBF15210503 SHELL CHEMICAL co. 09:43: 16 0.26 OS/21/90 04MBF15210513 SHELL CHEMICAL CO. 09:43:Lll 0.20 OS/21/90 OttMBF 1 5210523 SHELL CHEMICAL co. 09:43:57 0.26 OS/21/90 04MBF15210573 SHELL CHEMICAL co. 09:32:46 0.98 OS/21/90 04MBF15210583 SHELL CHEMICAL co. 09:34:00 0.83 OS/21/90 OLH1BF 1 5210593 SHELL CHEMICAL CO. 10:04:22 0.95 OS/21/90 04MBF 15210603 SHELL CHEMICAL co. 10:05:23 0.26 OS/21/90 04MBF15210673 SHELL CHEMICAL co. 09:41:52 0.40 OS/21/90 OLtMBF1 5210683 SHELL CHEMICAL CO. 09:42:23 0.31 OS/21/90 OLtMBF15210693 SHELL CHEMICAL CO. 09:34:57 0.83 OS/21/90 04MBF15210703 SHELL CHEMICAL CO. 09:36:14 0.31 OS/21/90 04MBF15210733 SHELL CHEMICAL co. 09:39:06 0.28 OS/21/90 04MBF 15210743 SHELL CHEMICAL CO. 09:38:42 0.30 OS/21/90 05LBKI0081093 SHELL CHEMICAL CO. 10: 00: 17 0.38 OS/21/90 06LBK 10081 373 SHELL CHEMICAL CO. 10:00:46 0.41 OS/21/90 07LBL15350510 SHELL CHEMICAL CO. 09:59:32 0.32 OS/21/90 07LBL15350~20 SHELL CHEMICAL CO. 09:58:51 0.58 015/21/90 1OLBK 10040523 SHELL CHEMICAL CO. 10:08:56 0.36 OS/21/90 10LBKt0040533 SHELL CHEMICAL CO. 10:09:31 0.25 OS/21/90 1OLBK 1012Q:I 33 SHELL CHEMICAL CO. 10:01 :23 0.55 OS/21/90 10LBK1012C~~3 SHELL CHEMICAL CO. 10:02:36 0.28 OS/21/00 11LBPtOl00290 SHELL CHEMICAL CO. 10: 11: 15 0.25 OS/21/90 i2KBK~Ot00030 SHELL CHEMICAL CO. 10: 10: 50 0.33 Productivity Report 101 PRODUCTI VIT'! REPORT SHIFT NO : 1 OPEF:ATOR NAME TUAN S. CHEOK NOTE: MH TIME IMPLIES MATERIALS HANDLING TIME IN MINUTES FOR HANDLING AUD STORING PALLETS DATE PRODUCT ID PRODUCT FROM START TIME MH TIME 0~/09/90 01KBP1001004 SHELL CHEMICAL CO. 12: 11: 25 0.75 05/09/90 01J:BP1001005 SHELL CHEMICAL CO. 12:07:49 0.61 05/09/90 01KBP1001006 SHELL CHEMICAL CO. 12: oe : 41 o.~e 05/09/90 01KBPI001007 SHELL CHEMICAL CO. 12:09:29 0.55 05/09/90 01KBP100100B SHELL CHEMICAL CO. 12:10:25 0.35 05/09/90 01MBFLt000002 SHELL CHEMICAL CO. 12:25:40 0.25 0~/09/90 01MBF4000021 SHELL CHEMICAL CO. 12:24:06 0.43 05/09/90 01MBF4000022 SHELL CHEMICAL CO. 12:24:51 0.53 05/09/90 10LBP1002003 SHELL CHEMICAL CO. 12:19:23 0.51 05/09/90 10LBP1002040 SHELL CHEMICAL CO. 12:20:03 0.31 05/09/90 10LBP1002041 SHELL CHEMICAL CO. 12:20:31 O. 3~ 05/09/90 10LBP1002042 SHELL CHEMICAL CO. 12: 14: 18 0.38 05/09/90 10LBP1002104 SHELL CHEMICAL CO. 12: 16: 33 0.36 05/09/90 10LBPI002105 SHELL CHEMICAL CO. 12: 17: 59 0.56 05/09/90 12LBP5000002 SHELL CHEMICAL CO. 12:23:38 0.35 05/09/90 12LBP5000015 SHELL CHEMICAL CO. 12:22:27 0.35' O~/09/90 12LBP5000017 SHELL CHEMICAL CO. 12: 23: 10 0.33 GRAND TOTAL: 2L+.83 Figllre C.5.2 Productivity Report 102 DA7E FRlr;TFR/SCREEN/F'lLE/IJ1F (P/S/F/D) F 2·TJMHARY N eerIES If you want a Maxlmum Value for t h i s Item e n t e r- It here. 