WCS – Warehouse Control System
WCS manages operations within the automated warehouse, converting business messages from the WMS (or ERP) into real-time instructions for various types of warehouse automation. It is used in organisations that require advanced management of the flow of load units within a conveyor system and other conveying equipment. In complex transport systems, it is responsible for determining and efficiently executing the route of the load unit, taking into account, in real time, the condition of the equipment as well as the occupancy of the conveyors and the planned load. These systems enable warehouses to operate more efficiently, while enabling significant improvements in logistics processes, cost reductions and increased operational efficiency.
Advantages of the system:
- Coordination and optimisation of the cargo unit transport process
- Mediation between the control of subordinate systems and the superordinate software layer
- Ensuring the integrity of storage and release operations throughout the material flow in the automated warehouse
Detailed description
WCS is a software with which it is possible to manage an automated warehouse and the equipment that goes into it. WCS monitors productivity and jobs, increases the efficiency of subsystems (including MFC and PLCS), usually integrated with a WMS or ERP system. Integration with host systems is based on a defined set of communication transactions and is done via the ERST API webservice and Apache Kafka.
WCS-class systems are mainly used in the E-Commerce industry, where high-performance warehouses handling online orders use the acquired data to manage the flow of goods and fulfil orders in as real-time as possible.
Relationships between systems
Functionalities
Optimisation of flow management
WCS allows the flow of many types of logistics media such as boxes, pallets, containers and more to be managed. In doing so, it takes into account:
- Conveyor sizes and weights
- Possible flow directions
- Availability of conveyor lines
- Condition of equipment
- Filling levels in buffers, loops, stations and other sensitive areas
- Variability of attributes and statuses
- Status of media – empty, full, open, closed, packed, available, unavailable, etc.
Visualisation of flows and real-time reporting
Near real-time visualisation is available from the web application and on mobile devices, while allowing:
- Cargo tracking
- Traffic tracking
- Observation of decision points
- Signalling of the filling of individual sections
- Observation of KPIs, quality and maintenance indicators
- Alerts in the app to inform operators or UR to take action
- Monitoring device statuses
Quality control stations
WCS enables a wide range of load quality control to be established at defined stations, through the detection of error codes and quality control. Exchanges acquired control status information with the host system.
Loading dock management
- Possibility of allocating a carrier and a semi-trailer to a loading frame
- Real-time control of loaded inertia and weight
- Reservation of space for cargo units
- Overfill alert
Stacker module – ASRS & High Bay Warehouse
- Management and monitoring of the stacker crane
- Optimisation, queuing and prioritisation of input and output tasks
- Selection of locations and storage units in a high-bay warehouse
- Stock control
Digital twin
- A virtual representation of the layout and logic is created for each project (Experior by Xcelgo Schneider Electric)
- Functionality and flow testing on a digital model
- Integration with WCS
- Integration with PLC (physical or emulated controller)
- Scenario testing
- Detection and elimination of bottlenecks
- Performance emulation through system loading
Technologies used
FAQ
What is a digital twin?
A digital twin is a virtual representation of a physical system that allows real-time simulation, testing and optimisation of processes. In the context of projects using tools such as Experior by Xcelgo by Schneider Electric, the digital twin includes:
- Virtual representation of the layout and logic: each project has a digital representation that accurately reflects the physical layout and logic of the system operation.
- Functional and flow testing: functional and flow tests can be carried out on the digital model, allowing potential problems to be detected and eliminated at an early stage.
- Integration with WCS and PLC: the digital twin can be integrated with warehouse control systems (WCS) and PLCs, both physical and emulated.
- Scenario testing: allows the testing of different operational scenarios, which helps to prepare for different situations in the production environment.
- Detection and elimination of bottlenecks: through simulations, bottlenecks in processes can be identified and removed, increasing system efficiency.
- Performance emulation (simulation): the digital twin allows performance to be simulated by loading the system, helping to assess its ability to cope with different load levels.
With the digital twin, systems can be accurately planned, tested and optimised before deployment, minimising the risk of errors and increasing operational efficiency.
What is the WCS?
WCS is a software with which it is possible to manage an automated warehouse and the equipment that goes into it.
The WCS monitors productivity and workstations, increases the efficiency of subsystems (including MFC and PLCS), and is usually integrated with a WMS or ERP system. Integration with host systems is based on a defined set of transactions in communication. The WCS converts business messages into real-time instructions for individual elements of warehouse automation.
The WCS’s functions include:
- optimisation of flow management;
- visualisation of the flow of goods in the warehouse;
- real-time reporting;
- cargo quality control;
- manages loading docks;
- ASRS module & High Bay Warehouse;
- digital twin.
