Logistics Questionnaire & Feedback

Revised 06/21/2011

Stryker Site1
Name:

Allentown

Site
Representative
:

Thomas Scalone

Date
Answered:

10-06-2015

The purpose of the Questionnaire is to give an overview of the Areas Business Processes and Structure to allow the project to prepare for their
implementation within the ProgramOne Core solution.
It will accelerate the process of configuring an instance and performing Solution Confirmation workshops, to eventually reach the point of having an agreed
design.
Highlight key
difference with core
Process
No.
Questions
Site Comment
model (Program
ONE)
1.
What
are
the
main
areas
of
the
Receiving,
Pallets
area,
Bins
area,
Packing/Staging
area,
Warehouse
warehouse and the use of each?
QA area, MRB Material Review Board or Quarantine
Structure/
area, Consignment or VMI area, Shipping area,
Definition
Flammable cabinets area, Platinum rings SAFE (lockExamples:
in, or secured), Freezer area, consumables area, Bulk
Receiving area, second hand stock,
Items in offsite 3rd party location.
instrument second hand, quarantine,
mezzanine, order consolidation etc
2.
What are the main free stock storage
Pallets, Bins, VWR (Supplies- floor stock) owned by
areas used?
VWR, Packaging supplier
(picking area, bulk area, pallet area etc)
3.
What will be the logic of the locator
SAP assigns a stock locator. Exact format of the locator
definition?
definition to be provided. 3 segment or two segment.
Will we use Row/Aisle/Bin Locators in
A.01.01 (Row/Aisle/Bin)... verify with Robert Roldan.
your Warehouse?
-verify if locators are labelled and bar-coded.
How will the locators be labelled?
- Currently do not maintain locator size (but would be a
What will be the size of locators in
nice to have with Oracle).
different areas?
Do you share warehouse space with
4.
Fremont only does sub-assemblies that ship to cork.
other divisions? Will the products stored
There will cables and power supply accessory, will be
be for US Distribution and Cork areas?
shipped to distribution center (Quincy, or Tier 1
Will the warehouse structure change
Kerkrade (Holland), Tier 2 (local warehouses). No
after the NV ERP go live?
finished goods in Fremont (except accessories).
Currently Raw material is in bldg 4, will be moving
inventory out of Fremont.
Are there any other sites where you store Offsite storage for bulk items. (Physically located at a
5.
material apart from the main
separate 3rd party site in Fremont). No finished goods in
Page 1 of 14

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Process

No.

Questions
warehouses?
Example sterilized products stored in an
external warehouse

General

6.

7.

8.

9.
Page 2 of 14

How many SKUs are you using in

Fremont?
How many of them are active, lot,
serial controlled, non lot or serial
controlled
How many transactions are performed
within the inventory function in
Fremont? (Daily , Monthly)

Shipments lines per day

per type (i.e. SOs,
STCs, LTCs)

Picks for Sales orders

Picks for Kits

Receipts

Internal Orders

RMA lines received per

day

Consignment returns per

day
How many people perform the
transaction functions currently in
Fremont and in which areas?
Will you organize warehouse operations
in shifts? Is there a specific time you will

Site Comment

Highlight key
difference with core
model (Program
ONE)

the offsite facilities.

Sterilization occurs at offsite facilities: Product (power
supply and in-zone detachment system). Single use
sterilized plastic: Sent to sterilizer facility (Isotron
Tullamore) in Ireland (not Cork). Then it moves it back to
Distribution centre (Quincy or Venlo).
--will be verified
--sub-assembly items are lot controlled (SAP will assign a
lot number, Vendor lot number is assigned manually)
-Supplies, consumable items are not lot controlled
-Benchmark- contract manufacturer of in-zone
detachment systems (items are serialized). - Tb verified.
TB provided. (Fremont will give us Raw material
information)
Ron/Stan Hsu to provide transaction information
regarding finished goods at the distribution centers
(Quincy).

