SCREEN OVERVIEW:
Header Detail:
The Sales Order Release screen has been developed to allow a warehouse manager to preview customer sales orders and allocate stock to the order before releasing the order as a picking slip to the warehouse/s.&edsp;

This screen expects a single order review at a time. This differs from the Sales Order Wave Release function where many orders are reviewed at a time.

The screen validates the SYSPRO sales order number selected and loads the sales order header and detail data for the user to review. An option to select a route is also included if you are running the Load Planning module. All orders shown in the load planning module must be linked to a valid SYSPRO route code.&edsp;

The comment field allows an order releasing clerk to add a note to this order which can be printed on the Pick Slip or Pick Slip Label. A typical comment make be "Please have ready for collection at 12pm"

Detailed Lines Grid:
The detailed sales order lines can be reviewed in the grid on this screen.

Right click options allow the user to do the following:
Copy - Copy the data from the grid to another field or application
Query Available Stock - This opens a windows that shows available stock in the warehouse together total Stock on Hand and Inventory allocated to orders
Flag Replenishment as Urgent -&edsp;&edsp;This function will look at the replenishment table. If there is a replenishment already scheduled for this product the function will mark it as Urgent so that it is prioritized.&edsp;

There are two functions on the far right of the grid. These are:

Reserve Stock:
This function allows a user to review all Track ID's in the warehouse and to manually reserve stock for this order.This function is used if the "Auto Reserve" function is not in use or if a releasing clerk wants to specifically pick a selected batch of stock e.g. a specific Lot Number.

Replace
This function allows a user to substitute a product that is out of stock with a replacement stock code. Based on settings the user can replace any stock code with any new stock code or the software will only allow replacement to stock codes that are setup in the SYSPRO Stock Code Cross Reference table. This function automatically closes the current sales order line and adds a brand new line for the replacement stock code. The order can then be released.&edsp;

Auto Reserve

The Auto Reserve button is used to apply the selected reservation rule to automatically allocate and reserve stock to this order. There are a range of standard Auto Reservation rules in the software as well as an ability to select a custom rule that will apply a site specific developed stock reservation rule. Please see the section on Auto Reservation below for a description on each of the standard reservation rules.

Clear Reservations

Should the user not want to proceed with the reservation the Clear Reservations button can be used to delete all stock reservations against this order. It is possible to open an order and reserve lines without Confirming the order into a Pick Slip. If the user closes the window at this point the order lines will remain reserved and this stock will not be available to other orders.

Reservation Rules

SPECIAL FEATURES&edsp;-

• The software can be set to release the printing slip/s without printing or release the picking slip/s with automated printing turned on. If the picking slip is not printed here it can be printed from the Load Planning module.

• All orders released are automatically linked to an MSN number (Master Shipment Number). Grouped orders going to the same customer and released in a batch from the Wave Release screen will have the same MSN. At checkout and dispatch these picking slips can be grouped together for shipment.

TECHNICAL

&edsp;Please refer to the settings help window Settings Help Menu for related settings that affect this module.

SYSPRO Requirements REQUIREMENTS & Business objects used

• N/a

DATASCOPE Table updates
&edsp;- On Release of the picking slip:
tblSalesOrders – Relevant Sales Order details from Syspro
tblPalletReservedAllocation – table to store reservation details before the picking slip is created
tblPalletReservedAllocationLock – table to store who has the sales order (or job) locked
tblBin/tblPallet/tblPalletItem – for queries on stock availability, reservation rules.

&edsp;- On Printing of the picking slip:
tblPickingSlip – Picking Slip Header Details
tblPickingSlipSource – Picking Source (Job or Sales Order), Customer Details
tblPickingSlipItem – Stock Items to pick for the picking slip
tblPalletReserved – Details of the reservations for the picking slip items

AUTO RESERVATION RULES

When using the Auto reservation function within the sales order releasing screens the software can be set to reference a predefined auto reservation rule or can be set to run a custom developed reservation. The custom rule allows a company to become very creative in what inventory should be reserved for an order and in what sequence. For instance a custom rule could validate the Sales Order Type field and based on this could run a completely different reservation process.&edsp;

The following list describes all of the standard reservation rules and their logic:

Rule 1 - Packs from Bulk then Pick face

This rule will first reserve full packs from bulk and then the balance from pick face.&edsp;
e.g.
If we have a requirement of 550Kg a pack size in 250Kg and a bulk pallet of 750 and some stock in pick face. The system will reserve 500 (2 Packs) from bulk and 50 from pick face.

