The main task for the warehouse management system (WMS) is to control mill’s material flow and optimise storage and logistics operations. It is an integral part of our Material Flow How® offering, enabling seamless integration with mill’s enterprise resource planning (ERP) and other production control systems.
Pesmel’s Material Flow WMS is built completely in-house using industry standard technologies. It enables optimal material flow and logistics, and it is an essential part of a fully automated high-bay warehousing solution. The WMS manages material flows from production to dispatch, inclusive of any intermediate warehousing requirements. It gives real-time, accurate inventory management, traceability, and on-time deliveries. Complex material flows with multiple product types require dedicated control systems.
“Our Material Flow WMS can handle demanding material flows with high number of stock keeping units, large product variations, volumes, and high capacities.”
Juha Maunula, ICT Product owner, Pesmel
“Our Material Flow WMS is customized according to the needs of each mill. It can handle demanding material flows with high number of stock keeping units, large product variations, volumes, and high capacities,” says Juha Maunula, ICT Product Owner, Pesmel ICT Engineering.The WMS can be fully integrated into the mill’s existing network and upper-level control systems such as manufacturing execution system (MES) and ERP. “The WMS is at the heart of our fully automated high-bay warehouse solution. We provide our customers with a system that connects to their ERP and upper-level functions so that our software can specify all required warehouse functions,” explains Pesmel Sales Director Samu Rantala. “It serves as a single point for other systems to integrate, simplifying the overall architecture of the facility.”
Besides warehouse functions the Material Flow WMS is capable of controlling third-party material handling equipment such as conveyor systems, automated guided vehicles, overhead cranes, and forklift trucks. The single piece of software displays the warehouse’s activities via a user-friendly interface. It makes overall system status easy to understand, reducing downtime and enabling prompt diagnosis of material handling equipment performance.
“We have had situations where the customer needed a system to handle the material flow process from warehouse infeed all the way to the processing lines with precise timing constraints.” Juha says. To facilitate the flow, several handling devices and two automated high-bay warehouses were required, all from different vendors. The customer wanted a single system to control all the equipment and, consequently, chose Pesmel’s WMS as it can handle such complex material flows integrating third-party hardware, too. What comes to the hardware, Pesmel was selected to supply the larger of the two high-bay warehouses at the site.”
Pesmel’s digital twin working as a development engine
At an early stage of a customer project Pesmel creates a simulation model which eventually develops into a digital twin. Part of the WMS, it is a virtual representation that serves as the digital counterpart of a physical process. Samu notes that demonstrating the customer animations and simulations of the warehouse “gives them confidence that the WMS software meets, or even exceeds industry standards.”
Digital twin can be used in daily operations: continuous optimization of automated storage, estimation of near future occurrences and support for operator decision making. It also plays an important role in planning and executing long term operations. These typically include data collection of equipment usage, preventive maintenance, and virtual testing of software updates. In addition, the digital twin is used effectively in commissioning, shortening the time used in the start-up phase. The WMS environment has already been represented virtually by the digital twin prior to the start of commissioning.
Continuous support build confidence
Customer’s confidence is built on continuous and close cooperation from the beginning of the delivery project throughout the process life cycle. “We introduce our development specialists to the customer’s own IT team. This makes it evident that choosing us as a one-stop-shop solution provider removes the need for third-party involvement. The key is seamless integration with either an existing, or totally new software environment,” explains Samu.
Juha adds that “we work with our customers to have an efficient implementation of all control software. This includes project support, post-commissioning and start-up. We make sure our customers are comfortable in running their system before we leave the site.”
Pesmel’s Material Flow WMS can handle complex material flows integrating third-party hardware”.
Samu Rantala, Sales Director, Pesmel
When operational, the customer’s new warehouse solution is supported by Pesmel’s service team. The 24/7 HelpDesk assists in solving any operational issues, specialists also provide remote access when needed. Furthermore, Pesmel is fully committed to developing its solutions and, in addition, all deliveries can be modernized or updated. Software upgrades keep them relevant and can provide new functionalities.
The road ahead
Pesmel is committed to continuous development of its entire offering. The years of development of WMS software has provided Pesmel with knowledge and experience that benefits both Pesmel and the customer. Successful implementation of demanding projects in particular, have been valuable in view of further development of software solutions. “There are plans for future development of the digital twin, especially when it comes to production and operator decision-making. We’re looking into how it could predict and simulate the future. There are also different initiatives based on artificial intelligence to boost circular economy and to reduce machine wear and energy consumption,” Juha says.