3 resources in future state for NV: Currently we have 8

resources in the warehouse.
Info to be provided later.
There are two shifts right now. Future state will be only 1
shift.

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Process

No.

Questions
be performing inbound activities and a
specific time you perform outbound?

10.

11.

12.

13.

Will we use any type of Automated

storage and retrieval systems?
carousels, conveyor belts etc
Will all of the stock be single lot serial
per locator? If not which areas/products
will not be like that?
What will be the scope of transactions
done at Fremont by the end of year?
Will there be any transfers between
warehouses and of what frequency and
type?
How many of the following we will
have?

Site Comment

Highlight key
difference with core
model (Program
ONE)

Currently wait until lot size, weight, shipping

requirements. When the skid is filled, it will be made
ready for shipment to Cork. For accessories, wait until
skid is filled, and ship to DC. No specific time for inbound
vs. Outbound. Receiving starts when shipment or truck
arrives from supplier. It could possibly be any time of the
day.
NA

All sub-assemblies, power supply and accessory items

will have Single LOT/ Serial per locator (currently in
SAP). Supplies/Consumables can be multiple items per
stock locator.
Transfers between offsite and back to Fremont, transfers
to DC (in case of rework), site to site transfers to DC and
Cork. All sub-assemblies are transferred out to Cork.
Accessories sent to DC/Cork.
1 receiving dock door, and 1 shipping dock door. 3
resources will do receiving/inventory movement/shipping.
There are 3 terminals which perform both receiving and
shipping transactions.

Receiving Stations
Shipping (or Packing) Stations
Inbound
Operations

Page 3 of 14

14.

Will we validate your receipts against a

document (i.e. bill of lading) or ASNs?
What happens if there is a mismatch
between document and validated
counts?

15.

Will we putaway based on medical

Yes it will be a manual/visual validation of the PO number

on packing slip/bol with PO Information in SAP. No
ASNs. In case of mismatch, the pallet is taken to the
Morgue or holding area till it is resolved. Purchasing /
buyer will be called based on the supplier and a new
PO/release or requisition document will be created to
receive it in.
Resins and extrusions will be stored in the same area

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Process

No.

Questions
practice, items usage and brand?
(i.e. bundle orthopaedics, knees of
Scorpio type together)

16.

17.

18.

19.

20.
21.

22.
Page 4 of 14

Is there any other element we will need

to be considering on putaway (i.e.
turnover of items )
Will we have fast moving items stored in
specific racks and if yes what exactly is
planned for fast moving items?

Will there be any special equipment

used for the inbound warehouse
processes
trolleys, forklifts, pallets etc
Are there any special considerations for
returns from consignment or RMA
putaways?

We are using B2B receipts as a way to

cross dock material specific to Sales
Orders. Is there a plan for any other
cross docking technique?
Do you plan to receive a complete pallet
of a single item?
Do you use any supporting document
for put away, ex. Put away list, labels
etc.
Standard Receiving -Ability to Receive
Goods from Suppliers/Internal Orders

Site Comment

Highlight key
difference with core
model (Program
ONE)

(Like material stored together). Will have assigned fixed

locators based on item. Supplies/consumables do not
have fixed locator. Operator has the ability to search for
an empty locator in SAP, or the process will be
manual/visual. Find an empty locator and putaway the
material to stock.

ABC classification of items based on fast-moving velocity.

We do have a separate fast moving area in the
warehouse. A items (weekly) moved in first, before Bs
(quarterly). Receiving person will get a notification that its
a hot item or receiving person will look it up in SAP (??).
To be verified.
Forklifts and pallet jacks and carts,

Finished goods will not be returned. Not a classic RMA. A

site to site transfer will occur if the cables or accessories
are not assembled correctly; the DC or Cork will send it
back. RMA is issued by Quality (not an SAP RMA
number). When you receive an RMA, it is coded to go
into MRB for further review.
Na. Possible in Cork or the DC.

