Download SAP Warehouse Management WM Introduction 26125078...
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SAP Warehouse Management (WM): Features, Functions, Best Practices, and Infrastructure
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Trey Jones Catalyst International
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© 2008 Wellesley Information Services. All rights reserved.
Why Are We Here? •
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The purpose of this Jumpstart session is to provide you with an understanding of the tools available in SAP Warehouse Management outside of just the vanilla setup so often implemented during the initial go-live The session will also provide knowledge of different SAP WM offerings, such as:
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SAP ERP Warehouse Management Task and Resource Management (TRM) SAP ERP Extended Warehouse Management (EE 2.0) SAP SCM Extended Warehouse Management (EWM)
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Tip 1
What We’ll Cover … • • • • • •
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SAP ERP Warehouse Management (WM) SAP WM Data Collection Task and Resource Management SAP ERP Extended Warehouse Management SAP SCM Extended Warehouse Management Wrap-up
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What We’ll Cover: SAP ERP Warehouse Management (WM) • • • • •
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SAP ERP WM Overview Stock Placement and Removal Storage and Handling Units in WM Cycle Counting Wave Planning
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SAP WM Terminology •
SAP ERP Warehouse Management
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Introduced with EE 1.0 of Release 4.7 Included in SAP ECC 5.0 and SAP ERP 6.0 (and latest version of SAP NetWeaver®)
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SAP ERP Extended Warehouse Management
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Any SAP ERP or SAP ECC release without EE 2.0 (extension set) activated Core module of Warehouse Management
SAP WM Task and Resource Management (TRM)
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Yard Management, Cross-Docking, and Value-Added Services Must be on at least SAP ERP 4.7; included in EE 2.0
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SAP SCM Extended Warehouse Management
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Not part of SAP ECC 5.0 and SAP ERP 6.0 4
SAP WM Evolution •
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Prior to the release of SAP ERP Extended Warehouse Management (EWM), SAP had continued to build on its original SAP R/3 Warehouse Functionality with each release Major increases in R/3 releases 4.6C and 4.7
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Key WM Features •
Placement strategies
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Fixed Bin, Near-Fixed Bin, Addition to Stock with Capacity Checks Bulk, Storage Unit Type Strategy with Position Codes (/) Identification Points (Storage Unit Management/Pallet IDs)
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Powerful picking control
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Wave Picking, Group Picking, Two-Step Picking Two-Step Confirmation FIFO, LIFO, Large/Small Quantity Strategies commonly used for Forward Pick Locations
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WM Monitoring Tools
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Warehouse Activity Monitor (WAM), Outbound/Inbound Delivery Monitor, Wave Picking Monitor
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What We’ll Cover: SAP ERP Warehouse Management (WM) • • • • •
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SAP ERP WM Overview Stock Placement and Removal Storage and Handling Units in WM Cycle Counting Wave Planning
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Standard SAP WM Strategies •
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The following two examples will use the same Master Data points in combination with Storage Type configuration settings in Placement and Removal Strategies Discussion:
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Capacity Checks Near-Fixed Bin Picking Large/Small Picking Rounding Quantities RF Queue Management
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Stock Placement — Near-Fixed Bin with Capacity
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Combination of strategies:
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Implement Capacity Check 3 for Fixed Bin Storage Type f Neutral Indicators per Bin and Material “Near-Fixed Bin” for Bulk and Rack Type Medias Together, provide “top off” functionality in Fwd Pick Bins while making replenishment process more efficient Other considerations: f Palletization data (LE Quantity) from WM2 View (Material Master View) can help with this process for separate transfer order (TO) line items per material
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Stock Placement — Near-Fixed Bin with Capacity (cont.) •
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Maximum Fixed Bin Quantity of 40 cases
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One pallet is equal to 10 cases
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Current Fixed Bin Quantity is 34 cases
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Stock Placement — Near-Fixed Bin with Capacity (cont.) •
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Transfer order for 14 cases — it will first attempt to Putaway the pallet quantity of 10 cases and then the loose 4 cases
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Stock Placement — Near-Fixed Bin with Capacity (cont.) •
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For Line 1, 10 cases, the proposed Destination Bin is the Reserve Storage Type near the Fixed Picking Bin
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Stock Placement — Near-Fixed Bin with Capacity (cont.) •
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For Line 2, four cases, sufficient capacity is found in the Fixed Bin and is identified as the Destination Bin
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Stock Removal — Large/Small Picking •
Large/Small Picking
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Pick Strategy where the source storage bin for picking is decided upon based upon the size of the order quantity
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Dependent upon Master Data and Search Strategies for Removal
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Rounding Quantity setting is an option within configuration at Storage Type level
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Stock Removal — Large/Small Picking (cont.) •
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Master Data
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Each Pick Area f Rounding Qty = Not Used f Control Qty = Case – 1 Each Case Picking Area f Rounding Qty = Case Quantity f Control Qty = Pallet – 1 Case Pallet Picking Area f Rounding Qty = Pallet Quantity f Control Qty = Not Used
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Stock Removal — Large/Small Picking (cont.) •
Where Master Data is:
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Each = < 8 Case = 8 Each Pallet = 32 Cases
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With the use of Rounding Quantities and Large/Small Picking, picking line items are pulled from different Storage Types within a single transfer order Completely standard functionality Can be used at multiple levels — Cascading Levels
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Stock Removal — Large/Small Picking (cont.)
