Media and book industry: Intralogistics taken to the next level. (Part 2/2)

Cross-docking, automatic replenishment, and separate material flow paths ensure that books are available at all times and orders leave the warehouse without delay.

Many processes run simultaneously in the warehouses of publishing houses and media companies: external purchases arrive, bestsellers are delivered by the pallet load, and at the same time, the first individual orders come in. Without clear control, bottlenecks, search times, and delayed deliveries quickly arise.

In the second part of our article, we show how companies in the media and book industry are stabilizing their intralogistics. This ensures greater transparency in the warehouse, less manual effort, and reliable availability of goods.

Challenge 3: Coordination of order-related external procurement

In addition to regular goods, order-related external purchases also arrive at one of our customers' goods receiving departments. These shipments reach the warehouse at the same time as the company's own books. This enables our customer to offer its customers the opportunity to order titles from other full-range suppliers. However, these external purchases do not follow the established goods receiving process, but increase the amount of manual sorting required.

Solution: Separation and cross-docking of order-related procurements

Employees scan each external shipment, sort it directly, and enter it using a pseudo item number. The system uniquely identifies the items without listing them as regular stock items. After sorting, the goods are sent directly to the packing station (cross-dock). There, they are packed together with other items from the warehouse. If there are any backorders, we store them temporarily. The WMS controls the entire internal distribution process. The goods do not remain in stock permanently, but leave the warehouse shortly after the goods receipt is recorded.

Challenge 4: Ensuring product availability

Employees pick orders and come up empty-handed. This problem occurs more often than expected. The reason usually lies in replenishment. Many processes are still manual or start too late. If goods are missing, picking stops, orders are delayed, employees become frustrated, and customers wait. Yet the goods are often in the warehouse. They are just not where they are needed. Stable availability of goods is the basis for reliable planning. It enables accurate reservations and realistic delivery commitments.

Solution: automatic replenishment with optimal use of space

Our WMS controls replenishment using clear rules. It continuously monitors stock levels in all relevant storage areas. If an item falls below the defined minimum stock level, the system automatically triggers a replenishment order. The WMS calculates the required quantity based on actual demand data and does not work with estimates. In addition, the system rounds up to full compartments, taking into account different compartment sizes. This ensures that sufficient goods are available while at the same time making efficient use of the available space in the warehouse.

Challenge 5: Parallel provision of large and small quantities

A new book is published, retailers place their orders, and pallets arrive at the warehouse. At the same time, the first individual orders come in. The same title is now located in several places in the warehouse. Large quantities are stored on pallets and can be quickly retrieved for large orders. Individual items are stored on flow racks so that employees can quickly pick individual copies. However, if there is a lack of coordination between the storage areas, problems arise. Stock levels differ, employees search for goods in several locations, and orders are delayed.

Solution: controlling separate material flow paths

The real problem is not double storage. The key factor is controlling material flows. Large quantities move through the warehouse differently than individual items and follow their own paths. They are picked and replenished differently. Anyone who tries to map all of this with a uniform process will inevitably lose track of the big picture.

Our WMS controls large and small quantities via separate material flow paths. The processes are seamlessly integrated.
Pallet and individual picking run in separate processes.
The system automatically synchronizes replenishment from the large quantity with removal from the flow rack.
The WMS manages inventory in real time across all storage areas.
It recognizes the location, quantity, and intended use of each book at all times.

Conclusion: Those who reliably manage returns, shipping, replenishment, and material flows work efficiently and gain a competitive advantage. To ensure that books arrive at readers on time, undamaged, and sustainably, every process in the warehouse must function properly. Automated processes, precise planning, and flexible control make this possible.

Part 1: Media and book industry: full control in the warehouse.

Another interesting article: No more logistics headaches in the media and book industry: Optimizing processes is child's play.