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LO530 Warehouse Management LO530
Release 676 07.11.2006
LO530 Warehouse Management.................................................................................................................................1 Copyright.................................................................................................................................................................2 Logistics Execution.............................................................................................................................................3 Course Prerequisites............................................................................................................................................4 Target Group.......................................................................................................................................................5 Course Overview.....................................................................................................................................................1 Course Goals.......................................................................................................................................................2 Course Objectives...............................................................................................................................................3 Course Content....................................................................................................................................................4 Course Overview Diagram..................................................................................................................................5 Main Business Scenario......................................................................................................................................6 Logistics Execution Overview................................................................................................................................1 Logistics Execution Overview: Overview Diagram...........................................................................................2 Logistics Execution Overview: Business Scenario.............................................................................................3 Logistics Execution Overview: Topic Objectives...............................................................................................4 Integration Process..............................................................................................................................................5 Overview.............................................................................................................................................................6 Warehouse Management.....................................................................................................................................7 WM Integration with Other Systems..................................................................................................................8 Logistics Execution Overview: Topic Objectives...............................................................................................9 Goods Receipt Process......................................................................................................................................10 Process for Stock Placement.............................................................................................................................11 Planning a Movement........................................................................................................................................12 Transfer Requirement Information....................................................................................................................13 Steps for Stock Placement.................................................................................................................................14 Transfer Order Information...............................................................................................................................15 Screen Sequence in Transfer Order Creation....................................................................................................16 Palletization Notices..........................................................................................................................................17 Transfer Order Confirmation............................................................................................................................18 Logistics Execution Overview: Topic Objectives.............................................................................................19 The Goods Issue Process...................................................................................................................................20 Steps for Stock Removal...................................................................................................................................21 Transfer Requirement Information....................................................................................................................22 Steps for Stock Removal...................................................................................................................................23 Transfer Order for Stock Removal....................................................................................................................24 Data Entry Help for Stock Removal.................................................................................................................25 Printing a Transfer Order..................................................................................................................................26 Change Destination Bin....................................................................................................................................27 Cancel Transfer Order.......................................................................................................................................28 Logistics Execution Overview: Unit Summary................................................................................................29 Logistics Execution Overview - Exercises 1.....................................................................................................30 Logistics Execution Overview - Solutions 1.....................................................................................................35
Logistics Execution Overview - Exercises 2.....................................................................................................37 Logistics Execution Overview - Solutions 2.....................................................................................................40 Warehouse Management Structure.........................................................................................................................1 Warehouse Management Structure: Course Overview Diagram........................................................................2 WM Structure: Business Scenario.......................................................................................................................3 Warehouse Management Structure: Objectives..................................................................................................4 Example of a Physical Warehouse Structure......................................................................................................5 Warehouse Structure in the System....................................................................................................................6 Storage Bins and Quants.....................................................................................................................................7 WM-System Hierarchy.......................................................................................................................................8 Examples of a (Physical) Warehouse Structure..................................................................................................9 The Warehouse Structure in the IM System.....................................................................................................10 Possible Structure with the WM System (1-1)..................................................................................................11 Possible Structure with the WM System (1-2)..................................................................................................12 Possible Structure with the WM System (2).....................................................................................................13 Possible Structure with the WM System (3).....................................................................................................14 Organization Structures in the Warehouse........................................................................................................15 Warehouse Level Data......................................................................................................................................16 Storage Type Level Data...................................................................................................................................17 Copying a Warehouse.......................................................................................................................................18 Warehouse Management Structure: Unit Summary..........................................................................................19 Warehouse Management Structure - Exercises 1..............................................................................................20 Warehouse Management Structure - Solutions 1..............................................................................................22 Master Data.............................................................................................................................................................1 Master Data: Course Overview Diagram............................................................................................................2 Master Data: Business Scenario..........................................................................................................................3 Master Data: Topic Objectives............................................................................................................................4 Master Data.........................................................................................................................................................5 Storage Bin Data.................................................................................................................................................6 Creating Storage Bins Automatically..................................................................................................................7 Define Sort Sequence for Placement / Removal.................................................................................................8 Master Data: Topic Objectives............................................................................................................................9 Material Data.....................................................................................................................................................10 Views in a Material Master Record...................................................................................................................11 Screens in a Material Master.............................................................................................................................12 Palletization Data..............................................................................................................................................13 Units of Measure...............................................................................................................................................14 Master Data: Unit Summary.............................................................................................................................15 Master Data - Exercises 1..................................................................................................................................16 Master Data - Solutions 1..................................................................................................................................18 Master Data - Exercises 2..................................................................................................................................21 Master Data - Solutions 2..................................................................................................................................23
Integration with Inventory Management.................................................................................................................1 Integration with Inventory Management: Course Overview Diagram................................................................2 Integration with IM: Business Scenario..............................................................................................................3 Integration with Inventory Management: Objectives..........................................................................................4 Inventory Management/WM Interface................................................................................................................5 Interim Storage Area Search...............................................................................................................................6 Interim Storage: Bin Types.................................................................................................................................7 Transfer Order Storage Type Search - Placement...............................................................................................8 Transfer Order Storage Type Search - Removal.................................................................................................9 TO Processing Overview..................................................................................................................................10 Automatic Creation of Transfer Orders.............................................................................................................11 Integration with IM: Unit Summary..................................................................................................................12 Integration with Inventory Management - Exercises........................................................................................13 Integration with Inventory Management - Solutions........................................................................................15 Goods Receipt.........................................................................................................................................................1 Goods Receipt: Course Overview Diagram........................................................................................................2 Goods Receipt: Business Scenario......................................................................................................................3 Goods Receipt: Objectives..................................................................................................................................4 Capacity Check...................................................................................................................................................5 Capacity Usage Based on the Material...............................................................................................................6 Capacity Check based on the SUT......................................................................................................................7 Capacity Check based on material and SUT (1).................................................................................................8 Capacity Check based on material and SUT (2).................................................................................................9 Handling Differences........................................................................................................................................10 Difference Indicator..........................................................................................................................................11 2 Step Confirmation..........................................................................................................................................12 Pre-allocated Stock Check................................................................................................................................13 Storage Type Search Control............................................................................................................................14 Storage Section Search Control.........................................................................................................................15 Variable Control by Storage Unit Type............................................................................................................16 Special Movement Indicator.............................................................................................................................17 Stock Placement Control...................................................................................................................................18 Stock Placement Strategy..................................................................................................................................19 Manual Bin........................................................................................................................................................20 Fixed Bin (F).....................................................................................................................................................21 Near Fixed Bin (K)............................................................................................................................................22 Addition to Existing Stock (I)...........................................................................................................................23 Pallet Strategy (P)..............................................................................................................................................24 Storage Bin Section Definition.........................................................................................................................25 Open Storage (C)...............................................................................................................................................26 Next Empty Bin (L)...........................................................................................................................................27 Bulk Storage (B)................................................................................................................................................28
Transfer Order and Multiple Printing................................................................................................................29 Setting Up Printing............................................................................................................................................30 Goods Receipt: Unit Summary.........................................................................................................................31 Goods Receipt - Exercises.................................................................................................................................32 Goods Receipt - Solutions.................................................................................................................................34 Goods Issue.............................................................................................................................................................1 Goods Issue: Course Overview Diagram............................................................................................................2 Goods Issue: Business Scenario..........................................................................................................................3 Goods Issue: Objectives......................................................................................................................................4 Full Stock Removal Options...............................................................................................................................5 Stock Removal Control.......................................................................................................................................6 Stock Removal Strategy......................................................................................................................................7 FIFO (F)..............................................................................................................................................................8 LIFO (L)..............................................................................................................................................................9 Partial Quantities First (A)................................................................................................................................10 Large/Small Quantities (M)..............................................................................................................................11 Cascadable through Quantity Rounding - M.....................................................................................................12 Picking Strategy for Fixed Bins (P)..................................................................................................................13 Shelf Life Expiration Date (H)..........................................................................................................................14 Stringent FIFO (***).........................................................................................................................................15 Goods Issue: Summary......................................................................................................................................16 Goods Issue - Exercises.....................................................................................................................................17 Goods Issue - Solutions.....................................................................................................................................19 Posting Changes......................................................................................................................................................1 Posting Changes: Course Overview Diagram.....................................................................................................2 Posting Changes: Business Scenario...................................................................................................................3 Posting Changes: Objectives...............................................................................................................................4 Stock Transfer / Transfer Posting........................................................................................................................5 Bin to Bin Transfer..............................................................................................................................................6 Create TO from Stock List..................................................................................................................................7 Material to Material / Change in Batch...............................................................................................................8 Posting Change: Material Number......................................................................................................................9 Stock Transfer/Transfer Posting (II).................................................................................................................10 Stock Transfer / Posting Change: Plant to Plant...............................................................................................11 Posting Changes During Stock Placement........................................................................................................12 Transfer Posting: Initiated in WM....................................................................................................................13 Customizing Posting Changes WM/IM............................................................................................................14 Posting Changes: Summary..............................................................................................................................15 Posting Changes - Exercises 1..........................................................................................................................16 Posting Changes - Solutions 1...........................................................................................................................18 Posting Changes - Exercises 2..........................................................................................................................20 Posting Changes - Solutions 2...........................................................................................................................22
Posting Changes - Exercises 3..........................................................................................................................23 Posting Changes - Solutions 3...........................................................................................................................25 Production Integration.............................................................................................................................................1 Production Integration: Course Overview Diagram............................................................................................2 Production Integration: Business Scenario.........................................................................................................3 Production Integration: Topic Objectives...........................................................................................................4 Scenario for WM Staging....................................................................................................................................5 Production Order Process Review.......................................................................................................................6 Production Supply Area......................................................................................................................................7 Control Cycle......................................................................................................................................................8 Material Staging Indicators.................................................................................................................................9 Production Storage Bins....................................................................................................................................10 Material Supply.................................................................................................................................................11 Decreasing the Quantity during TO Creation...................................................................................................12 Supply to Production Storage Bins...................................................................................................................13 Usage posting....................................................................................................................................................14 System Definition..............................................................................................................................................15 Distinctive Features for Repetitive Orders........................................................................................................16 Standard Reports...............................................................................................................................................17 Production Integration: Topic Objectives.........................................................................................................18 Scenario for KANBAN Replenishment............................................................................................................19 KANBAN..........................................................................................................................................................20 KANBAN Replenishment Strategy with WM..................................................................................................21 Setup of KANBAN Replenishment..................................................................................................................22 Production Integration: Summary.....................................................................................................................23 Production Integration - Exercises 1.................................................................................................................24 Production Integration - Solutions 1.................................................................................................................29 Production Integration - Exercises 2.................................................................................................................32 Production Integration - Solutions 2.................................................................................................................35 Delivery Processing.................................................................................................................................................1 Delivery Processing: Course Overview Diagram...............................................................................................2 Delivery Processing: Business Scenario.............................................................................................................3 Delivery Processing: Objectives.........................................................................................................................4 Overview of Shipping Process and WM.............................................................................................................5 Picking Process...................................................................................................................................................6 Transfer Order for Outbound Delivery...............................................................................................................7 Creation of Groups in the Delivery Monitor.......................................................................................................8 Two-Step Picking................................................................................................................................................9 Transfer Order Splitting....................................................................................................................................10 Creation of TOs: WMTA..................................................................................................................................11 Delivery Processing: Summary.........................................................................................................................12 Delivery Processing - Exercises 1.....................................................................................................................13
Delivery Processing - Solutions 1.....................................................................................................................15 Delivery Processing - Exercises 2.....................................................................................................................17 Delivery Processing - Solutions 2.....................................................................................................................19 Replenishment.........................................................................................................................................................1 Replenishment: Course Overview Diagram........................................................................................................2 Replenishment: Business Scenario......................................................................................................................3 Replenishment: Objectives..................................................................................................................................4 Replenishment for Fixed Storage Bins................................................................................................................5 Replenishment for Fixed Bins: Batch Report.....................................................................................................6 Planned Replenishment.......................................................................................................................................7 Creating TOs Automatically for TRs..................................................................................................................8 Replenishing Random Bin Management: TR/TO...............................................................................................9 Replenishment: Summary.................................................................................................................................10 Replenishment - Exercises 1.............................................................................................................................11 Replenishment - Solutions 1.............................................................................................................................13 Replenishment - Exercises 2.............................................................................................................................15 Replenishment - Solutions 2.............................................................................................................................16 Physical Inventory...................................................................................................................................................1 Physical Inventory: Course Overview Diagram..................................................................................................2 Physical Inventory: Business Scenario...............................................................................................................3 Physical Inventory: Objectives............................................................................................................................4 Inventory Methods..............................................................................................................................................5 Inventory Process................................................................................................................................................6 Enjoy in Warehouse Management Inventory......................................................................................................7 Continuous Inventory..........................................................................................................................................8 Cycle Counting....................................................................................................................................................9 Cycle Counting Time Interval...........................................................................................................................10 Inventory Based on First Stock Placement.......................................................................................................11 Zero Stock Check..............................................................................................................................................12 Zero Stock Check as Inventory.........................................................................................................................13 Inventory Sampling Procedure..........................................................................................................................14 Physical Inventory: Summary...........................................................................................................................15 Physical Inventory Processes with WM - Exercises.........................................................................................16 Physical Inventory Processes with WM - Solutions.........................................................................................20 Conclusion...............................................................................................................................................................1 Course Objectives...............................................................................................................................................2 Recommended Follow-up Courses.....................................................................................................................3 Recommended Follow-up Activities...................................................................................................................4 Warehouse Management Structure - Exercises 2................................................................................................5 Warehouse Management Structure - Solutions 2................................................................................................8 Appendix.................................................................................................................................................................1 Frequently-used Menu Paths...............................................................................................................................2
Warehouse Structure...........................................................................................................................................5 Case Study...........................................................................................................................................................6
0 LO530 Warehouse Management
LO530 Warehouse Management SAP AG 1999
R/3 System Release 4.6C September 2000 Material number 50041468
0.2 Copyright
Copyright 2006 SAP AG. All rights reserved. No part of this publication may be reproduced or transmitted in any form or for any purpose without the express permission of SAP AG. The information contained herein may be changed without prior notice.