Yes. Resin shipment (plastic material that can be melted

to be melded into tubes), possibly packaging supplies.
Receipt traveller, and receiving label,

Standard receiving in SAP, (receipt traveller is printed)

receive to rec lanes. Generates a sap lot number

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Process

No.

Questions
(Transfer Orders)

Page 5 of 14

Site Comment

23.

Inspection Required at Receiving

24.

Returns to Vendor (RTV)

automatically, --mm identifies batch number (same as the

lot number). Some supplies do not need lots. Lot
generation s based on setup on item level. Factory uses
sap generated lot number. Item also comes in with a
batch number from manufacturer, both are captured at
receiving (mandatory field prompted to the user to
capture it). Receipt labels: sap lot number/exp date/ part
number /des/qty, .rcpt from a sister plant (Cork),
acceptance label already on it, and goes directly to stock.
(Green label: cork uses green acceptance labels).
Inspection flag at the item level triggers a special label to
be printed: stage it to the inspection area based on the
label put it in the cart and sent to the inspection area.
Receipt traveller prints out at rcpt. Manual trigger to print
label (custom report in SAP). (PO/Part number/qty/ SAP
doc. Number/dates/part desc. Review Inspection
documents based on the item, inspect based on its
specs. Information about the inspection process is in
PDM - like a document database (Windchill). Capture
data manually in spreadsheet. Rec to iqc location, in
addition to the label, mm has iq flag. After it is passed,
released and changed status to unrestricted. (Material
status flag QI). Transaction to take it out of the QI flag
and move to unrestricted. All the 'unrestricted inventory is
moved to stock. Print accepted label. Review in sap
where item is stored. Print more acceptance labels.
Covered in Purchasing Jim Wisnewski

25.

Receive Expense Items

Covered in Purchasing

26.

Two Step Receiving Process, Receive

into Dock and then Putaway to Storage
Locators (Locations/addresses)

27.

Ability to Print Receiving Labels for a

(Raw Material), has the following main
information on it :

Fixed locator is setup per item. After qa process is

complete, the fixed-home-destination locator is looked up
in SAP. Then the move or putaway transaction is
completed in
Need sample of receiving label (4x3 labels)/receipt
traveller (8-11 document/ inspection label. Receiving
labels are bar-coded. Scanners are used to scan batch

Highlight key
difference with core
model (Program
ONE)

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Page 6 of 14

No.

Questions

Site Comment

Highlight key
difference with core
model (Program
ONE)

number/ part
SAP currently shows quantity in transit when material is
moved from Fremont to Cork/Or Quincy. (FOB is set to
the destination warehouse)
Na

28.

Able to View In transit material ( mainly

for internal order transfers)

29.

Ability to Putaway material based on

Locator Capacity

30.

Receive Material against ASN

na for Fremont

31.

Does your business require incoming

material to fill the forward pick locations
to fill whenever it comes in and stack
the rest in the bulk pick locations?

No putaway rules exist. Need to setup fixed locators.

Lookup fixed locator on material master and determine
putaway manually. Not system directed putaway.

32.

Do you drop ship from your Suppliers?

How?

Drop ship does occur and typically will be covered by

Customer service/purchasing track.
Place a po; send material to another supplier to perform
special operations. (Explore 2 way / 3 way receipt
matching functionality. Physically material is never
received in the warehouse, although a receiving
transaction may occur for account payables.

33.

Do you currently have the ability to scan

Vendor Item numbers with a mobile
device?

No scanning vendor items. Although vendor batch

number maybe scanned to reprint labels

34.

Do you currently use license plate

numbers for receiving and at what level
of detail? Carton, pallet, cart, etc.

na for Fremont

35.

Plan to Use RF devices/Scanners for

Receiving and Putaway

Use tethered scanners for label printing/ shipping out to

the sterilizer, can be used for receiving. No mobile wms/
or inventory interface available. Just a normal tethered
scanner for data entry.