'WAREHOUSE PICKSLIF rEM NAME f LOWER UPPER SORTS BREAK TOTAL COUNT Av~1 LIMIT LIMIT 1 -9 AID PIS T S/G/B S/G/B ~/8 - - - LOCATION ? TYPE KTN-1652 KTN - 1652 2 A CONT CODE LOT NO UNIT NO W'EIGHT 3 A S T GRAND PRODUCT ID • 1 A ..;;.r-. f I I I I I I I 1 HELP 2SELECT 3 PAGE 4BLANK 5 TO 6 TO 7 8MODIFY 9PRINT 10 EXIT! FORMULA LENGTH LINES TITLE TABLE REPORT REPORT SAVE F igllre C. 6 v~ar·erlollse Picks I i~l Repor-t Table 103 v A F FH')USE r'I CI: S 1.: f' ::Ii 1rPE~~"': ORDER NO ?UL.LiL(JA~ B'f : ~l~F'FC7 BY LOCATION P TYPE C0~JT CODE LOT NO UN:":" NO WEIGHT . ------8:'79 KTN-lf:,~2 e70 01J:BP 1001 OC4 6000 8579 Y.TN - 1 f,52 e.? o 01Y.BP1001 005 1500 8579 rTN-1c~,2 870 01Y.'BP100i 006 1500 e.':J79 Y.TN-1652 870 01Y.BP100t 007 1500 8~79 :r.TN-1t,~2 870 01J:BP1001 008 6000 8~67 :Y.TN-1652 870 01MBF4000 002 2J.tOO e.467 :Y.TN-1652 870 01MBF4000 021 1200 e~67 r.:TN-1652 870 01MBF4000 022 1200 8103 lTN-1652 870 1OLBP 1002 003 2160 eZ01A KTN-1652 870 10LBP 1002 040 102l 8201A :Y.TN-1652 870 1OLBP 1002 041 11 30 8103 J:TN-1652 839 10LBPI002 042 900 8103 KTN-1652 870 1OLBP 1002 104 720 8103 J:TN-lc52 870 ~OLBPI002 105 720 8001 ITN-1652 820 12LBPSOOO 002 4400 8001 KTN-lc52 820 12LBP5000 016 2200 8001 ~TN-1652 820 12LBP5000 017 2200 GRAND TOTAL: 36751 Warehouse Pickslip Report 104 DATE PRINTER/SCREEN/FILE/DIF (P/S/F/D) P SUMMARY N COPIES 1 SHIFT REPORT 1,..--. ITEM NAME LOWER UPPER SORTS BREAK TOTAL COUNT AVG I LIMIT LIMIT 1-9 A/D PIS T SIGlE S/G/B S/G/B OPERATOR 1D NAME TEL SHIFT NO 1 HELP 2SELECT 3 PAGE ~BLANK 5 TO 6 TO 7 8MODIFY 9PRINT 10 EXIT/ FORMULA LENGTH LINES TITLE TABLE REPORT REPORT SAVE F'igur e C.8 War-er10l..1Se Srlift Report Table 105 SHIFT REPORT OPERATOR ID NAME TEL SHIFT NO ------1231156789 RANDY 'HALTER (304)234-ge7c 2 283e.67e17 TUAN S. CHEOK (304)987-1234 1 ge.765q321 JIM HARLOW (304) 111 -2929 1 ~ F igl1re \..... 9 Marehousen Shift Report 106 DATE PRINTER/SCREEN/FILE/DIF (P/S/F/D) P SUMMARY N COPIES 1 WAREHOUSE CHARGES ITEM NAME LOViER UPPER SORTS BREAK TOTAL COUNT AVG LIMIT LIMIT 1 - 9 AID PIS T S/G/B SIGlE S/G/B CUSTOMER ID 04 04 F P T B DATE F P C NAME F P C ADDRESS F P C TEL F P eSTATE F p C ZIP F P PRODUCT ID 1 A WEIGHT DATE DAYS STORAGE HANDLING ) PRESS PgDn KEY TO SE HE PAGE « 1 HELP 2SELECT 3 PAGE 4BLANK 5 TO 6 TO 7 8HODIFY 9PRINT 10 EXIT/ FORMULA LENGTH LINES TITLE TABLE REPORT REPORT SAVE Figure C.10 Warehouse Charges Report Table 107 WAREHOUSE CHARGES : Customer ID : O~ Bl111ng Date 08/03/90 Name ~ SHELL CHEMICAL CO. Address : S. ROUTE 50 Tel : (61~)4Z3-757S State : OH ZlP : ll57l4 • Note: The charges are listed 1n cents/l00 IbS. except the transaction charges and the total charges are in dollars amount T.CHARGES PRODUCT ID WEIGHT DATE DAYS STORAGE HANDLING TRANS. ... ----~ ------_.. 3 80.40 01KBP1001004 6000 05/09/90 86 15 30 3 22.35 01KBP100!OO5 1500 05/09/90 86 15 30 3 22.35 01J:BP1001006 1500 05/09/90 86 15 30 3 22.35 01KBP1001007 1500 05/09/90 66 15 30 3 80.40 01KBP1001008 6000 05/09/90 86 15 30 3 33.96 01MBF~OOOOO2 2400 05/09/90 86 15 30 18.48 01MBF4000021 1200 05/09/90 66 15 30 3 18.48 01HBF.qOOOOZZ 1200 05/09/90 66 15 30 3 1250 OS/21/90 74 15 30 3 16.88 01HBK10290a03 16.68 01MB~10290913 1250 OS/21/90 14 15 30 3 3 16.86 01MBK10290923 1250 OS/21/90 14 15 30 3 16.88 01HBJ::10291083 1250 OS/21/90 74 15 30 1500 OS/21/90 74 15 30 3 19.65 O.qMBA70120023 19.65 04MBA70120043 1500 OS/21/90 14 15 30 3 560 OS/21/90 74 15 30 3 9.22 04MBF150JlO013 10.99 O.qMBF150.qOO23 720 OS/21/90 74 15 30 3 3 10.99 04MBF15100033 720 OS/21/90 14 15 30 3 10.99 04HBF15210253 720 OS/21/90 14 15 30 3 10.99 04MBF15210273 120 OS/21/90 