Replenishment Release [REP001]

This directed replenishment module is far more complex than the simple Pickface Replenishment module.. This module starts with a custom calculation built into core DATASCOPE PREMIUM WMS logic. As such, the actual rules to generate replenishment orders are endless. The user can quickly build advanced replenishment calculations by selecting various filters by warehouse, warehouse area, or stock code product class.

Like the Sales order wave releasing screen, a review screen allows the Replenishment Manager to review replenishment lines in logical groupings and release them in waves.

Auto-allocation logic can be applied to all lines. The process applies the preset stock allocation rules to find the most optimal stock to reserve. Once the lines have reserved stock from the bulk locations, the screen can be filtered by logical grouping before releasing Replenishment pick slips in waves.

The process output will be Replenishment pick slips, which can be picked as if they were Sales Order or Job pick slips but are instead used to top up the Pickface bins.

For example, the manager may sort the replenishment orders by bulk bin Area, Zone, or even Aisle and then release multiple picking slips for each grouping. So, if the release were done at the Aisle level, we would end up with a separate picking slip by Aisle.

This picking process applies full stock reservation logic, which manages stock availability in the bulk bin locations and ensures that the stock is not taken for a customer or another replenishment order.

Picked replenishment stock is moved to the destination area (Warehouse or pick face), and the standard replenishment putaway process is used to scan the stock into the destination bins.

To continue with the replenishment process, you must ensure you have pickface bins set first. For more information on setting up your pickface bins and the rules governing the calculations, refer to Pickface Bin Setup.

The Pickface Replenishment Service automatically generates replenishment tasks. It is part of the DATASCOPE Core services and should already be running. Please confirm whether this service is running.

• Due to the advanced Replenishment calculations, multiple orders can be generated daily. To break these hundreds of orders down into more logical pick slips, for example, to only generate pick slips for a specific Area or Zone and to have a manageable number of orders to be picked using the mobile scanner-based application Replenishment Picking, the user can set these various filters.

• Generally, you would only set one type of filter, depending on the scenario.

  • Source Warehouse Selection -this filter refers to the Source Warehouse from which stock must be picked to replenish a bin elsewhere.

  • Destination Warehouse Selection—This filter refers to the Destination Warehouse to which the stock must be replenished.

  • Calculation Type – This filter refers to the replenishment calculation type used.

    • If All is selected, all replenishment calculations will be used.

    • If List is selected, the user can select which replenishment calculation must be used. If custom replenishment calculations were not scripted, the built-in CORE calculation would be the only one on the list.

  • Destination Bin Range—By configuring this filter, the user can sort the replenishment orders by either All, Single, Range, or List of bins or by a specific Area or Zone and then release multiple picking slips for each grouping. This will typically be used if, for example, specific Bins must be replenished. Then, you would select the Single or List of Bins, but not a Source Warehouse or Destination Warehouse.

    • If you only want the outstanding replenishments for specific pickface zones to be handled together, you will only select the required zones from the Zone drop-down list.

  • Filter Flags – this filter can be used when lines are marked as Critical or Urgent. Typically, certain lines will be flagged as critical automatically if there is not enough stock in the pick face bin to satisfy the demand for the pick face (bearing in mind some orders will be split over pick face and bulk). Additionally, lines can be flagged as urgent from the Sale Order Wave Release screen if the user cannot release picking slips to the floor due to pick face shortages. Pick Slips can then be generated for only those items to ensure they are replenished first.

    • Critical—DATASCOPE PREMIUM WMS will automatically flag a replenishment request as Critical when the available QTY for the stock for that replenishment is less than zero. Selecting this option will filter out all critical replenishments only, and they can be treated as a priority.

    • Urgent—This refers to Sales Orders marked as Urgent on the Sale Order Wave Release. It is typically required when you want to reserve stock, but stock isn’t available, and the bin requires replenishment. This is set on the Sales Order Wave Release screen. Right-click on a sales order line and select the Flag replenishment as URGENT item.

    • Cross Dock Only – This selection indicates that the stock must be moved to the Pick face immediately. When building up TrackIDs (processing PO, LCT, or GIT Pre Receipts on the HTML5 mobile device) in advance to perform a Purchase Order, LCT, or GIT Receipt, you can be prompted to flag the stock code as Cross dock required if the stock code is one of the items on the replenishment list.

  • Stock Code Selection – this filter can be set on a single stock code or for a list of stock codes. Replenishment can happen for particular stock codes or even ABC Product Classes.

  • The ABC Class drop-down has four Classes to select from. Typically, when a company needs to establish the percentage each product contributes to the overall costs, they can use the ABC Classification facility in SYSPRO to monitor this over time. For example, you can categorize high-running, high-value items as “A” items and low-value, low-running items as “D” items. For more information on creating these ABC Classes, refer to Create a Custom Form Field. Once your Custom From field has been created in SYSPRO, you can add that field to a System Setting. Browse Settings / System Settings on the Ribbon Bar and locate the PICKFACE System name. Add the Custom Form field to the ABC_CFF_NAME setting name.