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RF Monitor • • •
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Transaction LRF1 Configurable queues Drag and drop users in between queues during day
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Key WM Features •
Stock Replenishment
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Random Storage Bin Replenishment Fixed Storage Bin Replenishment Two required programs run in batch or as SAP transactions: f RLLNACH1 f RLAUTA10 “Upon transfer order confirmation” option f Creates an automatic replenishment TO when a pick confirmation drives the Fixed Bin location below the minimum stock level
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Decentralized Warehouse Management
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What We’ll Cover: SAP ERP Warehouse Management (WM) • • • • •
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SAP ERP WM Overview Stock Placement and Removal Storage and Handling Units in WM Cycle Counting Wave Planning
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Key WM Features •
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Tracking by Pallet ID in the warehouse
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Storage Unit Management — logical grouping of material to a unique ID that can be managed as a single entity f Homogeneous or Mixed Pallets f Unique at the warehouse level Handling Unit Management — a physical unit that consists of the packaging materials and the goods contained therein f Cross-module functionality f Nesting functionality f Unique number across the supply chain by packaging material
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WM Without Storage Unit Management •
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Without Storage Unit Management, the bin contains 2 Quants:
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Material A for 200 EA Material B for 100 EA Warehouse-unique
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MATERIAL A 100 Ea
MATERIAL A 100 Ea
MATERIAL B 50 EA
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MATERIAL B 50 EA
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WM with Storage Unit Management •
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With Storage Unit Management, the bin now contains:
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Four Quants Two Storage Unit Numbers Warehouse-unique
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Storage Bin 01-01-01
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MATERIAL A 100 Ea
MATERIAL B 50 EA Storage Unit 12345
MATERIAL A 100 Ea
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MATERIAL B 50 EA
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Storage Unit 678910
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Handling Unit Management
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MATERIAL A 100 Ea
MATERIAL A 100 Ea
MATERIAL B 50 EA
Handling Unit 123456789
MATERIAL B 50 EA
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Handling Unit 1234ABCDE
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MATERIAL A 100 Ea
MATERIAL B 50 EA
Handling Unit 123456789
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MATERIAL B 50 EA
Handling Unit 1234ABCDE
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MATERIAL A 100 Ea
MATERIAL B 50 EA
Handling Unit 123456789
MATERIAL A 100 Ea
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MATERIAL B 50 EA
Handling Unit 1234ABCDE
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Storage Unit and Handling Unit Facts
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Storage Unit Management
Handling Unit Management
Requires the use of SAP WM
Does not require SAP WM
Cannot nest Storage Units
Can nest up to 999,999 levels of HUs (example: Level 1: Pallet, Level 2: Carton, Level 3: Each)
Can activate by Storage Type
Can activate by Storage Location
Does not require or include Packaging Materials
Requires defined Packaging Materials
SAP IMG configuration is not as complex
SAP IMG configuration is more complex
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Storage Unit and Handling Unit Facts (cont.)