74 15 30 3 10.99 04HBF15210283 720 OS/21/90 74 15 30 3 10.99 OJlHBF15210453 720 OS/21/90 74 15 30 3 10.99 04HBF15210463 120 OS/21/90 74 15 30 3 10.99 04MBF15210473 720 OS/21/90 74 15 30 3 10.99 04MBF15210483 720 OS/21/90 14 15 30 120 OS/21/90 74 15 30 3 10.99 04MBF15210493 3 10.99 04MBF15210S03 720 OS/21/90 74 15 30 30 3 10.99 04MBF15210S13 720 OS/21/90 14 15 30 3 10.99 04MBF15210523 720 OS/21/90 74 15 120 OS/21/90 14- 15 30 3 10.99 OltHBF15210573 3 10.99 OltHBF15210SB3 720 OS/21/90 74 15 30 30 3 10.99 0.qMBF15210593 720 OS/21/90 14 15 3 10.99 04MBF15210603 720 OS/21/90 74 15 30 30 3 10.99 OJ.tMBF15210673 720 OS/21/90 74 15 30 3 10.99 O.qMBF15210683 720 OS/21/90 74 15 30 3 10.99 O.qMBF15210693 720 OS/21/90 14 15 30 3 10.99 04MBF15210703 720 OS/21/90 74 15 30 3 10.99 OQMBF15210733 720 OS/21/90 74 15 30 3 10.99 04MBF15210743 720 OS/21/90 74 15 30 3 16.88 06LBI:I0081093 1250 OS/21/90 14 15 30 3 16.88 06LBJ:l0081373 1250 OS/21/90 74 15 30 3 22.98 07LBL15350510 1800 OS/21/90 74 15 30 3 22.98 07LBL15350520 1800 OS/21/90 74 15 30 3 16.88 10LBKiOO40523 1250 OS/21/90 74 15 30 3 16.88 10LB:Kl0040533 1250 OS/21/90 74- 15 30 3 15.88 10LBJ:10120533 1250 OS/21/90 74 15 30 3 16.88 10LBJ:l0120543 1250 OS/21/90 74 15 30 3 30.86 10LBP1002003 2160 05/09/90 86 15 30 3 16 .1 7 1OLBP 1002040 ' 1021 05/09/90 86 15 Fig1..1re C. 11.1 Warehouse Charges Report 108 WAREHOUSE CHARGES Customer ID : 04 Billing Date : 08/03/90 Name : SHELL CHEMICAL CO. Address S. ROUTE 50 Tel: (614)423-7571 State : OH Zip: ~5714 • Note: The charges are listed rn cent.sz t 00 Ibs , except the transaction charges and the total charges are in dollars amount PRODUCT ID WEIGHT DATE DAYS STORAGE HANDLING TRANS. T.CHARGES ------10LBPI002041 1130 05/09/90 86 15 30 3 17,58 10LBP1002042 900 05/09/90 86 15 30 3 14.61 10LBPI002104 720 05/09/90 86 15 30 3 12,29 10LBPI002105 720 05/09/90 86 15 30 3 12.29 l1LBP10100290 1750 OS/21/90 74 15 30 3 22.43 121:B1:40100030 2500 OS/21/90 74 15 30 3 30.75 12LBP5000002 4400 05/09/90 66 15 30 3 59,76 12LBP5000016 2200 05/09/90 86 15 30 3 31 .38 12LBP5000017 2200 05/09/90 86 15 30 3 31 .38 GRAND TOTAL: 1094 . 32 Figllr"e C. 11. 2 109 DATE PRINTER/SCREEN/FILE/DIF (PIS/riD) S SUMMARY N COPIES 1 PALLETS AND HOURS LOW'ER SORTS BREAK TOTAL COUNT AVG II ITEM NAME UPPER LIMIT LIMIT 1 - 9 AID PIS T S/G/B S/G/B S/G/B 'WAREHOUSE NO F P T PALLETS F P T HOURS PER MONT F P CAL HOURS P PALL F P 1 HELP 2SELECT 3 PAGE 4BLANK 5 TO 6 TO 7 8MODIFY 9PRINT 10 EXIT/ FORMULA LENGTH LINES TITLE TABLE REPORT REPORT SAVE Figt~re C.12 Pallets and Hour-s Report Table 110 PALLETS AND HOURS Warehouse no.: 08 Total no of pallets in this warehouse: 45000 Est1mated tot.al no. of man hours/month: 11550 Calculated no. of hours per pallet: 0.26 Pallets and Hours Report 111 DATE PRINTER/SCREEN/FILE/DIF (P/S/F/D) P SUMMARY N COPIES 1 H.H~ COST CONTROL ITEM NAliE LOWER UPPER SORTS BREAK TOTAL COUNT AVG LIMIT LIMIT 1-9 AID PIS T S/G/B S/G/B SIGlE WAREHOUSE NO F P T PALLETS F P T HOURS PER MONT F P OPERA'TION 1 A S T HOURS PER MONTH HOURLY COSTS COST PER OP HH COSTS PER OP GRAND 1 HELP 2SELECT 3 PAGE qrLAUK 5 TO 6 TO 7 8HODIFY 9PRINT 10 EXI7/ FORMULA LENGTH LI~ES TITLE TABLE REPORT REPORT SAVE ~ Materl"~l F 19l.lre" \..... 