Automatic Replenishment

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: 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

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.

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

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 button will be enabled and will display all the information for the generated replenishments.

Bulk to Pick Log

The Log screen showing the audit information for the created pallet movements

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.

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 -

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 -

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 -

Order Allocation

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

If a replenishment is generated a Replenishments report can be produced

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.

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: 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 -

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 -

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 is entered on to the system -

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

Generated Pick List showing the Replen Audit No:

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.

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

Reports

Pick Location by Stock Report (WHS1001) -

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

Oracle Data Extract (ORS0100) -

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 OBS Logistics © 2008

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