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Storage Unit Management
Handling Unit Management
Does not support Serial Number Management at Bin Level
Supports Serial Number Management at Bin Level
Only resides within the four walls of the SAP warehouse
Exists in warehouse along with IM, PP/PI, and SD
No Master Data
Master Data for packaging instructions and/or determination
Does not require Packing or Unpacking
Requires Packing or Unpacking if items change within the HU
Internal and external number ranges supported up to 20 digits
Internal and external number ranges supported up to 20 digits
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Pick Handling Units •
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Pick Handling Unit (Shipping Units)
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Enables a Handling Unit to be created with reference to the transfer order versus the outbound delivery Pick-and-Pass type environments Internal or External Handling Unit number ranges Automatic or manual creation of Handling Unit
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What We’ll Cover: SAP ERP Warehouse Management (WM) • • • • •
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SAP ERP WM Overview Stock Placement and Removal Storage and Handling Units in WM Cycle Counting Wave Planning
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Inventory Options •
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Multiple options available with SAP ERP WM
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Continuous Inventory: distribution of a physical inventory across a period of time, counting per bin f Continuous Inventory during Putaway Count performed for the first Putaway into each bin during a fiscal year Annual Inventory Zero Stock Check: inventory performed upon stock removal when the bin is empty Cycle Counting: performed at the level of material class f Following slide shows examples of configuration settings Cycle Counting at the Quant level f Commonly used in Mixed Bin environments
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Cycle Counting
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What We’ll Cover: SAP ERP Warehouse Management (WM) • • • • •
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SAP ERP WM Overview Stock Placement and Removal Storage and Handling Units in WM Cycle Counting Wave Planning
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Wave Planning •
Base/Order Picking
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Pick by single delivery Works well in operations with Low numbers of orders and Moderate to High numbers of picks per order
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Batch/Multi-Order Picking (Group)
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Multiple orders are grouped into small batches Works well in operations with Low to High numbers of orders and Low number of picks per order
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Zone Picking
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Order Picking where the picking areas are subdivided into individual pick zones Works well in operations with Moderate to High numbers of orders and Low to Moderate picks per order
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Wave Planning (cont.) •
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Wave Picking
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Variation of Batch and Zone Picking; multiple zones picked at one time and later sorted and consolidated for final shipment Works well in operations with Low to High numbers of orders and Moderate to High picks per order
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Wave Planning (cont.) • •
SAP offers tools to handle all types of picking methods Most common methods of manually creating waves are through Outbound Delivery Monitor
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Wave Planning According to Shipments also available Create by Delivery or Shipment Group Times
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Deliveries are assigned at the Header Level
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A single delivery cannot be split to two separate waves
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Wave Planning (cont.) •
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A background batch job is run periodically to create waves of one or more deliveries. The batch job then creates transfer orders for picking. The waves are created based on criteria maintained in the Load Wave Creation Table The batch job is scheduled to run every hour Hazardous and non-hazardous orders are split into two separate deliveries. The deliveries can be waved together based on the parameter table.
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Wave Planning (cont.)
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In certain situations, the user may need to trigger the batch job manually
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Use transaction ZTOCREATE: Creates waves and generates transfer orders for parts shipping points
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The batch job will run as normal using the criteria from the parameters table The batch job will also still run at its normally scheduled time The following slides show an example of using standard functionality with a custom front end for wave creation along with SAPConsole
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Grouping of deliveries and Zone Picking
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Wave Planning (cont.)
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1.
Access transaction ZTOCREATE.
3.
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Click Execute.
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2.
Access transaction ZWAVE. Warehouse number is populated based on the user profile.
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Click Execute.
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Modify the Date Created range if necessary. System will default previous working day through current working day.
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Wave Planning (cont.) • •
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All driven off of the printing of the batch sheet The wave group is a result of the user-defined requirements for the grouping of deliveries and material picking characteristics 5.
Click
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Select one or more wave groups to release by checking the box.
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Wave Release •
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Example of Wave Group Batch Sheet (printed at release)
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Picking by Wave
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1.
From the Shipping menu, select 1. Pick by Zone.
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The Pick by Wave Group transaction appears.
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Picking by Wave (cont.)
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2.
3.
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The printer is defaulted from the user’s profile. The pick label will print to this printer. Change the printer, if necessary. Enter the wave group by scanning field from the Wave Group Batch Sheet.
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If there are multiple picks from different zones, this screen will appear. In this example, there are picks from two zones. Enter a selection (1-2) from the list to pick from that zone. Note: This screen will not appear if all picks are from the same zone.
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Press Enter.
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Picking by Wave (cont.)
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6.
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The transfer order number, zone, source bin, material, quantity, and unit of measure for picking appear. Enter the bin the material is being picked from.
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Press Enter.
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Enter the material that is being picked.
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Press Enter.
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Wave Monitoring — Picking Progress
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11. Click Display open TOs.
A summary of transfer orders appears by status and storage type. Green indicates confirmed transfer orders while red indicates open transfer orders.
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In this example:
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• 83% of the transfer orders are confirmed (5 TOs)
10. Select a group with open transfer orders.
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• 1 TO is open and is coming from storage type VNA, section 005.
