View Replenishment requirements
- DATASCOPE WMS
Replenishment / Directed Replenishment / Replenishment Release [REP001]
Replenishment, the process of restocking inventory, is a crucial aspect of warehouse management. It involves moving products from bulk storage or reserve areas to pick locations or other areas where the products are needed to fulfil orders. The goal of replenishment is to ensure that there is always enough stock on hand to meet demand while minimizing excess inventory and maximizing space utilization within the warehouse. Effective replenishment processes, which you play a vital role in, are critical for maintaining accurate inventory levels, optimizing order fulfilment, and ensuring timely customer delivery.
DATASCOPE WMS has two replenishment modules to assist warehouses with the replenishment process.
The Replenishment Release screen can be opened to view the outstanding replenishment tasks (generated by the Pickface Replen Service running in the background). First, you will be presented with a filter screen to logically filter the outstanding replenishment tasks.
To start the process, the user can easily build advanced replenishment calculations by selecting various filters, different by warehouse, warehouse area, or stock code product class.
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Try it!
Open DATASCOPE WMS
From the Main menu, browse to Replenishment / Directed Replenishment / Replenishment Release
The Replenishment Pick Slip Release Filter screen will open.
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.
These filters can be set according to various scenarios. These will all depend on how the warehouse operates. Some scenarios are listed below:
o You may review all replenishment orders and sort them by bulk warehouse bin zones. You could then release a separate picking slip per Zone or Aisle in a zone.
o In another scenario, you may want to release the picking slips by pick face zone. You will be less efficient when picking in the bulk area, but your replenishment order will be easy to put away into the pick face.
o Yet another scenario would be to generate a replenishment by bulk warehouse zone to optimize the bulk picking and then release a second replenishment order from the staging area to the pick face where the pick is grouped by pick face zone.
Below, we will give you an overview of each filter that can be set. Generally, you would only set one type of filter, depending on the scenario.
Setting filters
Source Warehouse Selection -this filter refers to the Source Warehouse from which stock must be picked to replenish a bin elsewhere.
o Select the drop-down and select the applicable warehouse.
o Select the Add button.
o Multiple Warehouses can be selected as well.
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. For more information, refer to Configure Customized Replenishment Calculations
o If All is selected, all replenishment calculations will be used.
o 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.
o 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.
o 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.
o 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.
o 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.
This will mark any Replenishment for that particular stock code as a Priority 1 in the PickfaceReplenishment DB table. The Priority column is used to sort the requirement list so all Priority 1 lines are at the top.
o 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.
o 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. This screen looks very similar to the Sales Order Wave Release screen, and Auto Reservation works similarly.
The results can be reviewed or refiltered into logical groupings by selecting the Filter button in the top left-hand corner.
This can be done multiple times and release replenishments in waves.
Select your filters.
Let’s review the outstanding replenishments for two pick face zones to be handled together.
From the Replenishment Pick Slip Release Filter screen, select the required zones from the Zone drop-down list without using other filters.
Select OK
The data grid will load and only display pick face replenishments for Zones A and G.
Setup Replenishment Release
You can now start to reserve the stock. You can manually reserve each line by selecting the Reserve link or auto-allocate these replenishment tasks using the auto-reservation rule with DATASCOPE PREMIUM WMS.
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.
o 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.
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.
o Green – indicates a partial or full reservation.
o Purple – indicates the QTYs required are greater than the fill-to-max stock.
o Red – refers to unreserved lines.
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 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.
View and track the pick slip – Pick Slip Review screen.
On the Pick Slip Review screen, the pick slip will have a status of PRINTED, and the pickers can start picking the stock on the floor by using the HTML5 scanner-based screen – Replenishment Picking.
From the Main Menu, browse to Order Release / Pick Slip Management / Pick Slip Review.
Select the Replenishment option under Type to view only the Replenishment Pick Slips.
The Direct Replenishment pick slips can be monitored during the picking process.
For more information on the Pick Slip Review screen, refer to Pick Slip Review Overview
Pick Replenishment according to the Pick Slip assigned.
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 Sales Order or Job pick slip.
For more information on picking, refer to Replenishment Picking