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Process

No.

Questions

Site Comment

Highlight key
difference with core
model (Program
ONE)

36.
37.
Inventory
Accuracy

38.

39.

40.

Material
Management

41.

42.

Page 7 of 14

What are the inventory accuracy

processes used that will need to be
addressed (describe each)
I.e. Physical count (Annual stock
check), Cycle count
What is the frequency of each?
Do you rank your inventory by ABC
ranking in order to count it? How is the
ranking derived? (value, volume)
Will we allow inventory adjustments
independent of cycle counts and
physicals? If yes, Who will be allowed to
do inventory adjustments?
Will we have material movements
between areas of the warehouse? If yes
what types of movements will we have?
I.e. from pallet area to picking area
Locator Bar-coding and Scanning
Operations for Storage and Warehouse
Transactions

Cycle Count (based on ABC).

Yes. A is counted weekly, B items are quarterly, and C

could be semi-annual or annual depending upon the size
of the item.
Yes we allow inventory adjustment based on cycle count.
So if the adjustment is below a certain dollar amt (under
2000), then the inventory resource can perform
adjustment. If over $2000, then finance/purchasing will
need to approve the adjustment.
To be verified.

na

43.

Move Order Replenishment for Quick

Pick Locations set up by min-max levels

Verify if there is a replenishment report or if the process is triggered in

SAP currently. Replenishment happens manually based on kanban.

44.

Dedicated item-locator Setup for Quick

Pick Locations

SAP has fixed locators for items. Excluding supply and consumables.

45.

Picking Sequence attached to every

locator to optimize the Picking Order

Na

46.

Need to Create Locators in a Generic

fashion for Storage areas currently

E.g. SURM: Supply Raw Material - locator. Building 1 stock room has
storage locators, CHM1, CHM2 (Chemical/Inflammable locators), 2

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Process

No.

Questions

Site Comment

under one location (Like R1. For Row

1, R2 for Row 2 etc.)

Corrosive locators, FREZ (FREEZER), FRIG, G001 TO G020. In

building 4 we use, G001 and G008.

47.

Do you use back flushing: e.g.-Manufacturing Jobs are created by the

Sales order Schedule and would use
backflushing for Raw material usage.

Backflushing is used in manufacturing. Inventory is used for a job, and

then it is backflushed from a WIP locator. Material is issued to the job.
Then physically the kanban card tags the locator as empty and
subsequently it is replenished.

48.

Do you use any labels or tags for subassemblies or finished product coming
out of Manufacturing

WIP tags are used: Production lines uses WIP labels for all the labels.
A finished product (multiple labels are printed at the end of the finished
product completion; labels are also printed intermittent operations within
the WIP cycle).

49.

Ability to Cycle Count for selected parts

ABC classes. Generate cycle count a report is generated at the

beginning of the week. Also perform unscheduled cycle count in case of
discrepancy.

50.

Do you Perform Physical Inventory at

the year end

No physical inventory is performed

51.

Will there be any special equipment

used for the picking process of K&C
WIP orders
I.e. trolleys, forklifts, pallets etc
Product Label

Forklifts, pallet jacks, and carts are used during picking.

ucc and upc labels to be printed for box

and single units

Na. outside of SAP for SSCC or UCC labels. For UPC,

possibly on the finished good, when it ships to customer.

Will you be generating shipping

schedules? What will determine what
will be picked and shipped on a daily
basis for different types of orders?

There will be daily production orders that determine what

gets shipped. Based on demand coming from DC/Cork
based on plan. Production efficiency will drive what
needs to be built in Fremont.

52.

53.

Highlight key
difference with core
model (Program
ONE)

Finished good, sub-assembly, or WIP completion. Coming out of

production, they assign a product label. Also generate product label on
demand: Status (accepted material), part number, batch number, qty,
exp date, original plant, receiving date. Also allow to define qty of labels
to be printed.