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What We’ll Cover … • • • • • •
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SAP ERP Warehouse Management (WM) SAP WM Data Collection Task and Resource Management SAP ERP Extended Warehouse Management SAP SCM Extended Warehouse Management Wrap-up
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What We’ll Cover: SAP WM Data Collection • • •
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Text and Web-Based SAPConsole Mobile ITS Mobile Web Dynpro
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Data Collection History with SAP
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Hardware Advancement
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Web-Based SAPConsole/ Mobile ITS Real Time
Mobile Web Dynpro
Mobile Infrastructure
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Character-Based Store and Forward
Third-Party Interface Near Real Time
Character-Based SAPConsole Real Time
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Operational/Software Advancement 46
SAPConsole • • •
A core component of the SAP Logistics Execution System A powerful native SAP translation engine that puts the power of SAP into the hands of mobile workers Core components include:
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SAPConsole Translation Engine (SAPGUI) RF Monitoring Tool SAP Administrator
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Capabilities
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Allows shop floor or non-desktop-based SAP users to interact with SAP in a “real-time” environment via a “task-based manner”
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SAPConsole (cont.) •
SAPConsole is essentially a translator
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Sits between a telnet client (e.g., an RF device) and R/3 Telnet handles the communication between the RF devices and a telnet server Sits on the same box as the telnet server Translates commands from the RF device to R/3 commands
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Telnet
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Stands for “telecommunications network” Extremely efficient, stable, character-based protocol for clientserver communication (since 1983) Part of the TCP/IP suite of protocols
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SAPConsole — Architecture
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SAP System
Application
SAPConsole
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Telnet
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Web-based
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Presentation Server Windows NT/2000/2003/XP
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Ethernet RF devices with telnet session (remote connection) to telnet server
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802.11b/g Access Point
VT 220
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Access Point: routes connection through telnet: can hold a connection to host even if RF device is offline
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SAPConsole • • •
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Mature product SAP will continue to support text-based SAPConsole! Key features:
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Configurable menu paths Applications identifiers Bell signals Supports delimiters Remapping of function keys Supports multiple barcode formats Load balancing through telnet software
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What We’ll Cover: SAP WM Data Collection • • •
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Text and Web-Based SAPConsole Mobile ITS Mobile Web Dynpro
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Internet Transaction Server Mobile (ITSMobile) •
What is ITSMobile?
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Based on the ITS template technique, which states that an HTML template for the browser is provided for each application dynpro Conversion of Web Dynpro for ABAP to HTML screens
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System requirements
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Integrated ITS 640: Kernel Patch 161, SAP Basis Support Package: 20 700: Kernel Patch 88, SAP Basis Support Package: 11
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Through SAP NetWeaver, ITSMobile will be used to generate HTML code for typical 16x20 and 8x40 screens
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ITSMobile •
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Steps to an executable template:
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Generate HTML code for LM∗ or ZLM∗ transactions Create an Internet Communication Framework (ICF) service that can be used to call up these templates via HTTP Adjust templates manually if required for a better look or feel
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What We’ll Cover: SAP WM Data Collection • • •
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Text and Web-Based SAPConsole Mobile ITS Mobile Web Dynpro
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Mobile Web Dynpro •
Web Dynpro is a Java- or ABAP-based User Interface (UI) application for SAP
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It uses SAP’s Web Application Server (WAS) to allow for direct, online access to Web Dynpro applications Only Java Web Dynpro currently supports mobile devices
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Any Java developer will have the skill set necessary to develop these transactions The largest benefit of Web Dynpro applications is that they are developed through the SAP NetWeaver Development Studio, which allows you to quickly create advanced browser-based UIs for desktop and mobile use You can add/change colors, fonts, etc.
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Mobile Web Dynpro (cont.) Internet Mobile Web Dynpro
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What We’ll Cover … • • • • • •
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SAP ERP Warehouse Management (WM) SAP WM Data Collection Task and Resource Management SAP ERP Extended Warehouse Management SAP SCM Extended Warehouse Management Wrap-up
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Task and Resource Management (TRM) •
TRM requirements
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Release with EE 1.1 of SAP 4.7 Resides in LES suite of SAP ERP SAP WM must be activated for TRM
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Additional functionality:
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Three-dimensional warehouse Subdivides WM transfer orders into tasks f Seamless integration between WM and TRM Handles complex material handling operations and complex warehouse environments Understands limitations of resources and workloads Integration with RF devices and native SAPConsole
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TRM Landscape
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Warehouse Management System (WM) Inbound / Outbound Delivery Transfer Order Inventory Document
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Controls storage bins Controls goods
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SAP LES
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Task & Resource Management (TRM)
Task Creation Task Selection and Submission Task Confirmation Exception Handling
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Guided from LES Controls Resources Communicates Instructions
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Worker & Equipment Interface
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RF Terminal
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TRM Overview •
So, what does TRM really mean?
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Bin XYZ coordinates Interleaving Mechanization/automation integration Pick and Drop (P&D) locations (High Bay, N/A Storage) Handling Units Bundling tasks Pick-and-Pass
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What drives a client to TRM?
ROI from automated task assignment Interleaving Complex process (multi-step, clustering)
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TRM
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TRM — How It Works … •
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Resources
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Define properties of equipment and resource Assign capabilities and allowed activities Assign prioritization assignments Resource evaluated with availability, location, task status, and current load content
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TRM •
Site map management
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Bins (storage bin, work center, P&D) Grouping of locations Define routes with properties (length, duration, priority)
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Two components
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Bin Management Route Management
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TRM Monitor
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Traditional WM vs. TRM
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Take a Break!
