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Warehouse and DC Management (WM) SAP Best Practices for Retail (US) SAP Best Practices.

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Präsentation zum Thema: "Warehouse and DC Management (WM) SAP Best Practices for Retail (US) SAP Best Practices."—  Präsentation transkript:

1 Warehouse and DC Management (WM) SAP Best Practices for Retail (US) SAP Best Practices

2 Scenario Overview 1 Purpose This scenario describes the processing procedure for retail goods in a distribution center, using a warehouse management system with inventory management at storage bin level. In this scenario, distribution center will refer to a warehouse that is supplied by vendors, that stores the merchandise and then prepares it to be shipped to customers or stores. Benefits As warehouse processes depend greatly on the amount of space available, the organization of the warehouse and the merchandise stored there, this scenario should be viewed simply as an example for implementation purposes. However, with very little effort, this example can be adapted to fit any customer-specific situation. Key process flows covered Goods Receipt Processing Return Deliveries Internal Warehouse Replenishment Goods Issue Processing Warehouse Physical Inventory Tools and Workbenches Purpose and Benefits:

3 Scenario Overview 2 Required SAP EHP3 for SAP ERP 6.0 Company roles involved in process flows Retail Warehouse Clerk Retail Sales Person Retail Warehouse Manager SAP Applications Required:

4 Process Flow Diagram Create Purchase Order for Single Article Retail Warehouse Manager Retail Warehouse Clerk Retail Sales Person Create Purchase Order for Generic Article Post Rough Goods Receipt Create Inbound Delivery Appointment Planing 4.2 Receipt of incoming Goods Enter an Actual Appointment Alternative 2: Confirm with difference Alternative 1: Confirm without difference Log-on to the Terminal Search for the Article Document for Goods Receipt Create a Return Delivery Issuing the Article Document as Goods Issue / Receipt Slip Alternative 1: Asynchronous Warehouse Management 4.3 Put away Preparation Create a Transfer Order in the Warehouse Goods Collection 6.1 Replenishment Planning Create a Transfer Order Goods Receipt with Reference to the Rough Goods Receipt Putaway Processing 7.1 Create an Outbound Delivery Confirm Transfer Order Ressource Planning with the RF Monitor

5 Process Flow Diagram Create Transfer Order as a Picking Document Retail Warehouse Manager Retail Warehouse Clerk Alternative 1: Asynchronous Warehouse Management Log-on to the Terminal Alternative 1: Confirm without difference Alternative 2: Confirm with difference Resource Planning in the Monitor for Mobile Data Entry Monitor from Mobile Data Entry Monitor Creating Wave Picks Alternative 1: Automatic Capacity-Driven Creation of Wave Picks Create Transfer Orders in Collective Processing Alternative 2: Creating Wave Picks Manually Confirm Transfer Orders in Collective Processing Subsequent Delivery Split 7.3 Post Goods Issue Create Deliveries with Planned Picking Time Goods Issue in Collective Processing 8.1 Create a Physical Inventory Document Manual Entry Carry Out Inventory Recount Difference Statistics Determine Inventory Status Post Differences in Inventory Management Alternative 1: Manual Creation Post Differences in Warehouse Management Trigger Inventory Recount 9.1 Warehouse Activity Monitor 9.2 Outbound Delivery Monitor 9.3 Wave Pick Monitor Rough Workload Estimate After Goods Issue Rough Workload Estimate After Creation of Outbound Deliveries


7 Inventory Management - IM vs. WM Storage Location Storage bin Site Inventory Management on article level Fixed storage bin can be maintained in the article master (text field) Inventory Management on bin level Putaway / Picking strategies are used Storage bin is master data and can be determined by strategy (other than fixed) Whse number Storage type Storage section

8 Warehouse Structure - Warehouse PC1 GI-Area GR-Area 1 Gate 1 2 Gate 2 3 Gate 3 4 Gate 4 H01 High Rack Storage Random Storage Section 001 Fast moving items Section 002 Slow moving items K01 Picking storage type Fixed storage bins Section 001 Fast moving items Section 002 Slow moving items H01 / B01 / F01 Storage for Special Goods (depending on master data) Section 001 Total Section

9 Storage Bins - Warehouse PC1 10 Aisles, 10 Stacks, 10 Levels Level Fast moving items Level Slow moving items Bins to aisles, each with 50 bins Bins Fast moving, Bins Slow moving Aisles Picking Area 001 Aisles Picking Area 002 Aisles Picking Area 003 Bins KOM to KOM aisles, 25 bins each All Storage bins in Total Section Bins to GI-Area GR-Area 1 Gate 1 2 Gate 2 3 Gate 3 4 Gate 4

