Automatic Replenishment

From WMS


INTRODUCTION

This document describes the required screens to be used for setup and the process for Bulk to Pick Replenishment. Other guides describe the set up of company, user, warehouse, stock etc.

This is a generic guide based on the version of the CALIDUS 3pl system at the time of writing.

It can also be used by clients to specify their specific data values to aid initial system set up as well as for future reference.

Note that fields marked '**' are mandatory and are needed to ensure correct set up of the system.


AUTOMATIC REPLENISHMENT

There are three types of pick face replenishment that is supported by the CALIDUS 3pl WMS v770 system:

  1. Manual Bulk to Pick Replenishment using minimum and replenishment by levels
  2. Replenishment from allocation when a pick face runs to zero or below
  3. Replenishment from allocation using minimum stock and replenishment by levels

Note Note: Dynamic Pick faces are not supported in this version of the WMS.


MANUAL BULK TO PICK REPLENISHMENT

Setup

Replenishment runs at a stock code level, the minimum information that is required to be setup is: a dedicated pick face, a replenish at quantity and a replenish with quantity, which can be either a pallet, case or unit or a combination of, dependent on owner and the stock code requirement within the constraints of the warehouse.


The screen below is accessed via Stock Maintenance / Stock Warehouse Tab / Unbonded Stock Locations

Stock Warehouse, Unbonded Replenishment Locations


Key fields

Code Value Description Values
Pick/Bulk/Replenish Location type, for replenishment to, it will always be 'Pick' Pick
Order Type Will always be Home Use (alternative values are for a bonded location and are not applicable) Home Use
Seq Will always be '1' 1
Location Code This will be the dedicated pick face for the stock code, it can either be manually entered or selected from a List of Values (LOV) The stock codes pick face (must be correctly setup in location maintenance, usage type 2) If the location code is already assigned to a stock code the system will generate a warning message but will still allow the pick face to be assigned.
Replenish at Quantity The level at which the replenishment will be generated i.e. if the quantity is set to 10 cases and there are 9 cases in the pick face then the replenishment process will generate a movement.
Replenish Pallet If the pick face is to be replenished by a full pallet or number of full pallets Depends on size of pick face - but generally set to 1
Replenish by Quantity If the pick face is to be replenished by cases, then enter the number of cases to be moved. Dependent on setup and size of physical pick face. It is also possible to replenish by units
Putaway Priority The putaway priority for the stock code - taken into account by the free locations process during receipt Normally set to 1


Manual Bulk to Pick Replenishment Process

Process -

The Manual Bulk to Pick Replenishment Process is a three stage process.

  1. Checking the stock code(s) that may require replenishment and if below the minimum level generate a replenishment movement. (WHS0610)
  2. Create the movement print and new labels if required (WHS0700)
  3. Complete the movement (WHS0700)


Example -

Stock is located in bulk locations, but the stock codes assigned pick location is empty.

Stock Location Enquiry


Stage 1- Go to the Bulk to Pick Replenishment screen (WHS0610)

Bulk to Pick Replenishment


Parameters -

Enter the Stock Code 'From' and 'To' values
'Option' should be set to 'Replenish Case Pick'
'Order Type' should be set to 'Home Use'

Then select the Confirm button and the system will check the pick face level of the required stock codes and if applicable a replenishment movement will be generated. The Log messages section will display all the information for the generated replenishments.


Stock Movements

Stage 2 & 3 -

The replenishment is now ready to be completed as standard in the Stock Movements screen or via RF if enabled.

Stock Movements


Parameters -

  1. Select the Accept/Confirm button unless the replenishment is to be cancelled.
  2. The Print button will now be enabled - select the button and print off documentation and labels if required.
  3. Upon printing of the documentation and the movement being completed in the warehouse select the Confirm button to compete the replenishment on the system.


REPLENISHMENT FROM ALLOCATION WHEN A PICK FACE RUNS TO ZERO OR BELOW

Setup

Owner Maintenance -

Owner Maintenance


Parameters -

  1. Ensure that Allocation Rules are compatible with Replenishment, i.e. Allocation Rule '2' must be correctly enabled.
  2. Set Run Replenishment Report to 'Yes'


Stock Maintenance / Stock Warehouse / Unbonded Stock Locations -

Stock Maintenance, Unbonded Replenishment Locations


The Stock Code must have an assigned Pick Face, the Replenish at and Replenish by fields are not looked at when the process is started, this system will automatically move the next best pallet into the pick face.


Replenishment during the Allocation Process

Process -

An order is placed onto the system (generally line type 1, certain other line types do not use the replenishment functionality i.e. 3 & 4 which are targeting a specific rotation or pallet)

The order is allocated and the system determines from the setup of the owner and the stock code what the optimum stock to allocate to the order is.