54.
Outbound
Operations
Page 8 of 14

55.

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Page 9 of 14

No.

Questions

Site Comment

56.

What will be the Pick Release for Sales

order/ Supply/planned order ( e.g.:
performed in one of the two ways Immediate Release of the order for a
Customer Pickup and a Scheduled Pick
release for a Delivery based on the
Scheduled Ship date.

57.

Will you print any specific outbound

documents like: Ability to Print Pick
Slip /Pick Sheet, two types: Pick Slip for
Picking Goods from Storage locations,
and a work order sheet for
Manufacturing Jobs.

58.

Will we have cases that a delivery to a

customer may contain more than one
sales order

Yes for sub-assemblies shipped to Cork. Will also happen

for shipments/accessories that you have to fill a skid, you
will have different sales orders that have an ultimate shipto to the DC.

59.

Ability to Print Shipping Labels,

Containing Ship to Address, Number of
Cartons, Ship from Loc etc.

60.

Do you have any quick pick/ pick-face

or forward pick locations

ZL15N REPORT fires at ship confirmation and contains the following

info: batch number, delivery number, part number, qty, exp date,
receiving plant. - Also generate mailing labels; SHIP TO CORK (printed
from word), packing list enclosed label, Master pack list also
accompanies each shipment, individual packing list inside each box.
Commercial invoice, packing list are generated at the time of ship
confirm. One master commercial invoice is placed in each box, as well
as a packing list specific to that particular item. An actual shipment
tracking label is generated outside of SAP, via the DHL online portal by
the shipping department.
Na for Fremont

Highlight key
difference with core
model (Program
ONE)

Order type: STO - Stock Transfer Order, gets generated

based on the build plan/schedule. Material is pulled from
stock into an ICOS location> Intercompany Order
Shipment>Transact with the STO number, and SAP will
give a delivery number> Material in ICOS location is
allocated to this delivery number> A shipping transaction
is performed that relieves the inventory from stock>Order
is physically packed/consolidated to a pallet and shipped
out of the warehouse.
Email spreadsheet from Planner with STO
Number>Item>Quantity. Based on this spreadsheet,
Picker pulls the items from stock and puts it on a cart.> A
logical transaction is performed to move the material from
stock to ICOS> Another transaction allocates material in
stock against the STO (VL10B - ALLOCATION and pick
list printing, generates delivery> Based on this delivery
number, the shipping transaction VL02N is performed>
Packing Slip is printed> Inventory is issued out>
Currently for international shipments, they are shipped
out from building 5 to Cork> BOL is printed in building 5. .
(All shipments will happen from Building 4 for NV
(Stryker) in the future.

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Process

No.

Site Comment

61.

Require all Picking Tasks to be

automatically assigned to Picker for a
given Sales order.

Resources in each dept: ship 1, rec 2, stock room 2, 2 swing shifts: One
person will complete the pick for the entire order.

62.

Do you consolidate order/delivery

based on Staging lane logic (Multiple
pickers picking for the same
delivery/order)

Na for Fremont

63.

DO you Print Customer Facing

Documents (Bill of Lading and Pack
Slip), pallet manifest?

Packing list, shipping labels are printed at ship confirmation. BOL Is

generated by shipping department.

64.

Do you currently Use RF

devices/Scanners for Picking and
Shipping

Na. There are no handheld rf devices for shipping now. Building 5

shipping has handheld. Stock room does not have it.

65.

How many lines do we expect to have

per order? (i.e. 60% up to 3 lines, 20%
3-8 lines, 20% more than 8 lines) What
are the ordering patterns (i.e. order per
operation)? What are the quantity
patterns in the orders?
Is there any specific requirement as far
as the allocation of material? Will there
need to be any changes to the picking
rule logic?
Will we be using pick by label and wave
picking as per the standard solution?

Need to get these stats from the warehouse.

66.

67.

68.