10 Putaway – Post Goods Receipt GI Document Goods Receipt Movement type Article Quantity Site Stor. location Goods Receipt Movement type Article Quantity Site Stor. location Transfer Requirement Quant in the GR-Area of the Warehouse WM Warehouse

11 Putaway – Transfer Order Transfer Requirement Quant Putaway (physical movement) Confirm Transfer Order Confirm storage bin and quantity Create Transfer Order Automatical determination of storage bins Transfer Order

12 Warehouse Data in the Article Master Article Master Data Warehouse Management Warehouse number(PC1) Storage type(K01) Picking storage type(K01) Storage bin(KOM ) Maximum bin quantity(50) Minimum bin quantity(10) Rounding quantity(blank) Control quantity(blank) Replenishment qty.(blank)

13 Stock check – Triggering Replenishment Reserve storage Picking Zone Stock in bin smaller than minimum quantity? Trigger replenishment Transfer request is generated Create Transfer Order Confirm Transfer Order Physical Goods Transport

14 Picking – Delivery Delivery is relevant for picking Transfer order required ! ! Delivery Article Quantity Site Stor. Location Delivery Article Quantity Site Stor. Location Delivery Goods Issue WM Warehouse

15 Picking – Transfer Order Quant Confirm Transfer Order Confirm Picking Quantity Picking (physical movement) Quant In the shipping zone Create Transfer Order Automatical determination of storage bins Picking List Transfer Order Delivery Picking Storage Type

16 Picking – Goods Issue Goods Issue Delivery is relevant for picking Transfer order required ! ! Delivery Article Quantity Site Stor. Location Delivery Article Quantity Site Stor. Location Delivery WM Warehouse Picking is finished

17 Mass Processing of Deliveries Manual creation in the outbound delivery monitor using selection by: Shipping point Picking date Route, carrier... Free selection Automatic generation using selection by: Picking date / time Additional filter by several criteria (e.g. route, shipping point, ship-to-party...) Considering capacity restrictions: Weight, volume Maximum items on the picking list Working time... Group of Outbound Deliveries or Wave Pick Delivery

18 Mass Processing of Deliveries Collective Follow-On-Processing: Create transfer order Confirm transfer order Post goods issue Group of Outbound Deliveries or Wave Pick Delivery

19 Warehouse Activity Monitor List of all processes within a critical timeframe for execution: Unconfirmed transfer orders Open transfer requirements Critical deliveries... Direct follow-on-processing of the critical documents List of all critical documents

20 Rough Workload Estimate Information on: needed manpower needed transport capacity Estimated Workload in: Quantity Weight Volume Execution time Calculation of workload using: Logistics Load Category Unit of Measure Whse no. / storage type Warehouse process Planned Goods Issue Delivery

21 Mobile Data Entry in WM R/3 Application User interface SAPGui SAPConsole Online processing Mobile Data Entry: Mobile terminals in a radio frequency network Robust hardware made for use in the warehouse Built-in barcode scanner Touch screen for easy use Simplified SAPGui (SAPConsole) as user interface

22 Controlling the Warehouse via RF-Monitor transfer orders run into workload queues The warehouse employees are assigned the these queues and thus a workload of TOs. The overload of a queue can be avoided by monitoring the displayed TOs/employee relation. RF-Monitor of the warehouse manager The system provides the warehouse employees with transfer orders from their queue continuously. Touch screen of the warehouse employee Transfer Orders

23 Physical Inventory with WM Continuous Physical Inventory Inventory Difference Block storage bins Unblock storage bins Create Physical Inventory Document Print / Release Count List Count, Weigh, Measure, Estimate Record Inventory Count Results Process Difference List Activate Physical Inventory Document Clear differences in Warehouse Management Clear differences in Inventory Management Initialize Recount

24 Benefits of Continuous Physical Inventory Better distribution of workload in the warehouse The inventory can be carried out in periods with lower workload Periodic Inventories are usually time consuming and labour intensive Up-to-date information on the availability of the stock in the warehouse The cost of the inventory can be reduced by planning it carefully

25 Processes Goods Receipt and Return Deliveries

26 Processes Replenishment and Goods Issue

27 Process Variant Mass Processing of Deliveries

28 Process Warehouse Physical Inventory

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