Replenishment is the systematic movement of inventory from a reserve (bulk) storage location to an active (picking) location. The primary objective is to:
- Prevent Stockouts: Ensure continuous availability of items in pick-face locations.
- Optimize Picking Efficiency: Minimize picker travel time by ensuring frequently picked items are readily accessible.
- Maximize Throughput: Support high-volume order fulfillment by keeping pick zones adequately stocked.
- Maintain Inventory Accuracy: By managing planned movements, it contributes to overall inventory visibility.
Pre-requisite:
- Reserve Locations: Where bulk inventory is stored. These locations are often configured with "Allocation Zones" to define where inventory for replenishment can be sourced from.
- Active (Picking) Locations: The primary locations from which orders are picked. These locations are configured with "Replenishment Zones" and often have defined minimum and maximum capacities (units, volume, weight).
- Items: Items are configured with a "Replenishment Type" (Replen-type) which helps in determining suitable locations for replenishment and allocation.
- Replenishment Rules: These define the criteria for how and from where inventory should be allocated for replenishment. Key parameters include:
- Allocation Zone/Area: Restrict source locations to specific zones or areas.
- Allocation Method: Determines the order in which LPNs are selected (e.g., FIFO, LIFO, FEFO, Smallest LPN, Largest LPN).
- Replenishment UOM: The unit of measure (LPN, Case, Pack, Unit) at which inventory will be allocated.
- Consolidate and Distribute: A flag that allows units and cases from multiple source locations to be consolidated into a temporary LPN before being moved to the destination.
- Replenishment Task Templates: Define how replenishment tasks are created and broken down (e.g., by aisle, area, item). They specify the task types (Full LPN Replenishment, Cases/Packs/Units Replenishment) and can include ordering and selection criteria.
- Replenishment Templates: The overarching configuration that brings together the replenishment rules, task templates, and trigger modes. This is where you define the replenishment strategy.
- Replenishment Zones: Used to group locations that share common replenishment characteristics. Locations are assigned to a replenishment zone.
- Allocation Zones: Used to define groups of reserve locations from which inventory can be allocated for replenishment.
Setup Steps:
(1) Replenishment Zone : Crete Replenishment Zone
(2) Replenishment Type : Create Replenishment Type
(3) Assign Zone to Item: Item -> Warehouse > Replenishment Type = Replenishment Type (2)
(4) Task Template : Template Type = Regular > Save
--> Details -> Task type = Full LPN Replenishment
(5) Replenishment Rule : Replenishment Template > Replenishment Rule : Capacity Check Method = Units > Destination Location Type = Active Only | Replenishment Template > Replenishment Rule > Replenishment Rule Sequence : Allocation Location Type = Reserve > Allocation Method = First In First Out > Replenishment UOM = Lpns
(6) Locations : Replenishment Zone = Replenishment Zone (1)
(7) Replenishment Template:
Replenishment Zone = Zone Name (1)
Replenishment Rule = Replenishment Rule (5)
Task Creation Template = Task Template (4)
Replenishment Trigger Mode = Minimum Capacity
(8) Reserve Inventory : Check the Item + Lot + Qty
(9) Screen : Add Replenishment Pick screen (RF) need to be active
(10) Replenishment Template: Select and Run Template -> Replenishment Wave created
(11) Wave Inquiry : Search -> Check Allocation (Status = Allocated)
(12) Task : Find the task number
(13) RF : Replenishment > Replenish Full LPN
(14) Active Inventory : Check the details
(15) Wave Inquiry : Search -> Check Allocation (Status = Completed)
If you require information on the various triggering modes, kindly note them in the comments.
Thanks,
Pratip Chatterjee