14 -'-'. Handling Cost Control Report Table 112 M.H. COST CONTROL Warehouse no.: 08 Total pallets handled: 45000 Total hours/month: 11550 OPERATION HOURS PER MONTH HOURLY COSTS COST PER OP MH COSTS PER OP CLERICAL 900 9.5 8550 0.19 HAlIDLE RETURN 50 10. 5 525 0.01 INSPECT 2000 9.5 19000 0.42 LOADING 1500 10. 5 15750 O. 35 PICXING 2500 10. 5 26250 O. 58 R~NAREHOUSE 100 10. 5 1050 O. 02 STORIHG 1000 10.5 10500 0.23 SUPERVISIOli 2000 13. 5 27000 O. 60 UHLOADIllG 1500 10.5 15150 O. 35 GRAlID TOTAL: 2. 75 Figtlre C. 15 Material Handling Cost Control Report APPENDIX D: !BARSOFT DATA ENTRY SCREENS 113 Enter Screen Number for DATA ENTRY : SCREEN DIRECTORY No. Name Nc. Name No. Name 1 W' AREHOUSE UPDATE 2 PRODUCT INFO 3 CUSTOMER INFO ~ EMPLOYEE INFO 5 CUST QUANTITY INFO 6 WAREHOUSE CHARGES 7 M.H. COST CONTROL 8 "II AREHOUSE INFO 9 VIAREHOUSE CUBE UTIL 10 VI. ROW' BARCODE 1 HELP 2 PAGE 3 PAGE 4NUMBER 5 NAME 6 7 e 9 10 EXIT FORWARD BACKWRD SORT SORT Data Entry Screen Directory 114 ITEM: LOT NO TYPE: TEXT LENGTH: 10 WAREHOUSE UPDATE ~-~------: PRODUCT'S ID Ol.lMBF15210573 OPERATOR'S ID 123456789 LOT NO 04MBF1521 IN/OUT BOUUD OUT UNIT NO 057 CUSTOMER'S ID Oll- CONTAInER CODE 870 ORDER IIO N7316 PALLET WEIGHT 720 DATE OS/21/90 WAREHOUSE LOCATIon : ST8 TIME STARTED 09: 32:1.16 ACCOUNT FOR QUNTITY on HAllD 0 TIl1E FINISHED 09: 33: Lt5 TtME In MINUTES FOR HANDLING/STORING A PALLET : 0.98 :- OhlOUn 1 ver s 1 t y. Athen s • OhloU. S.A.------By: T. S. Che ck -: 1 HELP 2 NEXT 3 PREY qG~ TO 5REPEAT 6DELETE 7 SET 8SEARCH 9SEARCH10 EXIT RECORD RECORD IUDEX RECORD SEARCH NEXT PREY Figure D.2 Warehouse Update Data Entry Screen 115 ITEM: LOT NO TYPE: TEXT LENGTH: 10 PRODUCT INFO PRODUCT ID 01KBPI00100Q WAREHOUSE LOCATION : 8579 LOT NO 01KBPI001 OPERATOR ID #: 283867817 OPERATOR NAME: TUAN S. CHEOK UNIT NO DATE 05/09/90 TIME 12:11:25 QUANTITY Oll HAND 8998 CUSTOMER ID : Ott CUSTOMER NAME : SHELL CHEMICAL CO. ADDRESS S. ROUTE 50 CITY BELPRE STATE OH ZIP 1 HELP 2 NEXT 3 PREY 4GO TO 5REPEAT ~DELETE 7 SET 8SEARCH 9SEARCH10 EXIT RECORD RECORD IllDEX RECORD SEARCH NEXT PRE'! Figl..lre D.3 Pr-oduct, Inf o . Data Errtrv Screerl 116 ITEM: C NAME TYPE: TEXT LENGTH: 20 CUSTOMER INFO ( ) [ CUSTOMER I D 01 ] ( ] ( Customer Harne CORNIUG GLASS WORKS ) ( ) ( Address 1624 STAUNTON AVE. ) ( J ( City PARKERSBURG ) ( 1 [ State WV ZlP 26101 ) ( ] [ Contact Person PAUL TOPICHAK J ( ) ( T 1 t 1e PLAHT MANAGER ] ( 1 [ Telephone Uumber (304)422-6531 ] ( ] [ Ohio Unlversily, Athens, Ohio U.S. A. T.S.Cheok J 1 HELP 2 NEXT 3 PPEV 4GO TO 5REPEAT 6DELETE 7 SET 8SEARCH 9SEARCHI0 EXIT RECORD RECORD INDEX RECORD SEARCH NEXT PREY Customer Info. Data Entry Screen Fig1l r-e D. 4.1 117 ITEM: C NAME TYPE: TEXT LENGTH: 20 CUSTOMER INFO ( 1 ( CUSTOMER ID : 02 ] [ ] [ Customer Name DUPONT EI DENEMOURS ] ( ] ( Address P.O. BOX 1217 J [ ] ( City PARKERSBURG ] ( ] ( State WV Z1p 26102 1 ( ] ( Contact Person H. V. BRADLEY J ( 1 ( Tltle PLANT MANAGER J [ ) ( Telephone Number (304)853-2211 ] ( ) [ Ohio Unlverslly, Athens, OhIO u.s. A. T. S.CheoK J 1 HELP 2 NEXT 3 