Page 10 of 14

Questions

(We plan to have wave picking working

independent of picking batches by
installing latest oracle patches)
Do some customers require complete
order shipments?

Highlight key
difference with core
model (Program
ONE)

To be discussed with distribution team Ron/Stan Hsu or

Bob.
There are no particular allocation or reservation specs for
special orders.
Na

Yes. Internally we ship what we can that fits on a

skid/pallet. Some customers might require ship-complete
orders, DC

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Process

No.
69.

70.

71.

72.
73.

Questions

Site Comment

Are there any special equipment used

for the picking process
trolleys, forklifts, pallets etc
How do you pack material into boxes in
order to ship them to customers? Do
you have specific type/size of boxes
you are using? Will we use
cartonization or will we pack during
shipping?
Will we have specific dock doors/
staging lane to drop the material per
shipment area? (i.e.
Shipments to Cork specific staging lane
ICOS, shipments to north Distribution to
another etc?)

Big Joe (forklift), pallet jacks, and carts.

Will we be shipping products between

sites? What will be the frequency?
What will be the carriers we will use?

Yes. Shipping to Cork and Distribution. 100% of orders

will be between sites. Fremont never ships to a customer.
Domestic: FedEx
International: DHL
International between sites is also DHL.
Future state, we would like to integrate these carriers into
Oracle.

For Domestic
For international
For internal shipments across sites

Highlight key
difference with core
model (Program
ONE)

Na

ICOS: For STO orders, going to Cork. For capital

equipment, they have a specific staging lane.

Do you plan to integrate them with

Oracle?
74.

75.

Page 11 of 14

To what extent will we be planning

shipment departures - where a
departure consists of delivery lines that
are scheduled to be shipped in a
specific vehicle on a specific date and
time?
What is the list of documents that you
need to have available for shipping (i.e.
packing slip) Are there any regulatory

Na

Packing list, BOL info. No CFC is printed at the time of

shipping. Ship to San Jose or Costa Rica, extrusion
provides CFC (Certificate of compliance).

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Process

No.

76.

77.

Page 12 of 14

Questions
requirements as far as the documents
attached to shipments?
Any specific product labels needed like
EAN Labels etc.
Do you have any freight costs assigned
to shipments? (i.e. packaging costs)
How many locations do you have to
print the shipment documentation?

Site Comment

Highlight key
difference with core
model (Program
ONE)

EAN UCC labels might be required in Distribution.

Not done at the warehouse level. Possible setup in

finance, freight costs may be applied to a cost center and
cross charged through finance.
Just one location for now (building 5).

324953416

Logistics Questionnaire & Feedback

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Please use this section to provide detail of any business process that was not covered above, and that you wish to highlight / describe.
PROCESS

Site 1 Comment

Site 2 Comment

To allow configuration of Oracle we need the following information

MAJOR TOPIC

Requirement

Code

Description

For the Data Object(s) listed below, the Site should identify if they are required for Conversion and provide Volume of data and any specific requirements or
issues.
** This section is not required if the Data Conversion Kick-off has already taken place.
DATA
CONVERSION

Page 13 of 14

Volumes

Requirements / Issues

Comments

Conclusions

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Logistics Questionnaire & Feedback

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For the Business Document(s) listed below, the Site should identify if they are required and identify any specific requirements or issues.
The Site should add any additional Business Document that may be required.
A business document could be any customer facing document, document used for information passed inside the organization or excel spreadsheet used to
perform calculations. It is not supposed to be any type of reporting document
If not on the list provided by ProgramOne - Please provide copy Samples
Printer type (i.e. Hewlett
Packard Laser Jet - 4SI laser
printer or ZEBRA Z4M Label
BUSINESS DOCUMENT
Requirements / Issues
Comments \Conclusions
printer)

The Site should provide a listing of Interfaces that are used / required in this area.
INTERFACES

Page 14 of 14

From
System

To System

Requirements / Issues

Comments

Conclusions

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