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What We’ll Cover … • • • • • •
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SAP ERP Warehouse Management (WM) SAP WM Data Collection Task and Resource Management SAP ERP Extended Warehouse Management SAP SCM Extended Warehouse Management Wrap-up
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Key EWM Features •
SAP ERP Extended Warehouse Management (ERP EWM)
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Cross-Docking (ERP EWM) f Management of inbound and outbound movements f System-generated decisions Yard Management (ERP EWM) f Appointment scheduling, check in and check out, assignment of dock doors, loading/unloading activities Value-Added Services
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Dynamic Cycle Counting (DCC)
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This is not a piece of EWM, but in same extension set! Any location can be counted at any point in time Allows for counting inactive inventory documents
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What We’ll Cover: ERP Extended Warehouse Management • •
Cross-Docking Yard Management (YM)
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Drag and Drop Scheduling Tool
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Dynamic Cycle Counting
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Not a Piece of EWM, but Part of EE 2.0
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What Is Cross-Docking? •
Distribution method in which the goods flow in an unbroken sequence from receiving to shipping (dispatching), thus eliminating storage. Also called flowthrough distribution.
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Source: The Business Dictionary
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Cross-docking is the practice in logistics of unloading materials from an incoming vehicle and loading these materials in outbound vehicles with little or no storage in between.
Source: Wikipedia.com
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Planned Cross-Docking •
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A decision that establishes a link between a Planning document and Candidate document prior to the actual arrival of incoming stock and release of an outbound delivery or requirement
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Manual by Warehouse Manager Background One-Step or Two-Step Cross-Docking
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Opportunistic Cross-Docking •
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The system automatically designates a document or item for cross-docking after arrival of incoming stock of an outbound delivery or requirement A prerequisite is an open picking or putaway transfer order Does not override existing decisions, but will cancel open TOs With standard, only works in the form of one-step docking
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Goals of Cross-Docking • •
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Enable planned and opportunistic cross-docking Provide user-friendly interface for cross-dock planning and monitoring Evaluate utilization of cross-docking, considering the following:
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Ensure cross-docking does not contradict warehouse rules Establish a method of communication between incoming stock and outgoing demand based on customer requirements and organizational goals
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Enable automatic and manual decision-making modes
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Cross-Docking Overview •
Document types available for possible cross-docking decisions
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Inbound Deliveries Outbound Deliveries f Shipments f Groups Transfer Requirements
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FIFO can be considered through configuration settings
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Strict Duration Settings
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One-Step Cross-Docking
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Two-Step Cross-Docking
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One-Step or Two-Step?
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One Step Cross Docking
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Release Time Error
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Opportunistic Cross-Docking
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Putaway Transfer Order Qty: 10
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Cancelled Putaway Transfer Order Qty 10
Putaway Transfer Order Qty: 10
Inbound Delivery
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Putaway Transfer Order Qty: 10
YES Outbound Delivery Qty 10
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Pick Transfer Order Qty: 10 Source: Inbound Delivery
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Open TO of Same or > Qty and Material?
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A New Transfer Order Qty: 10
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Opportunistic Cross-Docking (cont.)
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Cross-Docking Monitor
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Cross-Docking Monitor (cont.)
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Cross-Docking Monitor (cont.)