PREY 4GO TO ~REPEAT 6DELETE 7 SET 8SEARCH 9SEARCH10 EXIT RECORD RECORD IHDEX RECORD SEARCH NEXT PREY 118 ITEM; C NAME TYPE: TEXT LENGTH: 20 CUSTOMER INFO [ ) ( CUSTOMER ID : 03 ] [ ) ( Customer Name GENERAL ELECTRIC CO. ] ( ] ( Address ROUTE 892 SOUTH ] [ ] [ crty WASHINGTOn ) ( ) ( State ';IV Zip 26181 ] [ ] ( Contact Person P. K. JONES ] [ ] ( Title PLAUT MANAGER ] ( J ( Telephone Number (304)863-7917 ) ( ] ( Ohio Univers1ty. Athens, Ohio U.S. A. T.S.CheoK J 1 HELP 2 UEXT 3 PREY 4GO TO 5REPEAT 6DELETE 7 SET 8SEARCH 9SEARCH10 EXIT RECORD RECOR~ INDEX RECORD SEARCH NEXT PREY Figtlre D.4.3 119 ITEM: C NAME TYPE~ TEXT LENGTH: 20 CUSTOMER INFO Customer name SHELL CHEMICAL CO. Address S. ROUTE 50 City BELPRE State OH Zip 4-5714 Contact Person S. J. SHEARER Tlile PLAUT MAUAGER Telephone Number (614)Lt23-7571 HELP 2 NEXT 3 PREY 4GO TO 5REPEAT 6DELETE 7 SET 8SEARCH 9SEARCH10 EXIT RECORD RECORD INDEX RECORD SEARCH NEXT PREY ~ D r F 1. gl1r"v J...... 4 4 Cus- t.omer Inf o , Data Errtry Sc e eri 120 ITEM: NAME TYPE: TEXT LENGTH: 20 EMPLOYEE INFO [ ] [ . EMPLOYEE ID # 283867817 PAY RATE/HOUR 10.50 ] ( J ( NAME TUAN S. CHEO~ SHIFT NO ] ( ] [ ADDRESS 1 SMART DRIVE ) [ ] [ CITY ATHENS ] [ ] ( STATE OH ZIP: 45701 TEL (614)593-3477 ) ( ) [ IN CASE OF EMERGENCY, PLEASE CONTACT POH G. YU ] [ ] ( EMERGENCY TEL (614)593-1485 1 [ 1 [ SPECIAL REMAR~S : CAN'T WORK ON FRIDAY AND WEEKEND! ] ( ] ( Ohio Univer~ity, Athens, Ohio U.S.A. T. S.Cheok__l 1 HELP 2 NEXT 3 PREV 4GO TO 5REPEAT 6DELETE 7 SET 8SEARCH 9SEARCH10 EXIT RECORD RECORD INDEX RECORD SEARCH NEXT PREY Figure D.5. 1 Employee Info Data Entry Screen 121 ITEM: NAME TYPE: TEXT LEUGTH: 20 EMPLOYEE INFO [ J [ EMPLOYEE ID # 987654321 PAY RATE/HOUR 12.50 ] [ ] [ NAME JIM HARLOW SHIFT NO J [ ] [ ADDRESS 1 WASHINGTON DRIVE ] ( J [ CITY PARKERSBURG ] [ ) [ STATE WV ZIP: 26253 TEL (30~) 111-2929 ) [ J ( In CASE OF EMERGEUCY, PLEASE CONTACT MARIA OKAY ] ( ] ( EMERGENCY TEL (304)292-9292 ] ( ) ( SPECIAL REMARKS : WOULD LIKE TO WORK OVERTIME J ( ] [ OhiO University, Athens, Ohio U. S.A. T. S.CheoK__J 1 HELP 2 NEXT 3 PREV 4GO TO 5REPEAT 6DELETE 7 SET 8SEARCH 9SEARCiil0 EXIT RECORD RECORD INDEX RECORD SEARCH NEXT PREY Figtlre D. 5.2 Ernployee Irifo Data Errtrv Scr'eerl 122 ITEM: NAME TYPE: TEXT LEllGTH: 20 EMPLOYEE INFO ( ] ( EMPLOYEE ID # 123456789 PAY RATE/HOUR 11.50 ] ( ) ( NAME RAnDY WALTER SHIFT NO 2 ] ( 1 ( ADDRESS 1 OHIO AVE. ) ( ) [ CITY PARKERSBURG ) ( ] ( STATE WV ZIP : 262~3 TEL (304)234-9876 ] [ ] ( IN CASE OF EMERGENCY, PLEASE CONTACT KATHY SOMEBODY ] ( ) [ EMERGENCY TEL (304)888-9898 J ( ] ( SPECIAL REMARKS: CAN"T WORK OU 'N'EEKEHD ] ( ) [_OhlO Un i ver s i t y, Athens, 01110 U. S. A. T. s. ChCOK_) 1 HELP 2 NEXT 3 PREY 4GO TO 5REPEAT 6DELETE 7 SET eSEARCH 9SEARCH10 EXIT RECORD RI=:CORD INDEX RECORD SEARCH NEXT PREY Figure D.5.3 Employee Info Data Entry Screen 123 ITEM: C NAME TYPE: TEXT LENGTH: 20 CUST QUANTITY INFO [ ) ( ] ( CUSTOMER ID : 04 1 ( ] [ ) ( CUSTOMER NAME: SHELL CHEMICAL CO. ] [ ] ( J ( TOTAL QUANTITY ON HAND: 8998 ] ( ) ( ) ( OhiO University, Athens, Ohio U. S.A. T. S.Cheok__J t HELP 2 NEXT 3 PREY qGO TO 5REPEAT 6DELETE 7 SET