Rule 2 - Smallest Absolute Variance

This rule will reserve from Bulk only and will select the pallet with the closest quantity to the requirement. This rule will not break bulk pallets but may over or under allocate on a specific line.
e.g.
If we have the following pallets available in bulk
Pallet&edsp;&edsp;&edsp;Qty
1001&edsp;&edsp;&edsp;100
1002&edsp;&edsp;&edsp;250&edsp;
1003&edsp;&edsp;&edsp;500&edsp;
1004&edsp;&edsp;&edsp;700&edsp;

For the following are some examples

Requirement&edsp;&edsp;Pallet Reserved
220&edsp;&edsp;&edsp;1002 (250) Over Reserved&edsp;
550&edsp;&edsp;&edsp;1003 (500) Under Reserved&edsp;
605&edsp;&edsp;&edsp;1005 (700) Over Reserved

Rule 3 - Exact from Pick face

This rule will simply reserve all the requirement from the pick face locations only. This rule will not over reserve it will only reserve if there is stock in the pick face, else nothing will be reserved.

Rule 4 - Pick face (if configured) then Bulk&edsp;

This rule will first try and reserve from pick face, provided one has been configured. If configured the system will also over reserve if this is allowed. If over reserving is not allowed or there is no pick face location set up, the system will reserve the stock from bulk in FIFO order. Prior to version 4.0.13 there had to be enough stock in pick face to fulfill the whole order. If not, the entire reservation was done from bulk. After 4.0.13 the system will reserve as much as possible from Pick face and then reserve the remaining quantity from bulk.

Rule 5 - Bulk/Pick face Optimized
This rule will perform the following in order and is designed to use up old stock first, then take from bulk without breaking pallet and finally from pick face but not depleting the pick face fully.
Reserve from any bulk pallet that will expire in the next 3 months
Reserve any full pallets where the quantity <= the requirement, this will be a loop that will continue until there are no pallet with a quantity <= requirement or the requirement is satisfied.
Reserve the remaining requirement from pickface provided the quantity required is within 40% of the minimum of the pickface, if not get from bulk.
The system will always exclude expired stock and if a stock items has an expiry of 0000-00-00 it will NEVER be reserved

Rule 6 - Reserve from Pickface, if cannot, then reserve from bulk

This rule will first reserve all quantities from pickface unless the requirement is more than the minimum pickface replenishment level for that stockcode.&edsp;&edsp;(No over-reservation in pickface will be allowed.)
If the requirement is more than the minimum level, no reservation from pickface and everything reserved from a bulk location within the same warehouse.
If there is no pickface setup for the product in the main warehouse, reserve from bulk within the main warehouse, provided there is sufficient stock in the bulk location.
If there is no pickface setup and there is insufficient stock in bulk in the main warehouse, the software will not reserve the line and manual reservation will be required.
Where the Auto-allocation rule does not automatically reserve stock, the user will be required to enter each unreserved line and manually reserve the stock by selecting which pallet and bin to use.
The Auto-allocation rule selects oldest pallets first by default.

Rule 7 - (used for WIP JOBS ONLY)

Each line will be divided by the SYSPRO pan size. Full pan sizes will be reserved in the supplying warehouse (as configured in the Pickface Management).
The balance will be reserved in the pickface warehouse.&edsp;
All job allocation lines will be auto allocated. As from version 4.0.15, if the SYSPRO pack size of an item is set to 999999.99, the line will not be autoreserved and will be highlighted in purple. The Operator will then need to manually reserve these; this is intended to cater for items where the packsize varies from time to time.

Rule 8 - Voice picking/Carton Cubing

This Rule is used when running in a voice Environment. It also performs warehouse splitting.
This rule can only be applied in an environment where the sales orders are loaded per warehouse (This will not work if a Sales Order has more than one warehouse).
This Rule affects the autoallocate process as well as the pickslip creation (confirmation) stage.

