Free Open Source Software - Warehouse Management Portal for VAI System 2000 (iSeries)

Warehouse Management Portal provides inventory and warehouse control through flexible and integrated systems using radio frequency. Originally written in RGP ILE for the iSeries because we needed serious warehouse management system without replicating the inventory management systems on the existing legacy system and with real time components for conveyors and reporting. Used in conjunction with RF Scanners and Information Portal, it is an effective warehouse management system with receiving, put away, picking, shipping, and physical inventory modules.

The VAI version of the RPGLE programs interfaces to the VAI files (e.g. vinitem, vinitmb, vcodetl, vpodetl) to validate item numbers, purchase order quantities, customer order quantities, etc. Infomation is pulled from the legacy files into the WMP files. All RF scanning is done over the WMP files. Reporting is provided through our Information Portal. We have included the entire Information Portal application, so you will have significantly more than just the WMP reports. Information Portal is a java application, running on a linux server. We normally use ubuntu on a low cost or existing pc to keep the cost down.

If you are using a different legacy system on your iSeries/AS400, the VAI version is the most generic and would probably be the easiest to modify to your application. 

In WMP we try not circumvent any process in the existing system. This is especially true when dealing with inventory and financial transactions. When faced with situations like this we will generally call the existing program to invoke the transaction or populate a data-entry screen with the data from our software and a user must finalize the transaction (we do this when you receive inventory). This helps to ensure that the existing system processes the transactions properly and allow for an audit trail. This design point can also reduce the cost if you upgrade your existing system. With VAI, this is pretty easy to do. For example, for boat receipts, we update the received quantity and then use the VAI posting option. For inventory movements, we create a VAI batch and use the VAI batch posting logic.

We will be registering the project on sourceforge and as soon as it is accepted will have all source code available on sourceforge, we expect before the end of July, 2008.

Here are copies of the key documentation for both WMP and Infportal:

• WMP Brochure (4 pages, pdf)
• WMP VAI Integration Overview (5 pages, pdf)
• WMP VAI User Manual (42 pages, doc)
• WMP VAI Technical Documentation (44 pages, doc)
• Inforportal Technical Documentation (13 pages, doc)
• Information Portal Entity Relationship Diagram (2 pages, pdf)

So what does all this cost? Unlike gas which more than tripled, the cost of the Radio Frequency scanners and access points has come down a lot. I will try to get configurations up for you, but some approximate prices are $1300 for initial access points and $300 per additional access point, and $1300-1500 for an RF scanner. The software is (will be) available for free download off sourceforge. We have been debating about pricing on support and what has worked well for some of our customers is $500 per month for installation support, on going support and minor modifications, which makes for simple cash flow planning. Anything major we will provide a fixed bid quote.

OK, so why bother doing this at all? Automating in the warehouse usually has the highest pay back of any application. Here are a few words I stole, opps, borrowed from John:

The purpose of Warehouse Management Software and Scanners is to manage and control your inventory. They help to standardize your warehouse processes and enforce company policies. They help you better track your inventory as it moves through your warehouse from its receipt all the way to shipping. They help increase the accuracy of the "on-hand" inventory and the accuracy of the orders being filled. Especially with scanners, they help reduce data entry errors due to human input. The margin of error can be 5-10% when people are hand writing and transcribing. And finally, they bring a level of accountability to the people who are working in the warehouse. When properly used and enforced, the combination of Warehouse Management Software and Scanners should increase your inventory accuracy, increase order accuracy, decrease your inventory carrying costs, and give you better data-points into your warehouse. Without proper usage and enforcement, Warehouse Management Software and Scanners will not solve the problem.