eSEARCH 9SEARCH10 EXIT RECORD RECORD INDEX RECORD SEARCH llEXT PREV F ig1.1re D. 6 Cust orne r Qllarlti ty Irifo Data Errtrv Sc:reerl 124 ITEM: C NAME TYPE: TEXT LENGTH: 20 WAREHOUSE CHARGES [ ] [ CUSTOMER ID 04 BILLING DATE 08/03/90 ) [ ] ( CUSTOMER NAME SHELL CHEMICAL CO. ] [ J ( J ( • ESTIMATED STORAGE CHARGES 15 CENTS/100 LBS FOR 30 DAYS ) ( ] [ HANDLIllG CHARGES 30 CENTS/l00 LBS FOR 30 DAYS ] ( J [ TRANSACTIOll CHARGES FOR INBOUND AND OUTBOUllD 3 IN DOLLARS J ( ] ( • TOTAL STORAGE AUD HAHDLING CHARGES : 45 ) ( ) ( J (_OhlO University, Athens, Ohio u. S. A. ______T. s. Cheok__J 1 .IELP 2 NEXT 3 PREY qGO TO 5REPEAT 6DELETE 7 SET eSEARCH 9SEARCH10 EXIT RECORD RECORD IHDEX RECORD SEARCH NEXT PREY Figure D.7 Warehouse Charges Data Entry Screen 125 ITEM: OPERATION TYPE: TEXT LEUGTH: 15 M.H. COST CONTROL WAREHOUSE NO.: 08 TOTAL NO. OF OPERATION : CLERICAL PALLETS RECEIVED: 45000 AVE. HAN HOURS/MONTH: 900 TOTAL HOURS/MONTH: 11550 AVE. HOURLY COSTS: $9. 5 Z OF HOURS/OPERATION: 7.79 AVE. HOURLY COSTS FOR TOTAL HOURLY COSTS: $95. 5 ALL WAREHOUSE OPERATIONS: $10. 61 TOTAL AVE. COSTS/OPERATION:$8550 CALCULATED MATERIAL HANDLING COSTS/OPERATION FOR A PALLET: $0. 19 • CALCULATED T.rROUG~PUT MATERIAL HANDLING COSTS PER PALLET: $2. 72 7 SET 8SEARCH SEARCH NEXT Figure D.S. 1 Material Handling Cost Control Data Entry Screen 126 ITEM: OPERATION TYPE: TEXT LENGTH: 15 M.H. COST CONTROL WAREHOUSE NO.: 08 TOTAL NO. OF OPERATION : HANDLE RETURN PALLETS RECEIVED: 45000 AVE. HAN HOURS/MONTH: 50 TOTAL HOURS/MONTH: 11550 AVE. HOURLY COSTS: $10. 5 X OF HOURS/OPERATION: 0.43 AVE. HOURLY COSTS FOR TOTAL HOURLY COSTS: $95. 5 ALL WAREHOUSE OPERATIONS: $10. 61 TOTAL AVE. COSTS/OPERATION:S525 CALCULATED MATERIAL HANDLING ~OSTS/OPERATIOll FOR A PALLET: $0. 01 w CALCULATED THROU~HPUT MATERIAL HANDLING COSTS PER PALLET: $2. 72 7 SET 8SEARCH SEARCH NEXT Figure D.8.2 Material Handling Cost Control Data Entry Screen 127 ITEM: OPERATION TYPE; TEXT LENGTH: 15 M.H. COST CONTROL WAREHOUSE NO.: 08 TOTAL NO. OF OPERATIon : INSPECT PALLETS RECEIVED: 45000 AYE. MAN HOURS/MONTH: 2000 TOTAL HOURS/MONTH: 11550 AVE. HOURLY COSTS: $9. 5 Z OF HOURS/OPERATION: 17.32 AVE. HOURLY COSTS FOR TOTAL HOURLY COSTS: $95. 5 ALL WAREHOUSE OPERATIONS: $10. 01 TOTAL AVE. COSTS/OPERATION:$19000 CALCULATED MATERIAL HANDLING COSTS/OPERATION FOR A PALLET: $0. 42 • CALCULATED THROUGHPUT MATERIAL HANDLING COSTS PER PALLET: $2. 72 8SEARCH NEXT Fig1..lr·e D.8.3 Material Handling Cost Control Data Entry Screen 128 ITEM: OPERATION TYPE: TEXT LENGTH: 15 M.H. COST CONTROL WAREHOUSE NO.: 08 TOTAL NO. OF OPERATION : LOADING PALLETS RECEIVED: 45000 AVE. MAll HOURS/MOUTH: 1500 TOTAL HOURS/MONTH: 11550 AVE. HOURLY COSTS: $10. 5 /. OF HOURS/OPERATION: 12.99 AVE. HOURLY COSTS FOR TOTAL HOURLY COSTS: $95. 5 ALL WAREHOUSE OPERATIONS: $10. 61 TOTAL AVE. COSTS/OPERATION:$157~0 CALCULATED MATERIAL HAUDLING COSTS/OPERATION FOR A PALLET: $0. 35 • CALCULATED THROUGHPUT MATERIAL HANDLING COSTS PER PALLET:S2.72 8SEARCH NEXT Figure D.8.4 Material Handling Cost Control Data Entry Screen 129 ITEM: OPERATION TYPE: TEXT LENGTH: 15 M.H. COST CONTROL WAREHOUSE NO.: 08 TOTAL NO. OF 'OPERATIon : PICKING PALLETS RECEIVED: ~5000 AVE. MAN HOURS/MONTH: 2500 TOTAL HOURS/MONTH: 11550 AVE. HOURLY COSTS:SI0. 