SAP AG 2006
Some software products marketed by SAP AG and its distributors contain proprietary software components of other software vendors. Microsoft, Windows, Outlook, and PowerPoint are registered trademarks of Microsoft Corporation. IBM, DB2, DB2 Universal Database, OS/2, Parallel Sysplex, MVS/ESA, AIX, S/390, AS/400, OS/390, OS/400, iSeries, pSeries, xSeries, zSeries, z/OS, AFP, Intelligent Miner, WebSphere, Netfinity, Tivoli, and Informix are trademarks or registered trademarks of IBM Corporation in the United States and/or other countries. Oracle is a registered trademark of Oracle Corporation. UNIX, X/Open, OSF/1, and Motif are registered trademarks of the Open Group. Citrix, ICA, Program Neighborhood, MetaFrame, WinFrame, VideoFrame, and MultiWin are trademarks or registered trademarks of Citrix Systems, Inc. HTML, XML, XHTML and W3C are trademarks or registered trademarks of W3C®, World Wide Web Consortium, Massachusetts Institute of Technology. Java is a registered trademark of Sun Microsystems, Inc. JavaScript is a registered trademark of Sun Microsystems, Inc., used under license for technology invented and implemented by Netscape. MaxDB is a trademark of MySQL AB, Sweden. SAP, R/3, mySAP, mySAP.com, xApps, xApp, and other SAP products and services mentioned herein as well as their respective logos are trademarks or registered trademarks of SAP AG in Germany and in several other countries all over the world. All other product and service names mentioned are the trademarks of their respective companies. Data contained in this document serves informational purposes only. National product specifications may vary. These materials are subject to change without notice. These materials are provided by SAP AG and its affiliated companies ("SAP Group") for informational purposes only, without representation or warranty of any kind, and SAP Group shall not be liable for errors or omissions with respect to the materials. The only warranties for SAP Group products and services are those that are set forth in the express warranty statements accompanying such products and services, if any. Nothing herein should be construed as constituting an additional warranty.
0.3 Logistics Execution
Level 2
Level 3 LO530
3 days
Warehouse Management
LO531 3 days Additional Topics in Warehouse Management
LO140 3 days Processes in Logistics Execution
LO610
2 days
Delivery Processes LO611
3 days
Transportation
SAP AG 1999
LO650
3 days
Cross - Functional Customizing in SD
0.4 Course Prerequisites
LO140 Processes in Logistics Execution
SAP AG 1999
0.5 Target Group
Audience:
Project team members responsible for the implementation of Warehouse Management
SAP and Partner consultants responsible for customer implementation of Warehouse Management
Duration: 3 days
SAP AG 1999
Notes to the user
The training materials are not teach-yourself programs. They complement the course instructor's explanations. Your material includes space for noting down this additional information.
There may not be enough time to do all the exercises during the course. The exercises are intended to be additional examples that are dealt with during the course. Participants can also use them to deepen their knowledge after the course.
1 Course Overview
Contents: Course Goals Course Objectives Course Content Course Overview Diagram Main Business Scenario
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1.2 Course Goals
This course will prepare you to: Gain an understanding of the basic Warehouse Management functions and the available tools used to configure the SAP Warehouse to your company’s requirements.
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1.3 Course Objectives
At the conclusion of this course, you will be able to: Perform basic WM functions such as putaway and retrieval of stocks and process posting changes Customize the integration with Inventory Management, Production Planning and Delivery Processing Discuss customizing options and settings within the Warehouse Management System
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1.4 Course Content
Preface Unit 1
Course Overview
Unit 7
Goods Issue
Unit 2
Logistics Execution Overview
Unit 8
Posting Changes
Unit 3
Warehouse Management Structure
Unit 9
Production Integration
Unit 10
Delivery Processing
Unit 4
Master Data
Unit 11
Replenishment
Unit 5
Integration with Inventory Management
Unit 12
Physical Inventory
Unit 6
Goods Receipt
Unit 13
Conclusion Appendices
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1.5 Course Overview Diagram
Course Overview
1
Goods Issue
7
Logistics Execution Overview
2
Posting Changes
8
Warehouse Management Structure
3
Production Integration
9
Master Data
4
Delivery Processing
10
Integration with Inventory Management
5
Replenishment
11
Goods Receipt
6
Physical Inventory
12
Conclusion
13
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1.6 Main Business Scenario
The model company is a producer and distributor of pumps. To optimize the logistics process, the company will implement Logistics Execution utilizing Warehouse Management functionality.
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2 Logistics Execution Overview
Contents: Logistics Execution Process Review
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2.2 Logistics Execution Overview: Overview Diagram
1
Goods Issue
7
2
Posting Changes
8
3
Production Integration
9
Master Data
4
Delivery Processing
10
Integration with Inventory Management
5
Replenishment
11
Goods Receipt
6
Physical Inventory
12
Course Overview Logi stics Logistics Execution E xec ut OverOverview view ion Warehouse Management Structure
Conclusion
13
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2.3 Logistics Execution Overview: Business Scenario
The project team must be oriented to the Logistics Execution Process.
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2.4 Logistics Execution Overview: Topic Objectives
At the conclusion of this topic, you will be able to: Describe the Logistics Execution Process
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2.5 Integration Process
Source determination
Invoicing
Goods Issue
Payment
IM
Inventory
Debitor
Creditor
Goods Receipt
Logistics Execution (LE)
Requirement
Requirement determination
Shipping
Accounts
Order Processing
Requirement
Presales Activities
PO Processing
Invoice verification
Payment
Purchasing (MM) SAP AG 1999
In version 4.5, the applications of Warehouse Management, Shipping and Transportation were brought together to form the Logistics Execution system. As part of SAP‘s Supply Chain Management, these components are combined to build strong links between processes of Production, Procurement and Sales and Distribution.
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2.6 Overview Presales Activities
Sales Order
External Supply Procurement
Invoice Verification
MRP Internal Supply Production
Inventory Management Posting Change Goods Receipt
Invoice Entry
Goods Issue
Shipping
Invoicing
Internal and External Accounting SAP AG 1999
Logistics Execution supports the flow of materials along the supply chain, not only between entities, but also within the warehouse for the entire supply chain management from the supplier through the customer. The Warehouse Management system is embedded in the total SAP system as well as in the material flow of the entire organization. Example: If a goods receipt is posted in the Inventory Management system, the stock level is increased in the WM system. Because of the goods receipt posting, an action is started in the WM system that notifies the user that material must be stored in the warehouse.
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2.7 Warehouse Management
Bin Management
Movements
Planning and Monitoring
Radio - Frequency
Warehouse Control
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What tasks does the SAP Warehouse Management system accomplish? Management of complex warehouse structures with various types of storage areas (high rack random storage, block storage, fixed bin storage, and so on) within one or several plants down to the storage bin level. Planning and Monitoring with such tools as the Warehouse Activity Monitor, Rough Workload Estimate, Time Performance and the Delivery Monitor. Processing of all stock movements such as goods receipts, goods issues, stock transfers using stock placement and stock removal strategies, also taking the characteristics of the individual materials into account. Direct Radio Frequency support. The control of information transfers between the WM system and automated control systems.
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2.8 WM Integration with Other Systems Inventory Management
Quality Management
Production Supply
Delivery Processing
Transportation
Human Resources SAP AG 1999
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The Warehouse Management system is integrated with other SAP system modules that provide the following functions: All goods movements in the WM system affect data posted in the Inventory Management system The handling of inventory samples in connection with Quality Management The supply of materials in connection with the PP/PI systems The processing of deliveries in conjunction with the Sales and Distribution Shipping system The processing of items through the Transportation system The processing of transfer orders using hand-held terminals Passing data to Human Resources for Incentive Wages
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2.9 Logistics Execution Overview: Topic Objectives
At the conclusion of this topic, you will be able to: Create a Goods Receipt in Inventory Management and follow through placement and confirmation in the Warehouse
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2.10 Goods Receipt Process
GR area
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Goods receipt: physical process When goods are received, they are usually transferred first to the goods receipt (GR) area. Stock placement into the warehouse takes place after a suitable storage bin has been determined for the goods. Goods receipt: process within the system Inventory Management (IM) A Material Document is created to represent the movement of goods into the warehouse. It is possible to enter palletization data at this point. An Accounting Document is created to represent the change in value of the goods in the warehouse. Warehouse Management (WM) A quant is created in the Goods Receipt area to represent the existence of goods now in the warehouse. A Transfer Requirement is created since the goods must later be transferred by means of a transfer order to a storage area within the warehouse.
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2.11 Process for Stock Placement
IM Goods Receipt
WM
IM
Transfer Requirement QUANT
Transfer Order
Confirmation/ differences
differences
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1. The goods receipt is entered in the Inventory Management system: material document created in IM accounting document created in IM quant created in the GR area in WM transfer requirement created in WM 2. The transfer order is created based on the transfer requirement. 3. The goods become available, upon confirmation of the transfer order. Also, any differences noted at put away are entered at this time. 4. Differences, if any, are moved to a storage type for differences, and when cleared in IM: a material document is created and an accounting document is created There are opportunities for automation at various points throughout the process.
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2.12 Planning a Movement
GR area Transfer requirement
Transfer order
HRS
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A Transfer Requirement (TR) is created in order to plan a stock movement. The TR indicates a need to move a specific quantity (quant) of a material into the warehouse (stock placement) or to move a quantity out of the warehouse (stock removal). The TR provides information about anticipated stock movements. The TR is later converted into one or several Transfer Orders (TO).
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2.13 Transfer Requirement Information
Goods Receipt area
Goods Issue area Transfer requirement
?
What How much Palletization When From where Reason/Origin
Storage area SAP AG 1999
A transfer requirement (TR) contains the following information: What is to be moved (material number)? How much is to be moved (quantity)? How is it palletized (material master)? What is the reason/origin (movement type / purchase order)? What has already been moved (if partial)? List display functions single transfer requirement (transfer requirement number) all TRs for a material all TRs for a storage type all TRs for a requirement (original document) all TRs for a material document
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2.14 Steps for Stock Placement
Goods receipt posting TO from TR
TO
Pallet slip
Stock available
Confirm transfer order
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When goods are delivered, the goods receipt is entered in the Inventory Management system. On the basis of the goods receipt posting, a transfer requirement and a quant in the GR area are created. To place the goods into storage, a transfer order is created on the basis of the transfer requirement. When the transfer order is created, the system determines the destination storage bin. The transfer order documents are used to physically place the goods into storage. The transfer quantity remains unavailable in the warehouse as long as the stock placement is not confirmed in the system. As soon as the physical stock placement has taken place, you confirm the transfer order and also enter differences, if any. Depending upon the system set-up, it is possible for the system to create transfer orders automatically in the background.
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2.15 Transfer Order Information
Goods Receipt area
HRS
Goods Issue area
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The transfer order is an instruction to move materials from a source storage bin to a destination storage bin within the warehouse complex. Transfer orders contain the following information: Material number Quantity to be moved Source, destination and return storage bins The information that the transfer order needs comes from several sources: Material master record Warehouse management movement type Strategies for finding the source or destination storage bins User entries Source documents, such as transfer requirements and deliveries
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2.16 Screen Sequence in Transfer Order Creation
TR
TR items
Transfer requirement list
Overview of TR items
Preparation screen
Details of TO item
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The transfer requirement list contains all transfer requirements that respond to the selection criteria entered. On this list, it is possible to select a transfer requirement, process it and post the transfer order in the background. The overview of transfer requirement items contains all the items in the selected transfer requirement. It is possible to select one or several items in the list and process them either in the foreground or in the background. On the preparation screen, the quantity of a specific transfer requirement item is distributed to different storage bins (where appropriate with a palletization recommendation by the system). The detail screen of a transfer order item contains a source item, a destination item, and sometimes also a return item.
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2.17 Palletization Notices Preparation screen
TR item 1
Transfer order
200 pcs
Item 1
50 pcs
Item 2
50 pcs
Item 3
50 pcs
Item 4
50 pcs
Mat. master Pallet S1 50 pcs SAP AG 1999
The preparation screen is used to divide the transfer requirement quantity among the various pallets (storage bins). Any previously entered palletization data in the transfer requirement is displayed in the preparation screen as default entries. If standard palletization is defined in the material master record, the system proposes distribution of the materials based on the storage unit type (SUT). If several SUTs are defined for the material, the system proposes that any remaining amount be placed on a smaller pallet. You can change the palletization recommendation or carry out the palletization manually. A user exit is also available for this process.
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2.18 Transfer Order Confirmation
TO Header TO Items --Item material src bin
TO item item...
material
dest bin
act quantity
1
tmx1
01-01
50
2
tmx1
01-02
45
3
tmx2
01-03
50
diff quantity ... 5
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When you confirm a transfer order or a transfer order item, you are verifying that the required quantity of material has actually been transferred from one location to another and that the processing of the transfer order or item has been completed. The TO Confirmation function allows three options: Standard 1st screen - confirm actual quantities equal to target quantities 2nd screen - enter differences, if any (one screen per line item) Input List One screen to confirm quantities and enter differences Pack ship unit - switch to packaging dialog of the delivery where you can create shipping units. Whether or not to automatically confirm transfer orders is set in Customizing.
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2.19 Logistics Execution Overview: Topic Objectives
At the conclusion of this topic, you will be able to: Create a Goods Issue in Inventory Management and follow through the removal process in the warehouse
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2.20 The Goods Issue Process
Goods issue area
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Goods issue: physical process: When goods are issued, stock removal from the warehouse takes place after the appropriate storage bin has been determined. The goods are usually transferred to the goods issue (GI) area before leaving the warehouse. Goods issue: process within the system Inventory Management (IM) A Material Document is created to represent the movement of goods into the warehouse. It is possible to enter palletization data at this point. An Accounting Document is created to represent the change in value of the goods in the warehouse. Warehouse Management (WM) A negative quant is created in the Goods Issue area to represent the existence of goods now in the warehouse. A Transfer Requirement is created since the goods are later transferred using a transfer order from a storage area within the warehouse to the GI area.
