Hastings Books, Music & Video exceeded its productivity goals by 30% since using bar codes, wireless terminals, EDI, and warehouse software instead of paper documents. As the people at Hastings Books, Music & Video know so well, there are hits and then there are mega hits. And the company's data collection and management system in its new 100,000 sq ft distribution center is clearly the latter.

Country music star Garth Brooks even visited the Amarillo, Texas, center to see it in action for himself.

The distribution center supplies books, music, and video products to Hasting's 110 company-owned retail stores in 14 states. Using multiple automatic data collection (ADC) technologies, the new information system manages all receipts, orders, inventory, and shipments.

Electronic data interchange (EDI) delivers data about incoming inventory, orders, and shipments. Warehouse management software (WMS) controls inventory and directs activities in the center. Meanwhile bar codes and radio frequency data communication (RFDC) terminals supply the information critical to the WMS and EDI systems.

"Our system verifies the accuracy of shipments and takes that burden off our stores," says Bob Volpe, vice president of distribution. "As a result," Volpe says, "our stores get the right merchandise in front of customers as much as 4 hours faster than before and that helps drive sales."

And Garth Brooks understands the value of driving sales. Hastings was one of the distributors of recordings by Brooks when he was an unknown. The star has long credited Hastings with a strong role in building his success, staying close to the company along the way. As Brooks saw and heard in his visit to Amarillo, the new information system brings important efficiencies to the distribution center too.

"We've al-ready exceeded our productivity goals by 30%," explains Volpe. "In addition, 98% of shipments are on time and our inventory accuracy in the warehouse is nearly perfect," he adds. As a result,"there are no Monday morning quarterbacks looking out and wondering if this expenditure was required," says Volpe.

Eliminating paper: What people do see is a warehouse that operates without paper. For the most part, Hastings places orders for books, music, and videos with its suppliers by EDI. These purchase orders are then transferred to the warehouse software database. When that inventory arrives at the Amarillo receiving dock, the WMS downloads expected receipts to hand-held RFDC terminals. Those receipts with bar codes, about half, are scanned by workers using the terminals and integrated scanner. In addition, all receipts pass through a cubing and weighing system. The WMS is then updated in real time. For items without bar codes, workers simply check actual against expected receipts displayed on their terminals, key entering data as they go. This is sent to the WMS, which updates its database and initiates bar code label printing at the dock.

Putaway is directed by the WMS. Pallet loads are sent, depending on inventory needs, to the back stock area or any of three forward pick areas (pallet pick, carton flow rack, and shelf rack). Workers scan the bar code on the inventory and the putaway location with an RF terminal to complete this step for the WMS. As inventory is required from back stock to replenish forward picking areas, the warehouse software directs its movement, informing workers over RF terminals.