Autoreserve:

The system checks the packsize (SYSPRO Pan Size).
a) Multiples of packsize – will be allocated from Pickface Source warehouse. The Pickface will be allocated first and then the bulk
b) Less than the packsize – Allocated form the warehouse on the Sales Order warehouse. Reserving will take place in bulk bins first and then pickface bins (to clear any bulk bins first)&edsp;

Confirm:
At Confirmation is where the carton cubing logic comes into effect.
A pickslip will be created for each sales order number and the system will add to the pickslip header.

1. Packsizes:

a. Create a new carton for every packsize
b. Write the new carton number to each reservation line in the reservation table

1. Less than Packsize:

a. Sort lines by wearer and then by SKU
b. Open a Large Carton
c. Allocated SKU to that carton
d. Allocate next SKU to carton
e. When the carton is full, open a new carton and load the SKUs
f. Once all SKUs have been loaded for the wearer, reduce the size of the last carton to the smallest size carton or bag that can still fit all of the wearer’s SKUs.

1. Multi Wearer Cartons:

a. In the case where a wearer’s SKUs can fit into a bag, the software wull not allocate a bag, but will sideline the requirement until the whole order has been processed. All bag allocations will then be grouped and reallocated into large cartons. These cartons will contain bags for multiple wearers.&edsp;
b. This will affect the process at the induction station. 1 carton label will be produced, but instead of just one PackingSlip, a packing slip for each wearer is produced. Each packing slip will be attached to the bag inside the carton for that wearer.

Rule 9 - MHE&edsp;

This Auto Allocation Rule caters for picking with different Material Handling Equipment (MHE) within the warehouse. At a high level, the following 3 steps are involved in the reservation of stock:

1. Reserve from single SKU Tracking IDs.

2. Reserve from Multi SKU Tracking IDs

3. Remainder from Single SKU Tracking IDs with current reservations

Rule 10 - Not in Use

This Rule Number is reserved and not in current use

• /

1. Identify all Tracking IDs for the Sales Order Lines Stockcode and Warehouse.

2. Sort the Tracking IDs by the Lot Expiry date

3. Reserve from these Tracking IDs in DATE order (results from sort – “oldest” first).

The picking strategies are set in WAREHOUSE SETTINGS under PICKING_SALES_ALLOCATION > AUTO_RESERVATION_RULE

Rule 12 - Consolidated Sequencing

• a

Look at the quantity to be reserved on the sales order line and check the following:

1. If the quantity is less than or equal the percentage defined in RULE_12_PERCENT, PICKING_SALES_ALLOCATION of the Maximum Level of the pick face bin of the stock code, create a full reservation against that pick face Bin. (This might create an over-reservation in pick face but this is allowed provided there is enough stock in the entire warehouse.). Note if (2) below has already been performed thus this is not the first iteration, the system should ignore the 40% logic and reserve what it can.

1. If the quantity is greater than the percentage defined in RULE_12_PERCENT, PICKING_SALES_ALLOCATION of the Maximum Level of the pick face bin of the stock code, Reserve from the pallet with the closest quantity available to the remaining requirement. I.e. try satisfy the order from one bulk location if possible.&edsp;&edsp;(If there are equal available quantities, take the oldest pallet based on SYSPRO’s Lot expiry date (if available), otherwise reserve in Pallet Number order.) NOTE the rule must search for pallets with quantity available greater or equal to the required quantity first and then if there is no pallet look for pallets with a quantity less than the required but still closest to the required quantity.&edsp;&edsp;&edsp;This is done to cater for the following scenario, qty required = 5, pallet A’s qty available = 7, pallet B’s qty available = 4. The variance between pallet B and the required qty is the smallest but it will be better to reserve from pallet A which can satisfy the entire line.

1. Once the first pallet has been reserved in point (1), re-calculate the requirement and then re-run point (1) and (2) on the revised amount until the entire requirement is satisfied.&edsp;&edsp;Where there is not enough stock in the entire warehouse, reserve what can be reserved.