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Cross-Docking Alert Monitor •
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Cross-Docking Alert Monitor
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Configurable Alerts; examples: f Deliveries Past Release Time f Transfer Requirements Past Time f Cancelled Transfer Orders per Opportunistic Cross-Docking
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Final Thoughts on Cross-Docking • •
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FIFO considerations are configurable Cross-docking is integrated with SAP Yard Management System (YMS) Will not create a decision if the Load Quantity is greater than the Open Decision Quantity
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Consider a BAdI for full or less-than-full pallet quantities
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Does not support Mixed Pallets Applies to Available Stock only Customer-specific requirements can be added
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Exclude materials Modify algorithms for “optimal” cross-docking
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What We’ll Cover: ERP Extended Warehouse Management • •
Cross-Docking Yard Management (YM)
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Drag and Drop Scheduling Tool
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Dynamic Cycle Counting
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Not a Piece of EWM, but Part of EE 2.0
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SAP Yard Management System (YMS) •
Built upon the concept of Handling Unit Management (not required)
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Trailers are Handling Unit Managed
Integrated with Transportation, SD, Cross-Docking (CD), and WM Appointment scheduling RF execution-enabled
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CHECK-IN
YARD MOVEMENTS
APPOINTMENT SCHEDULING
SAP YMS
SHIPMENT
DELIVERY
SAP YMS
UNSEALING
WEIGHING
UNLOADING
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BLOCK
SEALING
CHECK-OUT
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UNBLOCK SHIPMENT
SHIPMENT
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Yard Management •
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Linked to Warehouse Management (WM) in configuration
Can operate in an IM environment with correct degree of activation with Lean WM f Normal SD process (no transfer orders)
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YM Integration with LES •
Transportation Management
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Vehicle check-in/check-out and load/unload influence corresponding shipment statuses and dates Registration of drivers and equipment
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Shipping
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Scheduling takes into account ETA against assigned door and staging area Vehicle check-in updates door and staging area in the yard as well as delivery status for ATP depending on settings
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Cross-Docking
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Considers scheduling in creating cross-docking decisions Can include yard scheduling
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YM Capabilities and RF Activities •
Moves enabled through Yard Activities Check-In/Check-Out Scheduling Movements Weighing Loading/Unloading Sealing/Unsealing
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RF-enabled, delivered transactions
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Check-In/Check-Out System-Guided Movements Manual Movements Blocking/Unblocking Loading/Unloading Sealing/Unsealing
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YM Checkpoint Tool
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YM Yard Monitor
_________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ 91
Appointment Scheduling (YM) •
Varies upon Trailer Types, Delivery Types, Movements WM Locations can influence door selection Timing, Delivery Time, Current Time, and Availability
_________________________________
Warehouse 001 Material A
Multiple Scheduling Profiles
_________________________________
_________________________________ _________________________________
Staging Area
_________________________________ _________________________________ Yard Location Group Relationship
_________________________________ _________________________________
Material A
_________________________________ _________________________________ 92
SAP YM: Yard Monitor
_________________________________ _________________________________
SAP Yard Activity Monitor
_________________________________ _________________________________ _________________________________ _________________________________ _________________________________
SAP Shipment Document
_________________________________ _________________________________ _________________________________ 93
YM Drag and Drop Scheduling Solution • •
•
_________________________________
Built within SAP to work with SAP YM Real-time graphical view of the entire status of the yard at any time Key functionality:
_________________________________ _________________________________ _________________________________
Drag and drop task creation Tree and pictorial representation Multiple levels of pictorial display Trailers are color-coded to represent inbound vs. outbound and complete with gauges for loading status Pop-up detail when images are clicked Scheduling monitor
_________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________
94
YM Drag and Drop Tool
_________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ 95
YM Drag and Drop Tool (cont.)
_________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ 96
What We’ll Cover: ERP Extended Warehouse Management • •
Cross-Docking Yard Management (YM)
•
_________________________________ _________________________________ _________________________________
Drag and Drop Scheduling Tool
_________________________________
Dynamic Cycle Counting
_________________________________
Not a Piece of EWM, but Part of EE 2.0
_________________________________ _________________________________ _________________________________ _________________________________ _________________________________ 97
Dynamic Cycle Counting •
Previous Cycle Counting
•
_________________________________
An inventory document can only be created if there are no transfer orders open for the bin/material/Quant Counting only allowed against an active inventory document
_________________________________ _________________________________
Extension Set 2.0 Cycle Counting
•
_________________________________
_________________________________
Any location can be counted at any point in time Allows for counting inactive inventory documents
_________________________________
Dynamic Cycle Counting can only be leveraged if your warehouse is real time from inbound through outbound
_________________________________ _________________________________
Note: This is not a piece of the EWM License, but is a part of EE 2.0. This is free functionality!