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2.21 Steps for Stock Removal
IM Goods Issue
WM
IM
Transfer Requirement negative QUANT
Transfer Order
Confirmation/ differences
differences
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1. The goods issue is entered in the Inventory Management system: material document created in IM accounting document created in IM transfer requirement created in WM negative quant created in the GI area in WM 2. The transfer order is created based on the transfer requirement. 3. The goods become available, upon confirmation of the transfer order. Also, any differences noted at the time of stock removal are entered at this time. 4. Differences, if any, are moved to a storage type for differences, and when cleared in IM: a material document is created and an accounting document is created There are opportunities for automation at various points throughout the process.
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2.22 Transfer Requirement Information
Goods Receipt area
Goods Issue area Transfer requirement What How much When Where to Why
?
Storage area SAP AG 1999
A transfer requirement (TR) contains the following information: What is to be moved (material number)? How much is to be moved (quantity)? How is it palletized (material master)? What is the reason/origin (movement type/reference?) What has already been moved (if partial)? List display functions: single transfer requirement (transfer requirement number) all TRs for a material all TRs for a storage type all TRs for an account assignment all TRs for a material document
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2.23 Steps for Stock Removal
Goods issue posting TO for TR
Transfer order
Confirm transfer order
Material available
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For the removal of material, the goods issue is posted in the Inventory Management system. On the basis of this goods issue posting a transfer requirement and a negative quant in the GI area are created. To remove the goods, a transfer order is created from the transfer requirement. When the transfer order is created, the system determines the source storage bin. The goods are physically removed from the warehouse with the help of the transfer order documents. As soon as the physical stock removal is completed, the user confirms the transfer order. Here it is possible to enter differences. Depending upon the set-up, it is possible for the system to create transfer orders automatically in the background.
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2.24 Transfer Order for Stock Removal
Goods Receipt area
HRS
Goods Issue area
SAP AG 1999
For each stock removal a transfer order is created, which is used to transfer the goods from the warehouse to the GI area.
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2.25 Data Entry Help for Stock Removal
Preparation screen
TR item 1 300 pcs
Available stock
Bin
X 100
01-01-01
400 X 100 x 100 100
01-01-02 01-01-03 01-02-01 01-03-01
Transfer order Item 1
100 pcs
Item 2
100 pcs
Item 3
100 pcs
SAP AG 1999
If you select Stock Overview from the TO Create Overview screen, you can view the available quants and select the quants you want to process. On the preparation screen, quants of the required material are proposed by the system for stock removal. You can override the system proposal and manually enter the storage bin from which the quantity is to be removed.
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2.26 Printing a Transfer Order
Item 1
TA
Pick list
Item 1
Mat 1
Src. – Dest.
Item 2
Mat 2
Src. – Dest.
Item 3 . . .
. . .
Item 2 Item 3
Single printout
Multiple printout
SAP AG 1999
As a rule, transfer orders are printed immediately after they have been created. You can print transfer orders in different ways: as a single document (one TO item per page) as a combined document (multiple TO items on one page) as a picking list (several TO with different sort options per page) You can print with or without a bar code. Labels can be printed for each transfer order.
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2.27 Change Destination Bin
SAP AG 1999
As of release 4.5A, you can change the destination storage bin when you confirm transfer orders. This new feature is available in all standard situations. The situations in which you can enter the destination bin is self-evident since the destination bin field is only available for data entry in those cases. It is not possible for dynamic coordinates, return items, in Lean WM, when the destination bin is defined in the movement type, for posting change TOs, for inventory based on putaway and for addition to existing stock in a storage unit.
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2.28 Cancel Transfer Order
Before Confirmation
SAP AG 1999
It is possible to cancel transfer orders that have not yet been confirmed in the WM system. If, while placing goods into stock, you find a storage bin that cannot be used or if you determine that for some reason, a stock removal cannot take place, it is possible for you to cancel a transfer order. You can notify an external system of a transfer order cancellation from the WM system and notify the WM system of a cancellation from the external system. After a transfer order is canceled, reference documents (for example, the TR) are reopened.
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2.29 Logistics Execution Overview: Unit Summary
You are now able to: Describe the Logistics Execution Process Create a Goods Receipt in Inventory Management and follow through placement and confirmation in the Warehouse Create a Goods Issue in Inventory Management and follow through the removal process in the Warehouse
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2.30Logistics Execution Overview - Exercises 1 Unit: Logistics Execution Overview Topic: Goods Receipt At the conclusion of this exercise, you will be able to: • Create a Goods Receipt in Inventory Management and follow through placement and confirmation in WM. In your company, when goods are received from an external source, the material comes into a receiving area and is processed in the SAP System with the appropriate Inventory Management transaction. This material is then placed into a Goods Receipt area and identified with the Purchase Order number. It is the responsibility of the warehouse then to pick up the material from the Goods Receipt area and put it away. Once the material is put away, the warehouse will confirm that the material has been stored as requested. It is your responsibility to ensure that this process is efficient and to troubleshoot any issues that may arise. In order to test the efficiency of this process, you must understand all of the steps within the receiving process. In this exercise, you will walk through the complete cycle of a Goods Receipt, from the time materials are received on the dock until those goods are placed in the appropriate storage type in the warehouse. At several points along the way, you will need to verify the stock situation. The ## indicates your group number that has been assigned by your instructor. Wherever you see ##, please insert your group number. Please be sure to work only within your warehouse.
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1-1
Materials have arrived at the receiving dock with reference to a Purchase order. You know the material number but not the Purchase Order Number. Your Warehouse Number is 1## and your Storage Location is 01##. The ‘##’ is your group number that has been assigned by your instructor. Wherever you see ‘##’, please insert your GROUP NUMBER. Be careful to create and change data only within your warehouse number. 1-1-1 Check the stock situation of the material T-BW03-## before you begin.
Plant
Sloc
StorType
1000
01##
001
Available
For Putaway
Pick Quantity
1-1-2 Add this task to your Favorites. Change the text to Warehouse Management Stock Overview. 1-1-3 Now access the function for entering a goods receipt with reference to a purchase order. 1-1-4 Find the Purchase Order for material T-BW03-##. Enter the goods receipt for 100 pieces. Save/Post the document. Material Document ___________________ 1-1-5 Display the Stock Overview again for material T-BW03-## Plant
Sloc
StorType
1000
01##
001
1000
01##
902
Available
For Putaway
Pick Quantity
TOTAL 1-1-6 From the Stock Overview, display the quant data and determine the following information: Quant Number _______ Goods Receipt Date ____________________
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1-2
Convert the Transfer Requirement to a Transfer Order. 1-2-1 Display all TRs for your warehouse. (Add this task to your Favorites. Change the text to Display Transfer Requirements by Storage Type.) 1-2-2 Is there a TR for the Purchase Order you received in the prior section? _____. Display the TR and make note of the following information:
The Purchase Order number is displayed in the Requirement field.
Transfer Requirement number
________________________________
Requirement tracking number
____
__________________________
Source Storage type & bin number ____ __________________________ Material Document number
________________________________
Hint: The material document number is stored in the header information.
1-2-3 Now convert the Transfer Requirement (TR) into a Transfer Order (TO) in the foreground. 1-2-4 What palletization data is proposed? ______________________________ 1-2-5 How does the system default the palletization data? __________________ ____________________________________________________________ 1-2-6 What destination storage bins are proposed? ________________________ 1-2-7 Before posting, determine what stock placement strategy was used to determine the destination of the final storage bin. Environment → Storage Bin Search log
Putaway Strategy _____ _____________________
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Save the TO. TO Number _________________
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1-2-8 Display the WM stock overview for the material T-BW03-##. Plant
Sloc
StorType
1000
01##
001
1000
01##
902
Available
For Putaway
Pick Quantity
Is the material available in the destination storage bin? ____ Why or Why Not? _______________________________________________ _______________________________________________
1-3
Confirm the Transfer Order. (Add this task to your Favorites. Change the text to Confirm TO, One Step). 1-3-1 Once again, display the stock overview for the material T-BW03-##. Is the material now available in the destination storage bin? _______
Plant
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StorType
Available
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Pick Quantity
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2.31Logistics Execution Overview - Solutions 1 Unit: Logistics Execution Overview Topic: Goods Receipt
1-1 1-1-1 Logistics → Logistics Execution → Internal Whse Processes → Bins and Stocks → Display → Total Stock per Material (Warehouse Management) Field Name or Data Type
Values
Warehouse Number
1##
Material Number
T-BW03-##
Plant
1000
Select MM Stock Figures to see Inventory Management total stock.
1-1-2 Favorites → Add. Select Favorites → Change to modify the text. 1-1-3 Logistics → Logistics Execution → Inbound Process → Goods Receipt for Purchase Order, Order, Other → Enter Goods Receipt for Purchase Order 1-1-4 Select the match code icon in the first blank space next to Purchase Order to search for the Purchase Order Number. Select M:Purchasing Documents for Material. Field Name or Data Type
Values
Material Number
T-BW03-##
Plant
1000
Select the Purchase Order and choose enter. Select Item OK to receive the entire lot of 100 pieces. Enter Storage Location 01##. Save/Post the receipt. 1-1-5 Favorites → Warehouse Management Stock Overview. 1-1-6 From the Stock Overview, select the Plant Summary line for Storage Type 902 with a single click on the line. Then select Bin Stock. Position your cursor on the Quantity and select it to display the quant. 1-2 (C) SAP AG
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1-2-1 Logistics → Logistics Execution → Internal Whse Processes → TranRqmt → Display→ By Storage Type. (Favorites → Add, Highlite the line and choose Favorites → Change to change the description) 1-2-2 Yes, a Transfer Requirement was created by the Goods Receipt transaction. 1-2-3 Select the TR line item, then choose TO in foregr. 1-2-4 The system suggests 5 pallets with a quantity of 20 pieces each on a Europallet. 1-2-5 The system determines the default for the palletization data from the LE Quantities in the material master, warehouse management view. 1-2-6 Select the icon for Putaway Foreground. The system will recommend the placement bin for each pallet of 20. Enter to accept each recommendation up to TO Item 5. 1-2-7 On TO Item 5, select Environment → Storage Bin Search Log. The putaway strategy used is L – Next Empty Bin from Storage Type 001. Go back to the TO creation and Enter, then save. 1-2-8 Favorites → Warehouse Management Stock Overview. The material is not available in the destination storage bin until the Transfer Order is confirmed. 1-3
Logistics → Logistics Execution → Internal Whse Processes → Stock Transfer → Confirm Transfer Order → Single Document → In One Step (Favorites → Add, Highlite the line and choose Favorites → Change) Alternate Menu Path: Logistics → Logistics Execution → Inbound Process → Goods Receipt for PO, Order, Other Transaction → Putaway → Confirm TO → Single Document → In One Step Enter the TO Number. Review the active worklist and save to confirm. 1-3-1 Favorites → Warehouse Management Stock Overview. The materials are now available in the destination storage bin.
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2.32Logistics Execution Overview - Exercises 2 Unit: Logistics Execution Overview Topic: Goods Issue At the conclusion of this exercise, you will be able to: • Create a Goods Issue in Inventory Management and follow through the removal process in the warehouse. A Goods Issue to a Cost Center is often referred to as a ‘Miscellaneous Issue’. Typically, these types of issues are done in the warehouse when other departments are requesting materials outside of regular production or maintenance; for example, materials that are stocked in the warehouse, but not consumed by the production process. These materials are to be issued from the warehouse and expensed to a department’s cost center. In this exercise, your favorite Engineer has requested 5 Shafts, material TBW02-## for some testing. These shafts will be expensed to the cost center of the Engineering Department (Cost Center 1000). In your company, the process for this type of transaction is that the Goods Issue (GI) is posted first in IM, and the appropriate documentation is generated in the warehouse for material removal. The movement type for GI to a Cost Center is configured such that a transfer requirement is created in the warehouse as notification to move inventory from the warehouse to a GI area. You then create a Transfer Order with reference to the Transfer Requirement. The TO that is generated is printed in the warehouse and the materials are pulled from stock. Remember that a material is not available for subsequent functions within the warehouse until the confirmation process is complete. 2-1 An Engineer, Mr. KC Jones, has requested 5 shafts, material number T-BW02-## to be issued to his cost center 1000. 2-1-1 Before you start, note the stock balances for T-BW02-##. Plant
Sloc
StorType
1000
01##
001
Available
For Putaway
Pick Quantity
2-1-2 Post a goods issue transaction issuing the 5 shafts (T-BW02-##) to Mr. Jones’ cost center.
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Plant
Sloc
StorType
1000
01##
001
1000
01##
911
Available
For Putaway
Pick Quantity
TOTAL 2-2
Display all TRs for material T-BW02-##. (Add this transaction to your favorites and change the description to Display TR by material.) Select the one created by the GI transaction and determine the following: Transfer Requirement number Requirement tracking number
______________________________ ____ ________________________
Destination Storage type & bin number Material Document number
_______ _________________
________________________________
Material Document number is contained in the Header data.
2-3 Create a TO in the foreground with reference to your TR. 2-3-1 The Storage Type Search displays the storage type sequence the system will use to search for the stock to remove. What are they? __________ __________ Where does this sequence come from? _____________________________ _____________________________________________________________ 2-3-2 Let the system select the quant for removal. What removal strategy did the system use to select the quant for removal? ________________________________________ Environment → Storage Bin Search Log
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2-3-3 Display the Transfer Order. Which bins are affected? Stor. Type Source
Stor. Bin
_________________ ________________
Destination _________________ ________________ Return
_________________ ________________
2-3-4 Display the stock balance for T-BW02-##. Plant
Sloc
StorType
1000
01##
001
1000
01##
911
Available
For Putaway
Pick Quantity
For Putaway
Pick Quantity
TOTAL
2-4
Confirm the Transfer Order. 2-4-1 Confirm that you have completed movement. 2-4-2 Once again, view the stock overview.