  • Demand Creation Date – this filter is typically used when very old replenishments are still outstanding, and you would like to generate pick slips to replenish them. It will filter on the already-created replenishments based on the date the demand was originally needed.

The filters will be selected depending on how the warehouse manages replenishments, and therefore, various scenarios are possible.

• Select OK

• The Replenishment Release screen will open with the data grid loaded according to the filters set.

Reserve the stock.

• All lines in red require a reservation.

• You can Auto Reserve all the lines on the data grid or each line individually.

• When selecting the Auto Reserve button in the top-right-hand corner, the system will do what it can according to the rule configured.

• Select the Auto Reserve button to reserve the stock according to the configured rule.

• Select the Refresh icon to load the data grid.

• Rows in the data grid will turn green, purple, or red.

• When using the Auto Reserve button, you can review what the software did by scrolling to the far right on the data grid and clicking the Reserve link.

• The Replenishment Manual Reservation screen will open.

  • You can edit the Reserved Qty column.

  • Click on the Reserve button to save your changes.

• The option to right-click on a line also exists. Right-clicking on a line allows you to query available source or destination stock to make releasing decisions.

• The option to release only the selected line into a Replenishment pick slip also exists. Select the Release this Replenishment when right-clicking on a line.

• Once all stock has been reserved correctly and is highlighted in green or purple, you can release all the Replenishment pick slips in batch mode.

• Select the Confirm button to print the Replenishment pick slips.

Create a pick slip.

When selecting the Confirm button, you will print the Replenishment pick slip.

• The Printer pop-up will appear to select a printer.

• A pop-up screen will appear indicating the printed Pick Slip numbers.

• The default Replenishment Pickslip (DATASCOPE_REPLEN_PICKSLIP_LETTER.rpt) is letter size and will print out.

• The Pick slips are now in a PRINTED status and can be viewed under the Pick Slip Review screen.

• These pick slips follow the same status changes as a Sales Order or Job Pick Slip and end in a COMPLETE status when fully picked.

The picking of Replenishment picking slips works in the same way as all picking in the DATASCOPE WMS software: the slip is assigned to a picker, and all details are tracked, including what was picked from where to where, at what time, and by whom.

The warehouse staff will be required to open the HTML 5 scanner-based Replenishment Picking module on the scanner and follow the same process for picking a Simple Replenishment pick slip.

SPECIAL FEATURES

• Custom-scripted replenishment calculations can be embedded into the software and added as additional Calculation Types. For more information, refer to Plugin Customizations or discuss this functionality with your local DATASCOPE Solution Provider (DSP)

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TECHNICAL

• The Pickface Replenishment Service automatically generates replenishment tasks. It is part of the DATASCOPE Core services and should already be running. Please confirm whether this service is running by viewing the Pickface Replenishment Review screen (refer to the Pickface Replen Service Status field)

• The Auto Reserve rules must be configured under System Settings. From the Ribbon Bar, browse Settings / System Settings. Locate the REPLENISHMENT System Name and select the REPLENISHMENT_AUTO_RESERVE_RULE setting name. The following rules exist:

  §  OLDEST_FIRST – This rule will reserve the oldest pallets from bins defined by the replenishment source Warehouse selection (the source Warehouse refers to the Source Warehouse Selection on the filter screen) but will exclude RECEIVING bins and Picking pallets.

  §  SMALLEST_FIRST – This is the DATASCOPE PREMIUM WMS default. This rule will reserve the smallest available QTY pallet from the bins defined by the replenishment source Warehouse selection (the source Warehouse refers to the Source Warehouse Selection on the filter screen) but will exclude RECEIVING bins and Picking pallets.

  §  CUSTOM – This option will allow setting up a plugin with custom logic for the reservation. For example, you can configure a customized Pickface Replenishment auto-allocation rule, which may allocate the supplying stock to be from a specific pallet if the requirement is less than a case size, but if greater than a case size, fetch from a different pallet. The Replenishment Auto Reservation plugin must be configured under the Plugin Configuration screen. No custom rule has been developed, but this plugin can be used to develop your own custom rule.

• The Replenishment Pick Slip RPT template must also be configured under the System Setting REPLENISHMENT. From the Ribbon Bar, browse to Settings / System Settings and locate the System Name REPLENISHMENT. The default DATASCOPE_REPLEN_PICKSLIP_LETTER.rpt will be visible under the Setting Name PICKING_SLIP_RPT_TEMPLATE.

• The default replenishment pick slip is letter size. However, a 4x2.5 size template is available, which clients can use when printing a small label as a pick slip. This template does not contain the stock code details as the larger letter size replenishment pick slip. The pickers will get it from the mobile scanner picking screen. This label only instructs the Replenishers to start the Replen picking process and provides them with the pick slip number and a barcode to scan. To change the .rpt template to the smaller 4x2.5 size, update the Setting Name PICKING_SLIP_RPT_TEMPLATE to DATASCOPE_REPLEN_PICKSLIP_4X2.5.rpt.

SYSPRO REQUIREMENTS & Business objects used

• Custom Form Fields can be created for ABC Classes.

REFERENCE

REP001