If pick faces are in use, replenishment is enabled and dependent on the remaining Owner setup parameters the system will check the pick face, if there is not enough stock in the pick face or if the pick face is empty and the order quantity is less than a full pallet the system will generate a replenishment movement on the next pallet to be picked.

The pallet to be moved will have stock that requires picking to satisfy an order, dependent on the owner requirement, the stock can be picked off the pallet at either the bulk location and then moved into pick or the pallet can be moved first and then picked from the pick location.


Order Entry

Standard order line, Product and Quantity -

Sales Order Detail


Order Allocation

Allocation Audit Log


The order is allocated as normal, the audit log show the allocated pallet and the movement audit number.

Replenishments


If a replenishment is generated a Replenishments report can be produced

Replenishment Report


A report can be produced listing all replenishments and the dependent order number(s)


Stock Movement

The replenishment is now ready to be completed as standard in the Stock Movements screen or via RF if enabled.

Stock Movements


  1. The Print button is now active - select the button and print off documentation and labels if required.
  2. Upon printing of the documentation and the movement being completed in the warehouse select the Confirm button to compete the replenishment on the system.


Note Note: If a replenishment has been generated from allocation then it must be closed before the pick confirmation process can be completed


REPLENISHMENT FROM ALLOCATION USING MINIMUM STOCK AND REPLENISHMENT LEVELS

Setup

Owner Maintenance -

Owner Maintenance


Ensure that Allocation Rules are compatible with Replenishment, i.e. Allocation Rule '2' must be correctly enabled.
Set Run Replenishment Report to 'Yes'
Use Replen Level in Allocation to 'Yes'


Stock Maintenance / Stock Warehouse / Unbonded Stock Locations -

Unbonded Stock Locations Maintenance


The Stock Code must have an assigned Pick Face, a Replenish at Quantity and a Replenish by value


Replenish during Allocation using minimum Quantity Levels

Process -

An order is placed onto the system (generally line type 1, certain other line types do not use the replenishment functionality i.e. 3 & 4)

The order is allocated and the system determines from the setup of the owner and the stock code what the optimum stock to allocate to the order is.

If pick faces are in use, replenishment is enabled and dependent on the remaining Owner setup parameters the system will check the pick face, if there is not enough stock in the pick face or if the pick face is empty and the order quantity is less than a full pallet the system will generate a replenishment movement on the next pallet to be picked. In addition the system will then check the Replenish at Quantity, if the stock in the pick face is less than this value it will create a replenishment for the quantity of stock held in the Replenish by fields, i.e. pallet, case or unit or a combination.


Order Entry

Order Entry Detail


Order is entered on to the system -

Audit Log


Order is allocated and the audit log shows a generated replenishment due to the stock levels in the pick face falling below the minimum quantity level.


Pick List

Pick List


Generated Pick List showing the Replen Audit No:

Replenishment Report


System generated Replenishment Report -


Stock Movement

The replenishment is now ready to be completed as standard in the Stock Movements screen or via RF if enabled.

Stock Movement


  1. The Print button is now available - select the button and print off documentation and labels if required.
  2. Upon printing of the documentation and the movement being completed in the warehouse select the Confirm button to compete the replenishment on the system.

Note Note: Unlike the previous process, it may not be necessary for the movement to be completed before entering the pick details in Pick Confirmation as the there be sufficient stock in the pick face to satisfy the order, this movement will in effect be a top up.


SUPPORTING PROCESSES

Configurable EDI

Using the configurable EDI functionality it is possible to upload a file containing the Stock Code, Pick Face, Minimum Quantity and Replenish Quantity.

All key values are maintained in the EDI Structure STK_LOCATION.

Note Note: Refer to the EDI Wiki Guide for details on setup of the Configurable EDI functionality


Reports

Pick Location by Stock Report (WHS1001) -

Pick Location by Stock Report Output


The report shows all stock codes setup with assigned pick faces with their replenishment levels.


Oracle Data Extract (ORS0100) -

Oracle Data Extract


Using the Oracle Data Extract screen (ORS0100) the system allows for the extraction and reporting of data to help setup and maintain pick faces and their replenishment levels.



Document History

Version
Date
Status
Reason
Initials
Version 1
13/05/2013
In Progress
User Guide
LBW

Copyright Aptean © 2008

The information contained herein is the property of Aptean and is supplied without liability for errors or omissions. No part may be reproduced or used except as authorised by contract or other written permission. The copyright and foregoing restriction on reproduction and use extend to all media in which the information may be embodied