Plant
Sloc
StorType
1000
01##
001
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2.33Logistics Execution Overview - Solutions 2 Unit: Logistics Execution Overview Topic: Goods Issue
2-1 2-1-1
Favorites → Warehouse Management Stock Overview
2-1-2
Logistics → Logistics Execution → Outbound Process → Goods Issue for Other Transaction → Enter Goods Issue
Field Name or Data Type
Values
Movement Type
201
Plant
1000
Storage Location
01##
Cost Center
1000
Material
T-BW02-##
Quantity
5
2-1-3 Favorites → Warehouse Management Stock Overview 2-2
2-3
Logistics → Logistics Execution → Internal Whse Processes → TrnsRqmt → Display → By Material. Favorites → Add, highlight the entry and choose Favorites → Change. Field Name or Data Type
Values
Warehouse
1##
Material
T-BW02-##
Plant
1000
Storage Location
01##
Select the appropriate TR from the list display, then choose TO in foregr. 2-3-1 001, 002. These storage types default from the Storage Type Search Sequence table in customizing.
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2-3-2 Select the icon for Picking Foreground. Then choose Environment → Stor.bin Search Log. Back out of the search log, enter and save the TO. The removal strategy the system uses to select the quant for removal is FIFO (storage type 001). 2-3-3 Logistics → Logistics Execution → Internal Whse Processes → Stock Transfer → Display Transfer Order → By Material 2-3-4 Favorites → Warehouse Management Stock Overview.
2-4
Favorites → Confirm TO, One Step 2-4-1 Save the TO. 2-4-2 Favorites → Warehouse Management Stock Overview.
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3 Warehouse Management Structure
Warehouse Management Structure Elements
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3.2 Warehouse Management Structure: Course Overview Diagram Course Overview
1
Goods Issue
7
Logistics Execution Overview Ware h s Warehouse Mana ouManagement e gStructure e Struc ment tu re
2
Posting Changes
8
3
Production Integration
9
Master Data
4
Delivery Processing
10
Integration with Inventory Management
5
Replenishment
11
Goods Receipt
6
Physical Inventory
12
Conclusion
13
SAP AG 1999
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3.3 WM Structure: Business Scenario
The model company is a producer and distributor of pumps. To optimize the logistics process, this company will implement Logistics Execution utilizing Warehouse Management functionality.
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3.4 Warehouse Management Structure: Objectives
At the conclusion of this unit, you will be able to: Describe the basic elements of the warehouse structure Define possible warehouse structure scenarios with and without warehouse management
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3.5 Example of a Physical Warehouse Structure
Goods receipt
High rack storage 1
GR area
Bulk storage Goods issue
GI area
Fixed Bin area
SAP AG 1999
Example of a complex physical warehouse structure without regard to R/3, consisting of several storage areas: high rack storage, bulk storage, fixed bin area, goods receipt and goods issue area.
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3.6 Warehouse Structure in the System Storage type 001
Storage Storage type type 902 902 GR GR area area
Good receipt
High rack storage Storage type 004
Bulk storage Storage Storage type type 910 910
Storage type 005
GI GI area area
Goods issue
Fixed Bin area
SAP AG 1999
Possible representation of the physical structure in the SAP Warehouse Management system: The entire warehouse structure is managed under a warehouse number The various storage areas are defined as storage types that are differentiated according to their organizational and technical characteristics. Examples: GR area picking area with fixed storage bins high rack storage area with random picking bulk storage area with rows of the same material
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3.7 Storage Bins and Quants
Bin type
High bins
Lower bins
Fast-moving items Fast-moving items
Lower bins
Storage section
SAP AG 1999
Within each storage type the individual storage bins are defined. A storage bin is the smallest geographical or organizational unit (also called “coordinate”) that can be addressed by the system. Example: 02-04-09 (aisle 02, stack 04, level 09) Storage bins are identified by a bin type. Example: Bin type P1 for high bins Storage bins are organizationally grouped into storage sections. Example: Section 001 for fast-moving items. The existence of a material in a bin is defined as a quant. In bins designated for single-material storage, only one quant may be stored in the storage bin. In bins designated for mixed storage, different materials (or batches) may be stored in the same storage bin.
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3.8 WM-System Hierarchy
Warehouse (complex) number
Storage type
Storage section/ Picking area
Storage bin Quants are defined by:
Material / Batch Stock category Special stock Plant / Storage location Storage unit number
Quant
SAP AG 1999
Warehouse: Organizational divisioning, usually of a plant that is used for the purpose of managing materials or goods that are stored in storage bins. Storage Type: A physical or logical storage area that can be defined for a warehouse in the WM system. Storage Section / Picking Area: A logical or physical subdivision of the storage type. Storage Bin: The smallest addressable unit of space in a warehouse (often referred to as a “storage slot“). Since the address of a storage bin is frequently derived from a coordinate system, a storage bin is often referred to as a coordinate. Quant: The existence of a material or a batch (same lot number) of a material in a storage bin. The material quantity in a quant can be increased by an addition to existing stock.
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3.9 Examples of a (Physical) Warehouse Structure
Plants
Storage areas
A B
HRS
Picking area Bulk storage
HRS
Shelving area
SAP AG 1999
Example of a physical warehouse structure that can be depicted in the SAP System.
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3.10 The Warehouse Structure in the IM System
Plants
0001
Storage locations
0001 0001
0002
0002 0002
0001 0001
0002 0002
0003 0003
SAP AG 1999
In an Inventory Management system without Warehouse Management, the various warehouses are defined as storage locations. Example: Plant 0001 Storage loc. 0001 High rack storage 0002 Bulk storage Plant 0002 Storage loc. 0001 High rack storage 0002 Bulk storage 0003 Picking area The stock quantities are managed in cumulative form at the storage location level.
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3.11 Possible Structure with the WM System (1-1)
Scenario 1 Example 1 Plants
0001
0002
0088 0088
0088 0088
Warehouse number 001
Warehouse number 002
Storage locations
Storage types
001 001
002 002
001 001
002 002
003 003
SAP AG 1999
Scenario 1, Example 1: One Storage Location per Plant in One Warehouse Number. In this example, each warehouse is assigned directly to one storage location and one plant. In each warehouse, the various storage areas are represented by storage types.
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3.12 Possible Structure with the WM System (1-2)
Scenario 1 Example 2 Plants
Storage locations
0001
0002
0088 0088
0088 0088
0001 0001
Warehouse number 001
Storage types
001 001
002 002
003 003
004 004
SAP AG 1999
Scenario 1, Example 2: It is possible to manage warehouses from different plants or different company codes under one warehouse number. Warehouse areas (that is, storage types) that are not managed by the Warehouse Management system are defined in the Inventory Management system as storage locations (for example, storage location 0003).
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3.13 Possible Structure with the WM System (2)
Scenario 2 Plant
0001
Storage locations
0087 0087
0088 0088
0003 0003
Warehouse number 001
Storage types
001 001
002 002
003 003
004 004
SAP AG 1999
Scenario 2: Several Storage Locations per Plant in One Warehouse Number. You can assign any number of plant/storage location combinations to the same warehouse number to indicate actual ownership of the stock. When the goods movements between storage locations are initiated solely via IM postings, no further customizing settings are required. You only need to assign the storage locations to the respective warehouse number. In this scenario, the system can no longer determine the storage location from the contents of the fields Plant and Warehouse number automatically. When the system creates transfer orders for deliveries or transfer requirements, it copies the storage location from the reference document. When you create transfer orders without a reference document manually, you must enter the storage location in addition to the plant.
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3.14 Possible Structure with the WM System (3) Scenario 3 Plant
0001
Storage locations
0090 0090
0088 0088
0092 0092
Warehouse number 001
Storage types
902 902
004 004
005 005
100 100
916 916
SAP AG 1999
For this scenario there are two examples: Movement of Stock from the Goods Receipt Area Material Staging for Production The reason for this scenario could be to make the goods available for deliveries only after the goods receipt processing has been fully carried out. This is possible by allowing deliveries to pick stock only from storage location 0091.
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3.15 Organization Structures in the Warehouse
W A R E H O U S E
D O O R
S T A G I N G
Goods Issue
A R E A
Goods Receipt
SAP AG 1999
Door: A door in a warehouse can be used for both receiving and issuing goods. In Customizing it is possible to restrict the area of usage to either receipt or issue. The door from which delivery takes place is already defined in the delivery. Material Staging Area: The Staging areas are intermediate areas in the warehouse in which the goods are temporarily stored after unloading/before loading. In Customizing, these areas are assigned to the corresponding doors.
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3.16 Warehouse Level Data
Define Weights/ Units of Measure
Notifications & Messages
Assign Region Code
Assign Number Ranges
Define Blocking Logic
Allow Partial Picking
Control Data
Define Differences
SAP AG 1999
storage types: Unit of Weight Unit of Measure default data Blocking Logic Error Messaging / Notifications Number Ranges Define Doors Handling of inventory differences Interfaces: Inventory Management Shipping Production Quality Management
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3.17 Storage Type Level Data
Storage type Level Activate Storage Unit Management
Placement Strategies
Activate Hazardous Material Handling
Assign Inventory Methods
Removal Strategies
Activate Full Removal
SAP AG 1999
The characteristics of a storage type are defined using various indicators: control indicators for stock placement (examples: placement strategy, mandatory confirmation, mixed storage, addition to existing stock, capacity check, overdeliveries, hazardous material control). control indicators for stock removal (examples: removal strategy, mandatory confirmation, complete stock removal, return storage, zero stock check, negative stock). control indicator for inventory procedures
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3.18 Copying a Warehouse
001
002
SAP AG 1999
In WM, a default warehouse number is delivered with the standard system. The entries for this organizational unit are usually used as the basis for prototyping. If you require several warehouses for testing purposes or to define your company structure, it is often useful to copy an existing organizational unit.
Copy the respective warehouse numbers using the organizational unit copier (transaction /nEC09). You will need to then maintain number range data for the new warehouse numbers and activate the respective plants / storage locations in which you want to use the new warehouse number.
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3.19 Warehouse Management Structure: Unit Summary
You are now able to: Describe the basic elements of the warehouse structure Define possible warehouse structure scenarios with and without Warehouse Management
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3.20Warehouse Management Structure - Exercises 1 Unit: Warehouse Management Structure Topic: Organizational Elements in WM At the conclusion of this exercise, you will be able to: • Change the name of your warehouse • Verify your warehouse to plant / storage location assignment • Create a new high rack storage type • Create a new goods receipt interim storage type • Create storage sections for these new storage types Your company is implementing the R/3 Warehouse Management system. It is your responsibility to maintain the customizing. You need to ensure the flow of the warehouse data matches the business processes of your warehouse. In this exercise, you are setting up a high rack storage area and a receiving area. You will review and change some administrative information about the warehouse, create two new storage types and create the supporting data for these new storage types. 1-1
Review and change some administrative information about your current warehouse. Remember that a warehouse is first defined as part of the enterprise structure. The warehouse is activated when it is assigned to the plant/storage location. 1-1-1 In the Enterprise structure, change your warehouse (1##) description to a more appropriate description for your business. 1-1-2 Still within the Enterprise structure, check your warehouse assignment. Your warehouse is assigned to which Plant / Storage Location? Plant ______________
1-2
Storage Location ____________________
Once your warehouse has been defined, there are controls which you can set in WM Customizing to have your warehouse perform within your required parameters. In your warehouse, what values are set for the following parameters: Default Unit of Weight:
_______
SU management active: (on/off) _______________ 1-3
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Create a new storage type, ’015 – High Rack Storage Group##’ by copying the current high rack storage type ‘001’. LO530
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The placement and removal controls should have the following characteristics: Stock Placement control stock placement strategy ‘next empty bin’ stock placement requires confirmation activate SUT check activate storage section check Stock Removal control stock removal strategy ‘FIFO’ stock removal requires confirmation activate complete removal return stock to same storage bin 1-4
Now create a new interim storage type,’ 802 – GR area for group ##’ by copying storage type 902. The placement and removal controls should have the following characteristics: Stock Placement control stock placement strategy ‘none’ allow for mixed storage without limitation addition to stock is permitted Stock Removal control stock removal strategy ‘none’ negative stock will be allowed propose post. change at storage bin
1-5 Create Storage Sections for your new storage types. Storage Type 015 will contain two sections: 001 for Fast Moving items and 002 for Slow Moving items. Remember that the Goods Receipt Storage Type 802 must have one storage section (001 GR Area). 1-6 When you created the new storage type 015, you selected the option to activate the SUT check. It is this setting that will verify that the SUT is allowed in the bin type when you create the Transfer Order. You need to allow the SUTs E1 and IP into the storage type 015. Still in customizing under Strategies → Activate storage bin type search, add an entry assigning SUT E1 and IP to your new storage type 015.
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3.21Warehouse Management Structure - Solutions 1 Unit: Warehouse Management Structure Topic: Organizational Elements in WM
1-1 1-1-1 Tools → AcceleratedSAP → Customizing → Edit Project → SAP Reference IMG → Enterprise Structure → Definition → Logistics Execution → Define, Copy, Delete, Check warehouse number → Define warehouse number 1-1-2 SAP Reference IMG → Enterprise Structure → Assignment → Logistics Execution → Assign warehouse number to plant / storage location Plant 1000 1-2
Storage Location 01##
SAP Reference IMG → Logistics Execution → Warehouse Management → Master Data → Define Control Parameters for Warehouse Number Default Unit of Weight: KG SU management active: On
1-3
SAP Reference IMG → Logistics Execution → Warehouse Management → Master Data → Define Storage Type. Position on Warehouse 1##. Select Warehouse 1##, Storage Type 001 and choose Copy As. Modify fields as required, then Enter and Save.
1-4
SAP Reference IMG → Logistics Execution → Warehouse Management → Master Data → Define Storage Type. Position on Warehouse 1##. Select Warehouse 1##, Storage Type 902 and choose Copy As. Modify fields as required, then Enter and Save.
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1-5
1-6
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SAP Reference IMG → Logistics Execution → Warehouse Management → Master Data → Define Storage Sections → New Entries Field Name or Data Type
Values
Warehouse Number
1##
Storage Type
015
Storage Section
001
Description
Fast Moving
Warehouse Number
1##
Storage Type
015
Storage Section
002
Description
Slow Moving
Warehouse Number
1##
Storage Type
802
Storage Section
001
Description
GR Area
SAP Reference IMG → Logistics Execution → Warehouse Management → Strategies → Activate Storage Bin Type Search. Under Assignments, choose Storage Unit Types to Storage Type. Choose New Entries. Field Name or Data Type
Values
Warehouse Number
1##
Type
015
1st
E1
2nd
IP
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4 Master Data
Contents: Storage Bin Data Material Master Data
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4.2 Master Data: Course Overview Diagram
Course Overview
1
Goods Issue
7
Logistics Execution Overview
2
Posting Changes
8
Warehouse Management Structure
3
Production Integration
9
4
Delivery Processing
10
Integration with Inventory Management
5
Replenishment
11
Goods Receipt
6
Physical Inventory
12
MasMaster ter D Data ata
Conclusion
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4.3 Master Data: Business Scenario
Your company is a major producer of pumps. Engineering has designed a new flywheel for the chrome steel pump. Over the next units, this pump will be integrated into the warehouse processes and production area for sale of the final pump. You must create the master data to support this effort.