5 I. OF HOURS/OPERATION: 21.65 AVE. HOURLY COSTS FOR TOTAL HOURLY C03T3:$9~. 5 ALL WAREHOUSE OPERATIONS: $10. 61 TOTAL AVE. COSTS/OPERATION:$2~250 CALCULATED MATERIAL HANDLING COSTS/OPERATION FOR A PALLET: $0. 58 • CALCULATED THROUGHPUT MATERIAL HANDLING COSTS PER PALLET: $2. 72 7 SET SEARCH Material Handling Cost Control Data Entry Screen 130 ITEM: OPERATION TYPE: TEXT LENGTH: 15 M.H. COST CONTROL WAREHOUSE flO.: 08 TOTAL NO. OF OPERATION : REWAREHOUSE PALLETS RECEIVED: 45000 AVE. HAN HOURS/MOUTH: 100 TOTAL HOURS/MONTH: 11550 AVE. HOURLY COSTS: $10. 5 % OF HOURS/OPERATION: O. 87 AVE. HOURLY COSTS FOR TOTAL HOURLY COSTS: $95. 5 ALL WAREHOUSE OPERATIONS: $10. 61 TOTAL AVE. COSTS/OPERATION:$1050 CALCULATED MATERIAL HANDLING COSTS/OPERATION FOR A PALLET: $0. 02 If CALCULATED THROUGHP~JT MATERIAL HANDLING COSTS PER PALLET: $2.72 8SEARCH NEXT Figt~r·e D. 8. 6 Material Handling Cost Control 0ctta Entry Screen 131 ITEM: OPERATION TYPE: TEXT LENGTH: 15 M.H. COST CONTROL WAREHOUSE NO.: 08 TOTAL NO. OF OPERATION : STORING PALLETS RECEIVED: ~5000 AVE. HAN HOURS/HONTH: 1000 TOTAL HOURS/MONTH: 11550 AVE. HOURLY cOSTS~$10. 5 I. OF HOURS/OPERATION: 8. 66 AVE. HOURLY COSTS FOR TOTAL HOURLY COSTS: $95. 5 ALL WAREHOUSE OPERATrONS:$10. 61 TOTAL AVE. COSTS/OPERATION:$10500 CALCULATED MATERIAL HANDLING COSTS/OPERATIOn FOR A PALLET: $0. 23 )I CALCULATED THROUGHPUT MATERIA!.. HANDLInG COSTS PER PALLET: $2. 72 8SEARCH NEXT Material Handling Cost Control Data Entry Screen 132 ITEM: OPERATION TYPE: TEXT LENGTH: 15 M.H. COST CONTROL WAREHOUSE NO.: 08 TOTAL NO. OF OPERATION : SUPERVISION PALLETS RECEIVED: 45000 AVE. HAN HOURS/MONTH: 2000 TOTAL HOURS/MONTH: 11550 AVE. HOURLY COSTS:$13. 5 I. OF HOURS/OPERATION: 17.32 AVE. HOURLY COSTS FOR TOTAL HOURLY COSTS: $95. 5 ALL WAREHOUSE OPERATIONS: $10. 61 TOTAL AVE. COSTS/OPERATIOll:$27000 CALCULATED MATERIAL HAUDLING COSTS/OPERATIon FOR A PALLET: $0. 6 If CALCULATED THROUGHPUT MATERIAL HANDLING COSTS PER PALLET: $2. 72 7 SET SEARCH M ~ t e r i a l Handling Cost Control Figl.lr"e D.,8 8 '...c. Data Entry Screen 133 ITEM: OPERATION TYPE: TEXT LEllGTH: 15 M.H. COST CONTROL WAREHOUSE NO.: 08 TOTAL NO. OF OPERATION : UNLOADING PALLETS RECEIVED: ~5000 AVE. MAN HOURS/MONTH: 1500 TOTAL HOURS/MOUTH: 11550 AVE. HOURLY COSTS: $10. 5 Z OF HOURS/OPERATION: 12.99 AVE. HOURLY COSTS FOR TOTAL HOURLY COSTS: $95. 5 ALL WAREHOUSE OPERATIONS: $10. 61 TOTAL AVE. COSTS/OPERATIOU:$15750 CALCULATED MATERIAL HAHDLIUG COSTS/OPERATIOH FOR A PALLET: $0. 35 • CALCULATED THRCUGHPUT MATERIAL HANDLING COSTS PER PALLET: $2. 72 8SEARCH NEXT M~terial F 19ttr"e" D., 8 9 ~ Handling Cost Control Data Entry Screen 134 ITEM: T PALLETS TYPE: NUMERIC LENGTH: 10 WAREHOUSE INFO ( ] ( WAREHOUSE NO 08 ] ( ) ( J [ ] ( TOTAL no. OF PALLETS IN THIS WAREHOUSE 45000 ) [ ) ( ) ( ESTIMATED TOTAL NO. OF MAN HOURS PER MONTH: 11550 ] [ ) ( TOTAL AVERAGE HOURLY COSTS FOR :$95.5 ) ( CALCULATIOU PURPOSE OULY! J ( ) ( CALCULATED NO. OF HOURS PER PALLET : O. 26 ] ( J ( ] (__OhlO Unlversity, Athens, OhlO U. S.A. T. S. Cheok ) 1 HELP 2 NEXT 3 PREV ~(j0 TO 5REPEAT 6DELETE 7 SET 83EARCH 9SEARCH10 EXIT RECORD RECORD INDEX RECORD SEARCH NEXT PRE'! 