_________________________________ _________________________________ 98
Dynamic Cycle Counting (cont.) •
Solution benefits
• • • •
_________________________________ _________________________________
Allows you to count during all operations and shifts Can effectively interleave tasks Allows for automatic clearing of differences Count by quant on the RF
_________________________________ _________________________________ _________________________________
System leverages existing functionality (one new table) Leverages same document creation transactions Count against active and inactive documents New RF transactions replace old ones
_________________________________ _________________________________ _________________________________ _________________________________ _________________________________ 99
Dynamic Cycle Counting (cont.) • •
•
Settings by Storage Type If errors on cycle count, it will block the bin from further picks/puts Automatic clearing
_________________________________ _________________________________ _________________________________
Always No differences
_________________________________
Count by Quant
_________________________________
•
_________________________________
_________________________________
_________________________________ _________________________________ _________________________________ 100
Dynamic Cycle Counting (cont.) •
RF Transactions
•
_________________________________ _________________________________
System-Guided (LM58) User-Guided (LM59) User-Initiated (LM60) f Creates document on the fly
_________________________________ _________________________________ _________________________________ _________________________________
With DCC, be leery of SAP Notes required for implementation
_________________________________ _________________________________
For ease of use, enable DCC with upgrade to SAP ERP 6.0
_________________________________ _________________________________ 101
What We’ll Cover … • • • • • •
_________________________________
SAP ERP Warehouse Management (WM) SAP WM Data Collection Task and Resource Management SAP ERP Extended Warehouse Management SAP SCM Extended Warehouse Management Wrap-up
_________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ 102
SCM EWM Overview • • •
• • •
_________________________________
Fully integrated into SCM suite A part of the Service Parts Execution (SPE) section of SAP SCM 5.0 Recommended installation on a separate server (decentralized), although recently available on a centralized platform Connection exists back to SAP ERP 4.6C with Service Pack 6.0 SAP NetWeaver 7.0 platform New qRFC technology for interface to ERP system (combination of BAPI and CIF technology)
_________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ 103
SCM EWM Implementations Options
•
Designed to be flexible (any size warehouse, industry, etc.) The Standard Support Pack 6 connection is an IDoc-based connection similar to the Decentralized ERP WM connection
_________________________________ SCM EWM 2006 (5.0) and 2007 (5.1) EWM Deployment Option (Centralized (C) or Master Data Transactional Data Decentralized (D)) ERP Release
•
_________________________________
Custom IDoc 4.0-4.6B Connection Standard Support Pack 6.0 Connection 4.6C Standard Support Pack 6.0 Connection 4.7 Standard Support Pack 6.0 ECC 5.0 Connection
ECC 6.0 CIF
Custom IDoc Connection
_________________________________ _________________________________
D
_________________________________
Standard Support Pack 6.0 Connection D
_________________________________
Standard Support Pack 6.0 Connection D
_________________________________
Standard Support Pack 6.0 Connection D D (EWM 2006) qRCF D or C (EWM 2007)
_________________________________ _________________________________ _________________________________
104
Where Is Extended Warehouse Management?
_________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________
Source: Brian Carter, “EWM Overview,” SAP 2007
105
SCM EWM Overview •
_________________________________
Most significant changes:
_________________________________
4-digit warehouses, storage types, and storage sections; 18digit bins TRM functionality embedded into the solution f Assignment of work can be manual, automatic, or per request by activity f Priority weightings Improved packing specifications from ERP solution for different processes of warehouse activity
_________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________
106
SCM EWM Overview (cont.) •
_________________________________
Most significant changes: (cont.)
Improved standard RF execution with delivered RF wizard for screen flow Greater flexibility for process design with standard configuration f Example, the introduction of Activity areas. These are logical groupings of bins for warehouse activities such as picking and putaway. Allows for complex sorting of bins by area. Handling Unit Management defined at storage type level f Can exist with non-Handling Unit items in the same storage type and bin f Core functionality around the use of Handling Units Serial number tracking at the bin level
107
_________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________
SCM EWM – Inbound Processing
_________________________________ _________________________________
ERP
EWM
_________________________________ _________________________________ _________________________________
Inbound Delivery Notification
Inbound Delivery
_________________________________
(quantity reference)
_________________________________ _________________________________ Goods Receipt for Inbound Delivery
Inbound Delivery
_________________________________
(warehouse request)
_________________________________ 108
SCM EWM — Inbound Processing (cont.) •
New complex putaway strategies
• • •
_________________________________ _________________________________
Unloading Counting Deconsolidation Value-Added Services (Packaging) Putaway
_________________________________ _________________________________ _________________________________ _________________________________
Process-Oriented Storage Control vs. Layout-Oriented Storage Control Quality Inspection Engine within EWM Sample flow:
_________________________________ _________________________________ _________________________________
Slotting Æ Receive ASN Æ Validation and Corrections Æ Transport Unit Arrival and Management Æ GR Æ Putaway Bin Determination Æ Unload Æ Deconsolidation Æ Putaway
_________________________________ 109
SCM EWM – Outbound Processing ERP
_________________________________ _________________________________
EWM
_________________________________ _________________________________
Unchecked Delivery (ERP Processing)
_________________________________ Checked Delivery
_________________________________
Outbound Delivery Request
_________________________________
(quantity reference)
_________________________________
Outbound Delivery Order
_________________________________
(warehouse request)
_________________________________ Goods Issue Posting
Outbound Delivery (for GI posting back to ERP)