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4.4 Master Data: Topic Objectives
At the conclusion of this topic, you will be able to: Create storage bin data Create storage bin data using a template
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4.5 Master Data
Warehouse
Material
Warehouse Structure
Material General data Data/warehouse no. Data/storage type
Warehouse number Storage type Storage bins
SAP AG 1999
The master data of the Warehouse Management system is divided into: Warehouse structure data (for example, capacity, fire-containment sections) Material data (for example, weight, hazardous material data, palletization instructions) The characteristics of the warehouses and the materials are taken into consideration for all stock movements.
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4.6 Storage Bin Data
Warehouse no.: 001 Storage type 001 Storage bin: 01-02-02
Storage bin data Section Capacity Storage bin type Blocking indicator Inventory data Verification Data
Quant data Material number Stock quantity GR date Inventory data Inspection Lot SLED SAP AG 1999
Each storage bin is defined in the system by a master record. The master record contains the following: The bin characteristics data (storage section, storage bin type, max. weight, blocking indicators) is created when you create the storage bin master record. Bin usage and inventory information (number of quants, weight used, date of the last movement, inventory data, blocking indicators) is automatically maintained by the system during a stock movement. Whenever a storage bin becomes occupied, the system creates a quant which contains: storage bin identification material identification (material number, plant, batch, stock category, special stock) movement data (for example, GR date) stock quantities (total, available, currently in transfer for stock placement or stock removal) inventory data blocking indicators
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4.7 Creating Storage Bins Automatically
Warehouse Warehouse number number 001 001 Storage Storage type type 001 001
Level 01 to 04
Row A01 to A02
Stack 10 to 40
A01-10-01 A01-10-02 A01-10-03 A01-10-04 A01-20-01 . . . A02-10-01 A02-10-02 A02-10-03 . . .
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To define a range of coordinates, you must define: the location of the bins to be generated (warehouse number / storage type) the current number of the coordinate range the structure of the coordinates: template (shows the format of the bin coordinate) structure (shows how to increment) initial value (first coordinate / start value) final value (last coordinate / end value) increment (amount to be increased for each of the variable blocks) characteristics/features of the storage bins assignment to a storage section storage bin type max. weight
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4.8 Define Sort Sequence for Placement/ Removal
Storage type 001
Top view
Row
Storage bin Sort Sequence Sort field
R R
S S
L L
3 4
1 2
L L S S
R = Row (Aisle) S = Stack L = Level
without sort variable with sort variable SAP AG 1999
With all of the stock placement / removal strategies, you can influence the search for a suitable storage bin with the aid of a sort variable. The sort variable helps the system to search for storage bins. The system sorts storage bins by the sort variable first. If the sort variable has not been maintained, the system sorts by the storage bin coordinate itself. You normally define the sort variable before you create the storage bins. Without the sort variable, the system fills the storage type row by row. For example, the system fills the first row completely first, then the second row, then the third. This can result in a one-sided load of the warehouse. With the sort variable, the system fills the storage bins on a stack by stack basis for each row. When the system selects bins for stock received in the warehouse, it fills the lowest level in each stack first, then the second level in each stack, then the third level, and so on.
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4.9 Master Data: Topic Objectives
At the conclusion of this topic, you will be able to: Extend a material master view for WM data
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4.10 Material Data General Data Material number Description Weight Base unit of measure Order unit Hazardous material number ...
Plant-Specific Data
Warehouse No.-Specific Data
Requirements planning data Issue unit of measure Batch check requirement ...
WM unit of measure Storage type indicator Storage section indicator Storage unit quantity ...
Storage Type-Specific Data Fixed bin Control quantity Replenishment quantity Max./min. per storage bin Rounding quantity SAP AG 1999
The material data relevant for the Warehouse Management system is grouped as follows: general material data plant-specific data data specific to the warehouse number data specific to the storage type
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4.11 Views in a Material Master Record
Basic data
Purchasing
MRP
Sales
St
t
A B
Stock in plant/ storage in plant
Material master record
Work scheduling
Accounting
Quality assurance
Storage
Forecast
Warehouse management
Classification
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Each user department has its own view of the material master record. For each material type you can define which views of the material master record are possible. For each user you can define which views of the material master records are to be displayed/maintained. Each user can define which views will be displayed when the material master record is displayed/maintained. The data in some views is assigned to specific organizational levels: plant, warehouse or storage type level.
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4.12 Screens in a Material Master
Material Material
Views - Basic data - Purchasing - Accounting - Warehouse Management
(Ind. sector) (Material type) (Reference)
Organizational levels - Plant - Storage location - Warehouse no. - Storage type
Data screen(s)
: Standard screen sequence (without preselection) SAP AG 1999
The material type on the initial screen is proposed during the transaction "Create special". The industry sector can be preset on a user-individual basis. Additionally, you can suppress the display of the industry sector on the initial screen. The views and organizational levels can also be preset on a user-individual basis. The views selection and organizational level screens can be removed from the standard screen sequence by setting defaults in the material master.
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4.13 Palletization Data Warehouse 2
LE Quantity
Un
SUT
1
40
PC
IP
2
25
PC
E1
3
Transfer order
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The system uses the LE (Loading Equipment) quantity in conjunction with the storage unit type to propose how to pack a quantity onto loading devices upon stock placement.
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4.14 Units of Measure
Base unit of measure Alternative UoM in the plant (Issue/Order/Sales unit)
Piece 4 48 12
Carton
Warehouse Management Alternative unit of measure
Pallet quantity
Box
Palletization
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The Warehouse Management system uses the following units of measure: The base unit of measure (or stock keeping unit) is the basis for inventory management and evaluation. Quantities in alternative units of measure are always converted to the base unit of measure using the conversion factor. The alternative units of measure are for inventory management (unit of issue), purchasing (order unit), and sales (sales unit). These units of measure are defined at plant level. Alternative units of measure that are specific to the warehouse number are: WM unit of measure Palletization data (storage unit type).
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4.15 Master Data: Unit Summary
You are now able to: Create storage bin data Create storage bin data using a template Extend a material master view for WM data
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4.16Master Data - Exercises
1
Unit: Master Data Topic: Storage Bin Definition At the conclusion of this exercise, you will be able to: • Create storage bin data • Create storage bin data using a template Your company is a major producer of pumps. Engineering has designed a new fly wheel for the chrome steel pump. Over the next units, this pump will be integrated into the warehouse processes and production area for sale of the final pump. In this unit, you must create the master data to support this effort. In the first part of the exercise, you need to create a storage bin in the Fixed bin / Picking area. This is the area where you will store the finished pump. In the second part of the exercise, you will create a range of bins using a template for the storage type that was created in the prior unit. Your warehouse number is 1##. Please remember to be careful and create or change data only within your warehouse number. 1-1
In preparation for the sale of the finished pump, you must create the storage bin where the pump will ultimately be stored and later picked for delivery. 1-1-1 In warehouse 1##, in the Fixed Bin Storage Type, create a storage bin Box##. Assign the bin to a storage section.
1-2
Now you wish to create multiple bins using a template for the storage type 015 that you created in a prior exercise. In this area, you want to create 2 sequences of bins. In the first sequence, you have small bins (E1) and in the second you have the larger (P1) bins. 1-2-1 In the first section, you have 4 rows with 9 sections and 4 levels. You want to create a range of bins for the coordinates ranging from A-01-01 to D-09-04. These are the smaller bin type E1 bins with a weight limit of 1000 KG. These bins are assigned to storage section 001. How many E1 bins were created? _______ 1-2-2 In the second section, you have 5 rows with 8 sections and 3 levels. These bins have the coordinate range of E-01-01 through I-08-03. These are larger bin type P1 bins with a weight limit of 2000 KG and they are assigned to storage section 002. How many P1 bins were created? ________ 1-2-3 Display the empty bin list to verify you have E1 bin type in storage section 001 and P1 bin type in storage section 002.
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4.17Master Data - Solutions 1 Unit: Master Data Topic: Storage Bin Definition
1-1 1-1-1 Logistics → Logistics Execution → Master Data → Warehouse → Storage Bin → Create → Manually. Field Name or Data Type
Values
Warehouse Number
1##
Storage Type
005
Storage Bin
Box-##
Storage Section
001
1-2 1-2-1 Logistics → Logistics Execution → Master Data → Warehouse → Storage Bin → Create → Automatically. Select New Entries.
Field Name or Data Type
Values
Warehouse Number
1##
Storage Type
015
Sequence Number
001
Template
ACNNCNNCCC*
Structure
A BB CC*
Start Value
A-01-01*
End Value
D-09-04*
Increment
1 1 1*
Storage Section
001
Storage Bin Type
E1
Maximum Weight
1000 KG
* Columns must be lined up Enter. Select Environment → Create Bins. Create Online. 144 Bins are created. (C) SAP AG
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1-2-2 Field Name or Data Type
Values
Warehouse Number
1##
Storage Type
015
Sequence Number
002
Template
ACNNCNNCCC*
Structure
A BB CC*
Start Value
E-01-01*
End Value
I-08-03*
Increment
1 1 1*
Storage Section
002
Storage Bin Type
P1
Maximum Weight
2000 KG
* Columns must be lined up. 120 Storage Bins Created. 1-2-3
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Logistics → Logistics Execution → Internal Whse Processes → Bins and Stock → Display → Empty Storage Bins. Enter your warehouse number and storage type 015. Change the number of storage bins to display to 1000 You should see a list of bins for each section 001 and section 002 with the appropriate bin types and weight in each section.
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4.18Master Data - Exercises 2 Unit: Master Data Topic: Material Master At the conclusion of this exercise, you will be able to: • Create Warehouse Management views for an existing material master record • Create a Warehouse Management / Storage Type view for an existing material master record • Set up user defaults for maintaining the material master in the future For the new flywheel number that Engineering has designed, the material master record T-BW01-## already exists; however, the WM view for the flywheel has not yet been created. You must create the WM view for the new flywheel and for the finished pump number T-MS-##. In an effort to facilitate future material master maintenance, you want to set up your user defaults for maintaining the material master. 2-1
You need to create the appropriate Warehouse Management views in the material master in order to manage the materials within your warehouse. 2-1-1
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Create the Warehouse Management views for the new flywheel, material number T-BW01-##. The industry sector M and material type HALB have already been established. Organization structures are plant 1000 and your warehouse number 1##. Purchasing has made an agreement with your vendor that the material will be shipped either on industrial pallets holding 50 pieces or Europallets holding 30 pieces. On receipt, the flywheels should be directed to the Shelf Storage area and on removal picked from the Shelf Storage area and addition to stock is allowed.
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2-1-2
2-2
Now create the Warehouse Management view for the finished pump TMS-##. The finished pump is moved from production to Fixed Bin Storage. The material master must be created at the Storage Type level so the fixed bin can be assigned. The industry sector M and material type FERT have already been established. This material is being created for plant 1000, your warehouse number 1## and your fixed bin storage type (005). These pumps will come from your production facility stacked on industrial pallets with 5 pieces each. When these pumps are delivered from production, they are put into the fixed bin storage, therefore you want to assign a stock placement and a stock removal indicator of FIX. The storage bin you created in the first part of this exercise, Box-##, is the final storage bin for these pumps. You have capacity at this bin to hold a maximum of 50 pumps.
In the future you will only process material master records from the Warehouse Management view for plant 1000 and your warehouse 1##. Create the material master user defaults so the system will automatically default these values. You only want to see the view selection window when requested. You always want to see the organizational levels since you are working with various storage types. Set the Industry Sector to M and hide it.
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4.19Master Data - Solutions 2 Unit: Master Data Topic: Material Master
2-1 2-1-1 Logistics → Logistics Execution → Master Data → Material → Material → Create → Immediately Field Name or Data Type
Values
Material
T-BW01-##
Select Views
Warehouse Management 1 & 2
Organizational Levels:
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Warehouse
1##
Stock Removal
REG
Stock Placement
REG
Addition to Stock
On
LE Quantity
50;30
UM
PC
SUT
IP; E1
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2-1-2 Field Name or Data Type
Values
Material
T-MS-##
Select Views
Warehouse Management 1 & 2
Organizational Levels: Warehouse
1##
Storage Type
005
Stock Removal
FIX
Stock Placement
FIX
LE Quantity
25
UM
PC
SUT
IP
Storage Bin
Box-##
Maximum Bin Quantity
50
2-2 In the material create screen, select Defaults → Industry Sector. Set the Industry Sector to M and choose Hide Industry. Select Defaults → Views. Page down to find Warehouse Management 1 & 2. Select them and set View Selection so you only get the screen when you request it. Finally, select Defaults → Organization Levels. Set the Plant to 1000 and Warehouse to 1##. Do not set the Org/Prof field, so you will continue to be prompted for organization level data.
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5 Integration with Inventory Management
Contents: Inventory Management Interface
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5.2 Integration with Inventory Management: Course Overview Diagram Course Overview
1
Goods Issue
7
Logistics Execution Overview
2
Posting Changes
8
Warehouse Management Structure
3
Production Integration
9
Master Data
4
Delivery Processing
10
5
Replenishment
11
6
Physical Inventory
12
Int g with rat Inven eIntegration with tory ionManagement Inventory Mana geme nt Goods Receipt
Conclusion
13
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5.3 Integration with IM: Business Scenario
The project team is responsible for customizing the Inventory Management interface. An overview of this interface is essential to understanding the options for customizing.