135 ITEM: 'NW TYPE: NUI1ERIC LEllGTH: 7 WAREHOUSE CUBE UTIL ft LONG: 350 ft HEIGHT: 35 TOTAL NO. OF PALLETS IN THE WAREHOUSE: 45000 HEIGHT: 4-2 "in OBSTACLES (. IN SQ. FT. .) COLUMNS: 108 STAGING AREAS: 1200 OFFICES: 1600 SPACE CLEARANCE AROUND DOORS:LtOO W'ASHROOMS:LtaO SPACE TO PARK BY M.H. EQIUPMENT:650 TOTAL OBSTACLE AREA~:4q38 IN SQUARE FEET TOTAL OBSTACLE VOL. :155330 IN CUBIC FEET (MULTIPLIED BY HEIGHT) eSEARCH NEXT 136 ITEM: WAREHOUSE LOCATIOll TYPE: TEXT LENGTH: 5 w. ROW BARCODE ( 1 ( ) ( WAREHOUSE ROW ] [ ) ( ] [ ) ( Note: Th1s screen is designed to enter the warehouse location for ) ( J ( printing warehouse location hal" codes. The user may enter ] ( J ( any alphanumeric letters for the warehouse location. bu t, the ) ( ) [ tl!E~ length of the field is limlted to 5 characters. ) ( J [ ] ( Oh10 Universlly, Athens, OhlO 45701 T.S.C~eok ) 1 HELP 2 HEXT 3 PREY 4GO TO 5RSPEAT 6DSL2TE 7 SET 8SEARCH 9SEARCH10 EXIT RECORD RECORD IUD8X RECORD SEARCH NEXT PREY WarerlOl..1Se Row Barcode Data Ent rv Scr-een APPENDIX E: BAR CODE LABELS GENERATED BY !BARSOFf 137 Cr-ea t e , Du p l i ca t e , Erase, Modlfy or Run LABEL? (C/D/E/MjR): FORM/LABEL DIRECTORY No. Name No. Nam~ No. Narne 1 PRODUCT LABEL 2 EMPLOYEE ID LABEL 3 'II. LOCATION LABEL 1 HELP 2 PAGE 3 PAGE 4NUMBER 5 NAME 6 7 8 9 10 EXIT FORWARD BACKWRD SORT SORT Form/Label Directory 138 DATE PRINTERISCREEN/FILE/DIF (P/S/F/D) P SUMMARY N COPIES 1 ~. LOCATION LABEL ITEM NAME LOWER UPPER SORTS BREAr TOTAL COUNT AVG LIMIT LIMIT 1-9 AID PIS T S/G/B S/G/B SIGIB WAREHOUSE LOCATI A8080 A8080 F P !WAREHOUSE LOCAT F P 1 HELP 2SELECT 3 5 TO 5 TO 7 8MODIFY 9PRINT 10 EXIT/ FORMULA TITLE TABLE LABELS LABELS SA YE Figure E.2 Warehouse Location Label Table 139 A8(>8() THIS LABEL IS FOR WAREHOUSE LOCATION x y Z WAR E H 0 USE PAR~ Figure E.3 Warehouse Location Label 140 DATE PRINTER/SCREEN/FILE/DIF (P/S/F/D) P SUMMARY H COPIES 1 EMPLOYEE ID LABEL ITEM NAME LOWER UPPER SORTS BREAX TOTAL COUNT AVG LIMIT LIMIT 1-9 AID PIS T S/G/B S/G/B S/G/B !OPERATOR ID 263867817 283667617 F P NAME F P 1 HELP 2SELECT 3 4 5 TO 6 TO 7 8HODIFY 9PRIHT 10 EXITI FORMULA TITLE TABLE LABELS LABELS SA VE Figure E.4 Employee ID Label Table 141 XYZ WAREHOUSE, PARKERSBURG, wv 111111111111 IIIIII1111 TUAN S. CHEOJ< Figure E.5 Employee ID Label 142 DATE PR1NTER/SCREEN/F'ILE/D:F (P/3/F/D) P SUMMARY N COPIES 1 PRODUCT LABEL ITEM NAME LOWER UPPER SORTS BREAK TOTAL COUNT AVG LIMIT LIMIT 1-9 AID PIS T S/G/B S/G/B S/G/B P TYPE F P C NAME F P PRODUCT lD 01MBK10290e03 o 1MBr 10290803 F P C ADDRESS F P eSTATE F p C ZIP F P LOT NO F P C TEL F P UNIT NO F P !PRODUCT ID F P 1 HELP 2SELECT 3 5 TO 6 TO 7 8MODIFY 9PRINT 10 EXITI FORMULA TITLE TABLE LABELS LABELS SA VE Figttroe E.6 Pr·oduct Label Table 143 F'RODUCT TYPE FROM COMPAN'( SHELL CHEMICAL CO. F'RODUCT 10 (J 1MBK 1t)290803 ADDRES~ s. ROUTE ~O STATE OH 4~714 LOT NO TEL (614)423-7571 UNI T NO OSC) I II 1lIllllI u1I 1111111 Xyz ~JAREHQUSE PARKERSBURG, WEST VIRGINIA Figure E.7 Product Label