110
SCM EWM — Outbound Processing (cont.) •
Wave Planning and Execution
• • •
_________________________________ _________________________________
Definition and release at the Delivery Line Item Level Defined Process Routings for steps such as Picking, VAS, Packing, Staging, and Loading SAP-delivered Wave Templates Automatic, Manual, or Immediate Release
_________________________________ _________________________________ _________________________________
Kitting for Make-to-Order and Make-to-Stock Delivery Split functionality Sample flow:
_________________________________ _________________________________ _________________________________
Order Deployment Æ Route Determination Æ Wave Management Æ Pick Bin Determination Æ Warehouse Orders Æ Work Assignment Æ Picking Æ Packing Æ Staging Æ Loading and GI
_________________________________ _________________________________ 111
Extended Warehouse Management •
_________________________________
RF Framework
_________________________________
RF Wizard f Tool provided within EWM to custom design RF User Interface to the client’s needs without the use of ABAP Ability to add and remove fields from screens Adjust the size of screens Add fields from outside structures Adjust the position of fields along with the field size through Screen Painter Standard function keys are not displayed on an RF screen f Direct access through function key f Shortcuts available through RF command
_________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ 112
RF Screen Enhancement Wizard
_________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________
Source: Brian Carter, “EWM Overview,” SAP 2007
113
SCM EWM Slotting and Rearrangement •
Slotting
•
_________________________________ _________________________________
Process to ensure efficient storage and picking of goods Determines the optimal putaway parameters such as storage type, storage section, and bin type f Can determine a product Fixed Bin f Considers product data, storage requirement data, and packaging data Automatic update of Product Master Can execute in Simulation
_________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________
Subsequent tool for system-guided, warehouse rearrangement
_________________________________ _________________________________ 114
Additional Functionality •
_________________________________
Additional functions of SCM EWM 5.0
_________________________________
Yard Management Cross-Docking (integrated with Transportation) Transportation Management GTS (Global Trade Services) Country of Origin EH&S (Environmental, Health and Safety) Value-Added Services Route Determination Customer Returns
_________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ 115
Labor Management •
_________________________________
Most significant addition with latest version SCM EWM 2007:
_________________________________ _________________________________
Alert Monitors f SAP NetWeaver BI Integration f Actual vs. Planned Time Key Performance Indicators (KPI) f Direct and Indirect Time f Measurement Services (KPI Builder)
_________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ 116
Labor Management (cont.) •
_________________________________
Most significant addition with latest version SCM EWM 2007: (cont.)
_________________________________ _________________________________
Planning and Simulation f Traditional measurements: lines per hour, case per hour, etc. f Engineered labor standards: How long should it take to complete a specific task? f Operational Planning Visualization and Communication
_________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ 117
SAP SCM EWM 2007 Functionality •
_________________________________
Additional functions of SAP SCM EWM 6.0:
_________________________________
Enhanced Yard Management Solution Kitting-to-Stock Batch Management Enhancements Transportation Integration Enhancements Catch Weight Support RFID Enablement Goods Receipt Optimization Production Integration Enhancements Serial Number Search Capability Enhancement More Robust Material Flow Systems Support
_________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ 118
Why SCM EWM?
_________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________
Source: SAP
119
What We’ll Cover … • • • • • •
_________________________________
SAP ERP Warehouse Management (WM) SAP WM Data Collection Task and Resource Management SAP ERP Extended Warehouse Management SAP SCM Extended Warehouse Management Wrap-up
_________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ 120
Where’s the Fit?
_________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ 121
Resources •
Inventory Operations Consulting L.L.C
•
_________________________________ _________________________________
Dave Piasecki, “Order Picking: Methods and Equipment for Piece Pick, Case Pick, and Pallet Pick Operations,” July 2005, www.inventoryops.com/order_picking.htm
_________________________________ _________________________________
SAP Help
http://help.sap.com f SAP R/3 and R/3 Enterprise Choose the correct version of release Click on the proper language Logistics Logistics Execution Warehouse Management
_________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________
122
Resources (cont.) •
SAP PRESS
•
_________________________________ _________________________________
Martin Murray, SAP Warehouse Management: Functionality and Technical Configuration (2006).
_________________________________
EWM Overview
_________________________________
M. Brian Carter, “EWM Overview,” SAP Labs, 2007.
_________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ 123
7 Key Points to Take Home •
•
•
•
_________________________________
SAP Warehouse Management is a powerful, standard tool when completely configured and utilized in the warehouse The use of standard functionality with customized front or back ends can alleviate development efforts and future upgrade headaches SAPConsole is a mature product that will continue to be supported by SAP Task and Resource Management provides the ability for my warehouse to manage both resources and equipment together at a more detailed level than WM
_________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________
124
7 Key Points to Take Home (cont.) •
•
•
_________________________________
SAP Yard Management can be activated to extend warehouse management-type actions beyond the four walls of the warehouse into my yard SAP Cross-Docking can reduce material handling costs in my warehouse by providing seamless, system-guided direction for cross-dock opportunities SCM Extended Warehouse Management is the future of SAP Warehouse Management; however, ERP WM will continue to be used and supported moving forward
_________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________
125
Your Turn!
_________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________
How to contact me: Trey Jones
[email protected]
_________________________________ _________________________________ 126
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