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5.4 Integration with Inventory Management: Objectives
At the conclusion of this topic, you will be able to: Define how the WM Movement Type and thus, the interim storage type and bin are determined by a movement type in Inventory Management Define the overall process of Goods Movements in the WM system
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5.5 Inventory Management/WM Interface
Inventory Management
Stock in the storage location
Goods receipt document
GR posting in Inventory Management Quant GR area
Transfer requirement Interim storage
Warehouse Management
Inside the warehouse Quant in the warehouse
Transfer order
Stock placement in Warehouse Management
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In addition to quantity and cost updates in the Inventory Management system, a GR posting results in the following activities in the Warehouse Management system: A quant is automatically created in the interim storage area for goods receipt, that is, the stock quantity in Warehouse Management is the same as the quantity in Inventory Management (parallel inventory management)). A transfer requirement can be created automatically. This is used as an information help for stock placement later on. These automatic postings take place as a result of the Customizing settings.
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5.6 Interim Storage Area Search
Movement type
Inventory Management
Reference movement type
Movement type
Warehouse Management
Storage type search
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The movement type that is used for a material movement in the Inventory Management system, together with other indicators, is linked to a reference movement type for the Warehouse Management system. With the reference movement type and other indicators, the system determines the following information: movement type for Warehouse Management stock category of the quant to be generated indicator for generating transfer requirements From the WM movement type then, the following information is determined: interim storage type and interim storage bin control indicator for processing, confirming and printing transfer orders special movement indicator for storage type search
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5.7 Interim Storage: Bin Types Warehouse Number Movement Type
Ty
Dynamic
Stor.bin
FxdBn Dyn
Src Dest Ret
Fix ed
Pr e-
de f
Bin
in ed
SAP AG 1999
In the case of goods receipts that have a reference to a purchase order, you want to be able to identify the quants in the GR area according to the purchase order number. The quants are managed in the GR area (interim storage type) in a bin whose coordinate is the same as the purchase order number. This storage bin is created dynamically during the GR posting. Example storage bin: 4500000369. If the quant is posted from Inventory Management without reference to a Purchase Order, the quant can be directed to a predefined bin. A predefined bin is defined in the WM movement type table and generated only once in the WM system with transaction LX20 (Create Bins for InterimStorage Types). Example storage bin: GR area. In the case of a fixed bin, the system will look to the material master to find the storage bin defined for that material. If the fixed bin storage type is the same as the interim storage type, there is no transfer order required for the movement; however, you must ensure that a fixed bin is assigned to each material master at the storage type level. In this case, there are no WM-specific checks. In the case of picking from a fixed bin where the storage type is the interim storage type, the quant is removed from a fixed bin when the GI posting takes place.
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5.8 Transfer Order Storage Type Search - Placement
Movement Type / Transfer requirement type
(-) Source item
(+) Dest. Dest. item
Stor. type 902
Stor. sect. Source bin 001 GR area
St. type 001
Stor. sect. Dest. bin 002 05-06-01
(3) (2) (1)
Stock placement strategy Storage section search Storage type search
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With goods receipts, the source bin (interim storage bin) is assigned when the IM movement is posted and the transfer requirement is created (see "Interim Storage Type Search"). This data comes from the Movement Type. When you create a transfer order using the transfer requirement, the destination bin in the warehouse is assigned. The destination storage bin can be: entered manually by the user assigned directly by the system. In the creation of the Transfer Order, the system will first determine the storage type for placement using the placement indicator on the material master and the storage type search table. From the storage type, the system will determine whether or not storage sections are being used. If so, the storage section will be determined using the section indicator on the material master and the storage section search table. Finally, using the stock placement strategy for the storage type, the system will determine the bin for placement.
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5.9 Transfer Order Storage Type Search - Removal
Storage type search
(1)
Stock removal strategy
(2) (-) Source item
Stor. type 001
Stor. sect. 002
Source bin 05-06-01
(+)
Stor. type 9XX
Stor. sect. 001
Dest. bin GI area
Dest. Dest. item
Transfer requirement / Movement TYpe (+) Return item
Stor. type 001
Stor. sect. 002
Return bin 05-06-01 Stock return control + Stock placement strategy
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With stock removals, the system assigns the destination bin (interim storage bin for goods issues) when the movement is posted in the IM system and the transfer requirement is created (see "Interim Storage Type Search"). When you create the transfer order, the source bin is assigned. The source bin can be: entered manually by the user assigned by the system using the storage type search and removal strategy. The storage section is not considered for stock removals. If picking areas are being used, the picking area is considered. If a quantity remains after complete stock removal from the bin, the system also assigns a return storage bin.
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5.10 TO Processing Overview IM
Goods movement
WM
MM - Mov.Type
Ref. Mov. Type
WM - Mov.Type Transfer requirement
Interim storage type search
TO processing Storage type search Storage section search
Storage bin type search Storage bin search
SAP AG 1999
During a goods movement, the reference movement type is used as a key to convert the MM movement type into a Warehouse Management movement type. The WM movement type defines the interim storage type and interim storage bin. The subsequent creation of a transfer order is influenced by: the movement type material-specific factors: stock placement and removal indicators, storage class, water pollution class, stock category and special stock indicators the put-away and picking strategies for each storage type As an option, you can specify a storage section control factor or a section search within a storage type with material-specific section indicators, storage class and water pollution class As an additional option, the system can check whether a particular storage unit type may be stored in a specific storage bin or storage bin type. Finally, using the strategy assigned for the storage type, the storage bin is determined and suggested.
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5.11 Automatic Creation of Transfer Orders IM IM Document Inventory Management
WM Transfer requirement
Mail
asynchronous Error Transfer order
Warehouse Management SAP AG 1999
It is possible to set up your system so that transfer orders are created automatically when you post material documents in the Inventory Management system. When the system is configured for this process, you create material documents in the normal manner in the IM system and the Warehouse Management system subsequently creates the corresponding transfer requirements and posting change notices. The definition of the WM movement type determines whether the system will automatically create transfer orders from the transfer requirements and posting change notices initiated in the IM system. This process takes place in the background. If there are errors, the system can send an express mail message to a specified user. The user can then process the error from within the message. When you post a material document in the IM system, and movement types both “with” and “without” automatic transfer order creation exist in that document, the system goes directly to the screen to “create a transfer order for a material document”.
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5.12 Integration with IM: Unit Summary
You are now able to: Define how the WM Movement Type and thus, the interim storage type and bin are determined by a movement type in Inventory Management Define the overall process of Goods Movements in the WM system
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5.13Integration with Inventory Management - Exercises Unit: Integration with Inventory Management Topic: Integration with Inventory Management At the conclusion of this exercise, you will be able to: • Verify the link between IM and WM movement types • Change an existing WM movement type • Customize a WM movement type You have created Storage Type 802 for external receipts in your warehouse. You now need to customize the system so that all Purchase Order receipts and reversals are directed to this area. In this exercise, verify the existing movement types and then modify the WM movement types to fit the structure you created. Remember to work only within your warehouse number! 1-1
Before you can modify the WM movement type to direct goods receipts to the goods receipt area 802, you must verify the link between the IM movement type and the WM movement type. 1-1-1 Compare the movement type 101 for a Purchase Order Goods Receipt to a 101 Production Order Goods Receipt. Find the Reference Movement Type: Movement Type
Movement Indicator
Reference Movement Type
101
B
______________________
101
F
______________________
1-1-2 Now find the WM Movement Type: Movement Type
1-2
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Movement Indicator
WM Movement Type
101
B
______________________
101
F
______________________
Update the 101 WM movement type for purchase order receipts so that new receipts are directed to the 802 Goods Receipt area. Also modify the 102 movement type so that reversals will come from storage type 802. Production receipts will continue to be directed to storage type 901.
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1-3
Now test your configuration. Your supplier delivers 100 pieces of material T-BW01##. Enter a goods receipt for the purchase order for storage location 01##. Search for the Purchase Order number using the material number. 1-3-1 Enter a Goods Receipt for 100 pieces of the material T-BW01-##. 1-3-2 Display stock balance. If your stock shows in storage type 802, your configuration is correct.
Plant
Sloc
StorType
1000
0100
802
1-4
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Available
For Putaway
Pick Quantity
Process the TR by converting it to a Transfer Order and confirming it.
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5.14Integration with Inventory Management - Solutions Unit: Integration with Inventory Management Topic: Integration with Inventory Management
1-1-1
SAP Reference IMG → Logistics Execution → Warehouse Management → Interfaces → Inventory Management → Define Movement Types. Choose Assign WM movement type references to IM movement types. Position on: Field Name or Data Type
Values
Movement Type
101
Value updating
X
Qqty updating
X
Movement Type Movement Indicator Reference Movement Type 101
B _______101_____
101F _______101_______ 1-1-2 SAP Reference IMG → Logistics Execution → Warehouse Management → Interfaces → Inventory Management → Define Movement Types. Choose LE-WM Interface Inventory Management. Movement Type Movement Indicator WM Movement Type 101B ________101____ 101F ________103______ 1-2
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SAP Reference IMG → Logistics Execution → Warehouse Management → Activities → Transfers → Define movement types. Position on your warehouse and movement type 101. Select and choose the entry. Modify the Src Storage Type to 802. Also modify the 102 movement type Dest to 802.
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1-3 1-3-1 Logistics → Logistics Execution → Inbound Process → Goods Receipt for Purchase Order, Order, Other Transactions → Enter Goods Receipt for Purchase Order. Select the match code for Purchase Order Number and choose M:Purchasing Documents for Material. Enter the material T-BW01##. Select the entry and post the goods receipt for a quantity of 100 pieces. 1-3-2 Favorites → Warehouse Management Stock Overview
1-4
Logistics → Logistics Execution → Inbound Process → Goods Receipt for Purchase Order, Order, Other transaction → Putaway → Create Transfer Order → by Material. Favorites → Confirm Transfer Order, One Step
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6 Goods Receipt
Contents: The Goods Receipt Process: Influencing factors and options for customizing
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6.2 Goods Receipt: Course Overview Diagram
Course Overview
1
Goods Issue
7
Logistics Execution Overview
2
Posting Changes
8
Warehouse Management Structure
3
Production Integration
9
Master Data
4
Delivery Processing
10
Integration with Inventory Management
5
Replenishment
11
GooGoods ds R Receipt eceip t
6
Physical Inventory
12
Conclusion
13
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6.3 Goods Receipt: Business Scenario
In the model company, the process for goods receipt is such that a Transfer Order is created immediately following the Inventory Management receipt. In this unit, the participant will customize the goods receipt transaction to fit the business practice then test the process.
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6.4 Goods Receipt: Objectives
At the completion of this unit, you will be able to: Customize the goods receipt activity so that the Transfer Order process immediately follows the Inventory Management process Customize the storage type and storage section search so materials are put away into the appropriate storage bin Explain the printing customizing options for Transfer Orders
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6.5 Capacity Check
Option 1 Check By Weight
Option 2
Check By Quantity
Storage Type Option 3
Check By Palletization
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Capacity check is activated at the storage type level. Weight. The weight of the material that is being transferred to the storage bin is checked against the remaining weight capacity of the bin. Maximum quantity for a bin in the storage type: For each storage type you can define the maximum quantity of material that can be stored in a bin. This is often the method used with the Fixed Bin Strategy. Storage Unit Type: You can stipulate that the storage bin can contain only one standard storage unit type. This is taken from the first SUT field on the material master record. With strategies B (Bulk) and P (Storage Unit Management), the maximum bin occupancy or stack height depends on the bin type and the SUT. For bulk storage, capacity checking is defined in the block definition.
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6.6 Capacity Usage Based on the Material
Storage Bin 01-01-01 Total Capacity = 100 Material 4711 Capacity Usage = 11
9 x 11 = 99 Remaining capacity = 1
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The storage of materials in a bin can be based on a neutral indicator. The basic prerequisites for these capacity checks include: Each storage bin must have a dimensional and unit-less capacity Each material can use a specific capacity for each unit of measure Each storage unit type can have a specific capacity for each storage unit Example 1: Capacity usage based on Material The material is managed in the base unit of measure “pieces” and has a capacity usage of 11 per piece. Storage Bin 01-01-01 has a capacity of 100. Nine pieces of this material can be stored in storage bin 01-01-01. This leaves a remaining capacity of 1. This capacity check is advantageous if you can stack materials as desired into this storage bin. It could also replace capacity checks 2 and 3 if there are different batches that result in mixed storage.
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6.7 Capacity Check based on the SUT
Storage Bin 01-01-01 Total Capacity = 100
Material 4711 SUT Capacity = 12
8 x 12 = 96 Remaining capacity = 4
SAP AG 1999
Example 2: Capacity usage based only on SUT (storage unit type) (Must be using SUM in this storage type) Eight wire baskets can be stored in storage bin 01-01-01. This leaves a remaining capacity of 4. This capacity check is advantageous when the SUTs are next to each other and the materials can be removed one at a time from each container.
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6.8 Capacity Check based on material and SUT (1)
Storage Bin 01-01-01 Total Capacity = 100
Material 4711 Capacity Usage = 11 SUT Capacity = 12
(8 X 11) + (1 X 12) = 100 eg cubic feet Remaining Capacity = 0
SAP AG 1999
Example 3: Capacity usage based on the sum of the material and SUT (must be using SUM in this storage type) Eight pieces can be stored in storage bin 01-01-01 on an E1 pallet. This leaves no remaining capacity for the bin.
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6.9 Capacity Check based on material and SUT (2)
Storage Bin 01-01-01 Total Capacity = 100
Material 4711 Capacity Usage = 11 SUT Capacity = 12
(4 X 11) + (4 X 12) = 92 eg cubic feet Remaining Capacity = 8
SAP AG 1999
Example 3: Capacity usage based on the sum of the material and SUT (must be using SUM in this storage type) If the material is stored in the bin with one piece per E1 pallet, 4 pallets will fit in the bin (44 + 48) and a remaining capacity of 8 exists. This capacity check is advantageous if the pallets are stacked on top of each other and the thickness of the pallet must be taken into consideration. Before you make the first stock placement, you need to define the type of capacity check and the capacity usage of material and storage unit types. Changes that are made to these parameters afterwards cause automatic changes to storage bins, storage units and quants. If you make changes in the operational system, you must run report RLS10200 to adjust the occupied capacities for bins, storage units and quants. Active Capacity Check: There is a switch that can be set at the storage type level so that the capacity check is integrated into the bin search. When searching for an empty bin without active capacity, the system assumes that a bin found through customizing can be used and the capacity check happens after the search. If using active capacity, the search process may take longer because each bin is examined individually.
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6.10 Handling Differences
GR posting
50 pcs
TO item SRC GR Target 50 pcs DEST HRS Confirm Target 50 pcs Actual 40 pcs Diff. 10 pcs
40 pcs
Difference 10 pcs
Difference posting inventory management
SAP AG 1999
If a difference is determined during a stock transfer, you can enter this into the system during confirmation.
When the transfer order item is confirmed, the difference is posted to the storage bin that has been specified for the difference indicator.
In a second step, the differences are cleared in the Inventory Management system either manually or using the batch input procedure. When differences are processed in the system, the quantity of stock in the Inventory Management and Warehouse Management systems remains the same.
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6.11 Difference Indicator
Differences can be directed to: A pre-defined coordinate (Eg: Storage Type 999, Bin: Differences) A dynamic coordinate (Eg: Storage Type 999, Bin = TO Number) The source storage bin of the movement type for the TO item
SAP AG 1999
You can specify a predefined coordinate by entering the interim storage type for differences in the Typ field the identifier of the storage bin coordinate in the Diff.bin field You can specify a dynamic coordinate by entering the interim storage type for differences in the Typ field selecting the TO column for the interim storage type If a discrepancy occurs during the confirmation process, the system generates the coordinates for the storage bin based on the transfer order number. You can specify that the difference is posted to the source storage bin of the movement type for the transfer order item by selecting the SrcBn column. If the source storage type does not allow negative stock balances, the system checks whether the stock balance is going to be negative. For more information, see Negative Stock Check. If you use this type of difference indicator, the transfer order item cannot contain a return. Furthermore, you cannot use this difference indicator for stock removals from bulk storage.
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6.12 2 Step Confirmation
2
1
First confirmation when goods are picked from the bin
Second confirmation when goods are placed in the goods issue area
SAP AG 1999
Business Background: With the two-step confirmation procedure, the complete confirmation process is split into two separate steps. The first step is the confirmation of the removal from the source bin. In the goods issue process, this would be the bin from which the material is picked. Then the goods are transferred to the destination bin or area. When they are put away at the destination bin, the second confirmation for the putaway is done. In the goods issue process, this would be the goods issue area. Customer Benefits This reflects the physical process in the warehouse and is important when working with radio frequency devices. The source bin is available for putaway as soon as the first confirmation is complete. Two-step confirmation reflects real-time work in the SAP system. As a result of the separation of the picking and putaway process for every transaction, improved performance for delivery processing is achieved. The first confirmation is often done on the transfer order item level; at this point the delivery is not updated. The second confirmation is done for the complete transfer order; then the delivery update is performed. Additional information: A transfer order split is done if one step and two step confirmation occur in one single TO document. Even with two step confirmation switched on, it is possible to confirm the first and the second step in one step. Differences handling is possible for each step.
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6.13 Pre-allocated Stock Check
Goods Receipt area
Reserve storage
Production storage area XX Pre-allocated stock check
Bin Bin XY XY
Pre-allocated stock Bin XY Mat. XX Qty 20 pcs SAP AG 1999
If the pre-allocated stock check is active for a movement type, the system checks during stock placement if the material has an entry in the pre-allocated stock table. By pressing a function key you can display all storage bins for which the material has been pre-allocated. You decide during TO creation if and how you want to fill the pre-allocated storage bins.
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6.14 Storage Type Search Control
Goods Receipt area
High rack storage
X Material
Fixed Bin Picking Area
Y Material
Stor. type ind. 00 3
FIX-Y Material Y Storage type indicator 003
SAP AG 1999
In the material master record it is possible to define a storage type indicator for stock placements. In the storage type search table you can define a default vector of 30 storage types. Access Optimization: When storage type indicators are used and several materials with different stock categories (such as special stock) exist, the number of entries in the storage type search table can become very large. To decrease the number of these entries, you can define an access strategy for the storage type search table using the access strategy table.
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6.15 Storage Section Search Control
Goods Receipt area Section 001
Section 002
Fast-moving items
Slow-moving items
X Material
” LLL d. “ n i . ct . se Stor Y Material
(LLL = Storage section indicator for slow-moving items)
Mat. Y Stor. sect. ind. LLL SAP AG 1999
In the material master record you can define a storage section indicator. In the storage section search table you can define a default/check vector of 30 storage sections. The storage section is checked only if the storage section check in the storage type is active. If the storage section check is activated, the system will search for a storage bin defined in the storage section search table. If the check is set to X, the system will also check whether a stock placement is allowed for this table. If the check is set to Y, the system will allow a manual override at the time of TO creation, even if the section is not defined in this table.
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6.16 Variable Control by Storage Unit Type
Goods Receipt area
1 SUT S
Small bins
Std. pallet SUT IP
Industrial pallet Mat. X 100 pcs IP 50 pcs S1
Large bins
SAP AG 1999
In the material master record you can define up to three different palletization instructions for the material. If the SUT (storage unit type) check in the storage type is active, the system will first check if the SUT is allowed in the storage type. The system will then check whether the SUT is allowed for that storage bin type. You can define up to 30 SUTs in a storage type and up to 30 storage bin types for a storage unit type. As an option, you can enter *** as an allowed SUT in the customizing table. This entry means that all the SUTs are allowed in this storage type. The system then searches for a suitable storage bin for the SUT based on the allowed bin types per SUT.
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6.17 Special Movement Indicator
Goods receipt posting Special movement indicator
Interim storage area
Fixed bin storage
Fixed bin storage: FIX- Mat
Inside the warehouse
High rack storage
SAP AG 1999
Using the special movement indicator, you can ensure that the GR posting creates a quant in a storage type in which a fixed bin is defined for each material. The quant is placed directly into this storage bin and no transfer requirement is created. The interim storage bin is the final storage bin for the quant. The special movement indicator is set either on the warehouse management view of the material master record or can be set at the time of the Inventory Management movement. This indicator is used to determine the warehouse management movement type, and thus the interim storage type for the creation of the quant. Using this indicator, different WM movement types can be assigned to one IM movement type.
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6.18 Stock Placement Control Storage Type Control
Placement Strategy Changeable Destination Bin Allow Mixed Storage Allow Addition to Stock Activate Storage Unit Management Activate Storage Unit Type Check Assign Capacity Check Method
SAP AG 1999
You need to define important control indicators at the storage type level that determine the material flow (putaway and picking activities) and the way inventory is handled in each storage type. These control indicators are only meaningful when they are implemented in a particular combination. Not all indicators are allowed in every situation. Once defined, some of these indicators can only be changed with great caution. Some control settings can only be implemented based on strict prerequisites. For example, storage unit management can only be implemented if no stock at all exists within a storage type. Certain capacity checks can only be activated if all factors have been configured that pertain to that particular type of capacity check. You should be especially cautious when changing control indicators that pertain to stock placement strategies.
There are indicators in the storage type record that can be overwritten in the movement type. That is to say, certain functions, such as confirmation requirement for putaway and picking or allowing posting changes in the same bin, are valid in general for a particular storage type, but not for a particular posting (for example, goods receipts from production do not need to be confirmed).
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6.19 Stock Placement Strategy
Manual Bin Fixed Bin (F) Near Fixed Bin (K) Addition to Existing Stock (I) Storage Unit Type (P) Open Storage (C) Next Empty Bin (L) Bulk Storage (B) User Exit
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Stock placement strategies are used to search for an appropriate storage bin within a storage type when goods are to be placed into storage. For each storage type, a stock placement strategy is defined that serves to optimize warehouse usage and the flow of materials.
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6.20 Manual Bin
SAP AG 1999
The system does not use a strategy to search for a storage bin. The user enters the destination storage bin when the transfer order is created. This procedure is used if the search for a storage bin is done on-site by the warehouse worker. First the warehouse worker searches for the appropriate storage bin. Then the data about the storage bin (for example, storage type and coordinates) is entered into the transfer order.
We recommend that you use "no strategy" for mixed storage and interim storage types.
Since no strategy is used, you leave the Stock placement strategy field blank in the storage type record.
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6.21 Fixed Bin (F)
AA FIX-AA
FIX-BB
FIX-DD
FIX-EE
FIX-CC
Material AA Stor. type 005 Fixed bin: Fix-AA
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With stock placement strategy “F” (fixed bin assignment), the system reads the fixed bin that is defined for the storage type in the material master record. If no fixed bin is defined, an error message appears. Characteristics combination: addition to existing stock allowed capacity check
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6.22 Near Fixed Bin (K)
AA
BB
AA FIX-AA
FIX-BB
FIX-DD
FIX-EE
FIX-CC
Material AA Stor. type 005 Fixed bin: Fix-AA
SAP AG 1999
Strategy K refers to stock placement of a material into a storage bin NEAR the fixed bin of the material. So that if your fixed bin is full, the system would recommend a bin in close proximity to the fixed bin. Strategy K will assign a destination bin in a storage area that serves as a goods buffer area for fixed bin storage. Although the fixed bin storage and reserve storage are in the same physical unit, they are defined as different storage types. The same conditions must exist for both storage types. The coordinate structure for bins in both storage types must be the same with the same sequence. The bins located above one another in the fixed bin storage area and the reserve area must have the same coordinates in the shelf and aisle areas, but different level numbers. You can customize so that put away is attempted first in the fixed bin storage area, then in the reserve area. Strategy K only searches in the reserve area and does not check the fixed bin area. Search first occurs within the same stack, then right beside the same stack, then the aisle on the opposite side, then neighboring aisles.
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6.23 Addition to Existing Stock (I)
AA
AA
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With stock placement strategy “I”, the system looks for a storage bin where the material already exists. If the system cannot find such a bin or if the capacity of the bin will be exceeded, it looks for the next empty bin. Characteristics combination: capacity check addition to existing stock allowed no mixed storage
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6.24 Pallet Strategy (P)
Bin type PA
Standard pallet
Standard pallet
Standard pallet
SUT: P2
02-10-01
Bin type PA
Industrial pallet
Industrial pallet
SUT: P1
02-09-01
Bin type PA
Standard pallet
SUT: P2 02-08-01 industrial pallet
SAP AG 1999
With stock placement strategy “P”, the maximum number of quants is defined dependent on the bin type and storage unit type. The first stock placement determines how the storage bin will be divided as well as which and how many quants can be placed into the other sections of the shelf.
If you assign the same bin type and a different storage unit type to the same section key, is also possible for you to putaway more than one type of pallet into the same storage bin.
Characteristics combination: SUT check mixed storage
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6.25 Storage Bin Section Definition
Storage bin P-001
1 A 2
B 3
11
A A
22
B B
33
SAP AG 1999
Rack storage is frequently designed so that a shelf section can accommodate different storage unit types (SUT). For example, a shelf section may accommodate a number. You define the maximum number of quants for each combination of storage bin type and SUT. The first time goods are transferred into the storage bin the system determines what type of bin sectioning is assigned to the shelf section. The system also determines which and how many SUTs can be transferred into the positions (compartments) of the shelf sections. The section indicates where exactly a quant is stored within the bin. You can recognize the section by the last positions following the ‘\‘ in the bin coordinate. You can define up to 99 sections per bin.
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6.26 Open Storage (C)
Storage type 003 Y
B
Material X
Bin XXX
Bin YYY
Material F
SAP AG 1999
With stock placement strategy “C”, the first available storage bin in the storage section is always proposed, unless the bin is blocked. It is possible to enter another storage bin manually.
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6.27 Next Empty Bin (L)
High rack storage (top view)
Stock placement sequence without sort field Stock placement with sort field SAP AG 1999
With stock placement strategy “L”, the system assigns the first empty bin for stock placement (random storage). This strategy is especially suited for high rack storage and shelf storage. The sort sequence of the storage bins can be influenced by a sort field (for example, cross-line placement).
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6.28 Bulk Storage (B)
XX
Row 02
Bin: A05-01 Quant: XX SUT: IP
A05-02 XX S1
A05-03 ZZ S1
A05-04
SAP AG 1999
General characteristics of stock placement strategy “B”: customer-individual definition of storage bins (for example, row / row block) definition of the capacity (stack height) based on the storage unit type and special material characteristics one SUT per line compressed stock placement possible blocking for further stock placements upon first stock removal, with automatic unblocking upon final removal partial quantities and mixed storage possible time limit for FIFO (set placement block based on time limit) variable control possible via the block storage indicator in the material master record Characteristics combination: addition to existing stock allowed SUT check
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6.29 Transfer Order and Multiple Printing
Print Report: Multiple Processing and Two- step picking:
RLVSDR40 RLKOMM40
SAPSCRIPT form Header
Transfer order
Main section
Footer SAP AG 1999
Transfer Orders are printed using Print Report RLVSDR40. You can sort and print transfer order items from several transfer orders using report RMKOMM40 with the multiple processing task. In the standard system, various forms are available for printing individual transfer orders, combined picking lists and transfer orders from posting change notices. All transfer order printing is available for barcode scanning.
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6.30 Setting Up Printing
Create the spool indicators for each warehouse number Create the print indicators for each warehouse number Assign the printer to the movements
Assign the printer to the storage type / picking area Assign the print codes to the movement types Assign the print reports to the warehouse numbers Define the print control for multiple processing SAP AG 1999
The spool code defines data to be passed on to the spool file. This data includes number of copies to be printed, dataset name of the printout in the spool system, whether to print immediately and whether to delete after print. The print code defines such things as the SAPscript form that is to be used for printing and the spool indicator. A Transfer Order always contains a movement type. Depending on the movement, you can assign different printers and spool codes. You can also suppress printing of the Transfer Order if required. You assign a print code to a movement type. You can designate a specific printer for each storage type or picking area. Each warehouse number must also have a print report. SAP recommends that you use a separate print report because in most cases, modifications are required in the delivered print report. The procedure for this is contained in the program documentation for RLVSDR40. Before you begin the table maintenance, you should look at each table individually and see which ones are required. Then, maintain the tables in the sequence given. Printing user exits MWMD0001 + MWMD0002
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6.31 Goods Receipt: Unit Summary
You are now able to: Customize the goods receipt activity so that the Transfer Order process immediately follows the Inventory Management process Customize the storage type and storage section search so materials are put away into the appropriate storage bin Explain the printing customizing options for Transfer Orders
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6.32Goods
Receipt - Exercises Unit: Goods Receipt Topic: Customizing the Goods Receipt At the conclusion of this exercise, you will be able to: • Customize the goods receipt activity so the Transfer Order process immediately follows the Inventory Management process • Customize the storage type and storage section search functions so materials are put away into the appropriate storage bin In your company, the process for a goods receipt is such that a Transfer Order should be created immediately following the Inventory Management Goods Receipt. When the materials are received, the receiving personnel enter the goods receipt into the IM system with reference to a Purchase Order. The Transfer Order is created dynamically in the background and printed. When the materials have been put away to their final location, the Transfer Order is then confirmed. Received materials are to be directed to storage type 015. Materials on the smaller (E1) pallets are directed to the front of the warehouse (section 001) while the larger (IP) pallets are directed to the rear of the warehouse (section 002). It is your responsibility to configure and test this process in the SAP System. Please remember to work only within your warehouse.
1-1
When material is received into your warehouse, it is placed into storage type 015. Because this is the process for the majority of your materials, you would like to accomplish this without using a storage type or storage section placement indicator. The material you are testing with is T-BW04-##. You must first verify the material master data. 1-1-1 Look at the material master record and verify that the storage section and storage type indicators are blank. Also note the palletization data. Stock Placement
_______
Storage Section
_______
Palletization
_______________________
_______________________ 1-2
Now you want to customize the process. In the first step, you will set the Transfer Order to be created automatically in the background following the Goods Receipt. Then you will customize the storage type and storage section search functions to place the material into the appropriate storage type and section. 1-2-1 Add an entry in the LE-WM Interface table for your warehouse and movement type 101 with reference to a purchase order so the TO is created in the background when the transaction is run. If there is an error, you want to
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send a mail message to help you troubleshoot the problem. You want to find an existing entry in this table, copy it and modify it for your warehouse only. 1-2-2 To direct the materials to storage type 015, you must make an entry in the Storage Type Search table. You want materials to be first placed into 015. If there is not available space, you want the materials to be directed first to high rack storage type 001, then alternatively to shelf storage type 002. Make the appropriate table entry. 1-2-3 You must now make an entry in the Storage Section Search table. When materials arrive, you want them to go first to the smaller bins in the front rows of the warehouse (section 001), then to the larger bins in the back of the warehouse (section 002). Make this entry in the storage section search table. 1-2-4 When you created the bins for storage type 015, in section 001, you created bin type E1 and in section 002, you created bin bype P1. E1 represents the smaller bin sizes and P1 represents the larger bins. When small pallets are received, they will be directed to the smaller bins in section 001 first. The larger pallets will not fit in section 001, so they will be directed to section 002. These entries are found in the Storage Bin Type Search table. 1-3
Now test your configuration. There is a purchase order that exists for material TBW04-##. Find the purchase order and process the goods receipt for a quantity of 80. You will have 1 pallet of 50 (SUT IP) and 1 pallet of 30 (SUT E1). If you have configured the warehouse correctly, a TO will be automatically created and the materials will be directed to storage type 015 with the pallet of 30 going to storage section 001 and the pallet of 50 going to storage section 002. You will need to confirm the TO before the materials are available. 1-3-1 Process the goods receipt for a purchase order for Material T-BW04-##, quantity 80. 1-3-2 Display the Transfer Order and note the following information: Item 1: Source Storage Type _____ Storage Bin ______________ Section ____ Destination Storage Type _____ Storage Bin ______________ Section ____ Item 2: Source Storage Type _____ Storage Bin ______________ Section ____ Destination Storage Type _____ Storage Bin ______________ Section ____ The storage section is not displayed on the first page of the Transfer Order display. If you select the bin, you can see the storage section.
1-3-3 Confirm the TO.
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6.33Goods Receipt - Solutions Unit: Goods Receipt Topic: Customizing the Goods Receipt
1-1-1 Logistics → Logistics Execution → Master Data → Material → Material → Change → Immediately. Enter material T-BW04-##. Select the Warehouse Management 1 view for your warehouse number 1##. Stock Placement BLANK Storage Section
BLANK
Palletization: 50 PC IP 30 PC E1 1-2 1-2-1 Tools → AcceleratedSAP → Customzing → Edit Project → Goto → SAP Reference IMG → Logistics Execution → Warehouse Management → Interfaces → Inventory Management → Define Movement Types → LEWM Interface inventory management. Find the row for all warehouse (***), Reference movement type 101, Movement Indicator B, WM Movement Type 101. Select the row and enter Copy As. Specify the target entry by entering your warehouse number 1##, and in the column IM ->, enter A. Also enter an A in the Mail column to send mail in case of an error. Enter and Save. 1-2-2 SAP Reference IMG → Logistics Execution → Warehouse Management → Strategies → Activate Storage Type Search → Determine Search Sequence. Position on warehouse 1##, activity E. Modify the storage type sequence of the first entry to read: W…
Oper
1##
E
TyIn
S S Stor…
W…
Ref.
0
0
S.
1 ST
2 ST
3 ST
015
001
002
1-2-3 SAP Reference IMG → Logistics Execution → Warehouse Management → Strategies → Activate Storage Section Search → Determine Search Sequence. Select New Entries. Whn
Ty
1##
015
SecI
Clas
WPC
1st
2nd
001
002
3rd
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1-3-1 Logistics → Logistics Execution → Inbound Process → Goods Receipt for Purchase Order, Order, Other Transactions. Search for the Purchase Order number by selecting the matchcode M:Purchasing Documents for Material and entering the material number T-BW04##. Verify the quantity of 80. Select OK and Save. 1-3-2 Logistics → Logistics Execution → Inbound Process → Goods Receipt for Purchase Order, Order, Other Transactions → Putaway → Display Transfer Order → By Material. Enter your warehouse number 1## and material T-BW04-##. 1-3-3 Favorites → Confirm TO, One Step.
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7 Goods Issue
Contents: Customizing the Goods Issue Process
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7.2 Goods Issue: Course Overview Diagram
Course Overview
1
GGoods oods Issue Issue
7
Logistics Execution Overview
2
Posting Changes
8
Warehouse Management Structure
3
Production Integration
9
Master Data
4
Delivery Processing
10
Integration with Inventory Management
5
Replenishment
11
Goods Receipt
6
Physical Inventory
12
Conclusion
13
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7.3 Goods Issue: Business Scenario
In the model company, the process for goods issue is such that a Transfer Order is created in the foreground, immediately following the movement in Inventory Management. In this unit, the participant will customize the transaction to fit the business practice then test the process.
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7.4 Goods Issue: Objectives
At the conclusion of this unit, you will be able to: Customize the goods issue activity so that the Transfer Order in the Warehouse is created in the foreground, immediately following the Inventory Management process and the goods are picked from the optimal location.
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7.5 Full Stock Removal Options
Transfer to another bin
Return to same bin
Retain at destination SAP AG 1999
When stock is removed from a storage type for which "complete removal" has been defined, sometimes a smaller quantity remains after the required quantity is picked. The remaining quantity is returned to a storage bin via a "return" sub-item in the transfer order. With the Warehouse Management (WM) component there are three methods for returning quantities to a storage bin: Stock remains at the destination bin, that is, the storage bin to which it is being transferred Stock is returned to the source bin, that is, the storage bin in which it was originally stored Stock is transferred to another storage bin When stock is returned to another storage bin, the system uses the stock placement strategy specified for the storage type. You can change the default that the system proposes for the return storage bin in the transfer order.
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7.6 Stock Removal Control Storage Type Control
Removal Strategy Confirmation Control Allow Negative Stock Allow Zero Stock Check Activate Full Removal Activate Rounding Quantity Post Change to Same Bin
SAP AG 1999
Again, you define important control indicators at the storage type level that determine the material flow (putaway and picking activities) and the way inventory is handled in each storage type. These control indicators are only meaningful when they are implemented in a particular combination. Not all indicators are allowed in every situation. Once defined, some of these indicators can only be changed with great caution.
Also, some control indicators for storage types are mutually exclusive; legal or internal directives may not allow some combinations of indicators. In these cases, an error message will appear if a combination is not allowed. You should carefully check and test any new combinations before they are released in the production system.
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7.7 Stock Removal Strategy
FIFO (F) LIFO (L) Partial Quantities (A) Large/Small Quantities (M) Cascadable with Rounding (M) Fixed Bin Picking (P) SLED (H) Stringent FIFO (***) User Exit
SAP AG 1999
A stock removal strategy is the procedure used to search for a suitable quant for stock removal within a storage type. For each storage type you define a stock removal strategy (FIFO for example) that serves to optimize warehouse usage and the flow of materials. You can define the stock removal strategy Stringent FIFO to apply to more than one storage type.
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7.8 FIFO (F)
Goods Receipt: 3-1
4-1
5-1
3-1
Goods Receipt = Current Date Goods Receipt = Document Date Goods Receipt = Posting Date
SAP AG 1999
With this picking strategy the system proposes the oldest quant in the storage type as the quant that should be transferred.
The system generally calculates the "age" (length of time in storage) of a quant on the basis of the goods receipt posting date from the Inventory Management (IM) application component. The system automatically sets the goods receipt date in the quant and in the transfer requirement for every goods receipt posting in IM. When the transfer order is created, this date is copied over to the quant record of the destination storage bin.
You can accept the goods receipt date that the system sets or you can enter a different date. Regardless of whether the system proposes the goods receipt date or you enter a different date, the date is used to calculate the age of the quant. This date influences the sorting sequence for each material.
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7.9 LIFO (L)
5-4
5-3
Last In, First Out 5-2
5-1
SAP AG 1999
For some warehouse organizations or sectors of industry, the FIFO principle cannot be used. For example, in the building material industry material that is being stored temporarily, that is, material that is going to be transferred immediately out of the warehouse, is stacked on material that is already in the warehouse. If the FIFO strategy is used during picking, the material lying on top must be moved so that the warehouse worker can reach the material with the oldest goods receipt date. The LIFO strategy is provided for such situations. When the system searches for a quant to remove from stock, it always selects the last quant that was placed into stock.
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7.10 Partial Quantities First (A)
100 pcs
Order amount
100 pcs
80 pcs
100 pcs
30 pcs
SAP AG 1999
With stock removal strategy “A”, the system compares the requirement quantity with the largest bin quantity in the storage type. If the requirement quantity is the same or larger (for example, because an entire pallet is required), stock is removed from this bin. If the requirement quantity is smaller, it is removed from a pallet with a partial quantity.
When the system searches for a quant, it follows these steps: If the required quantity in the transfer order is the same or greater than the quantity of a standard storage unit, the system attempts to remove a standard storage unit from stock. If no standard storage units are available, partial storage unit quantities are used. If the required quantity in the transfer order is less than the quantity of the standard storage unit, the system first tries to remove partial storage unit quantities from the stock. If no partial storage unit quantities are available, full storage units are broken.
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7.11 Large/Small Quantities (M)
Quantity to be removed smaller / larger than control quantity
? Fixed bin storage
High rack storage
Small quantity Stock removal strategy: M
Large quantity
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With stock removal strategy “M”, only an amount smaller than or equal to the control quantity defined in the material master record can be removed from the storage type. If the requirement quantity is larger than the control quantity, the system searches for a quantity in the next storage type (default vector in the storage type search table).
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7.12 Cascadable through Quantity Rounding- M
1 - 19 = Piece Storage Type=005 Control Qty = 19
Material Master: Palletization Qty = 100
20-100 = Box Storage Type = 001 Control Qty = 99 Rounding Qty = 20
Multiples of 100 = Pallet Storage Type = 007 Rounding Qty = 100
SAP AG 1999
Quantity rounding is meaningful in combination with picking strategy “M”. If pallet quantites, carton quantities or individual quantities are to be picked from a chain of storage types, this can be done by defining the rounding quantity and control quantity in the material master record. First, in customizing, switch on the round off quantity field at the storage type level. For the first storage type of the search sequence, (pieces) enter the number of pieces in a carton minus 1 as the control quantity. For requirement quantities greater than or equal to a carton, the system will skip over this storage type. For the second storage type of the search sequence, (cartons) enter the pallet quantity minus 1 as the control quantity and the rounding quantity equal to the carton quantity. For requirement quantities greater than or equal to one pallet, the system skips this storage type and generates transfer order items for complete carton quantities only. In the third storage type, you do not enter a control quantity, but the rounding quantity is equal to the pallet quantity. The system then generates transfer order items for full pallets only. For remaining quantities, the system returns to the storage type sequence and picks from the first or second storage types. Note: the system does not round to zero so if there are not enough individual pieces in the first storage type, a carton will be broken. Also, if the requested quantity is larger than the available quantity in a bin, it is not rounded. If a carton plus a few individual pieces are located in a bin in the second storage type, and the requirement quantity is greater, the bin will be emptied.
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7.13 Picking Strategy for Fixed Bins (P)
AA BB FIX-AA
FIX-BB
FIX-DD
FIX-EE
FIX-CC
Material AA Stor. type 005 Fixed bin: Fix-AA
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Picking Strategy P allows the bin from the material master to be posted, even if the bin has no stock quantities, thus driving the on hand balance of the fixed bin to a negative quantity. Characteristics combination: Stock Placement Strategy ‘F’ Negative Stocks are allowed
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7.14 Shelf Life Expiration Date (H)
IM Goods receipt area
Goods receipt 20 Feb Material 4711 Expiration date 21 March
OK Goods receipt Material 4711 Expiration date 13 July Goods issue on 22 February Material 4711
4711 6/10
4711 4/3
4711 7/13
Stock removal strategy “H” Goods issue area
4711 3/21
Material 4711 Minimum remaining time 150 days
SLED Control List Type Bin Mat. Rem.Time 001 A 4711 - 12 days 001 B 4711 - 9 days ..... ... ....... - 6 days
SAP AG 1999
For materials managed with shelf life expiration date (SLED), the expiration date is noted in the quant data when the goods are received. At that time the system checks whether the SLED entered is allowed or not. By using stock removal strategy “H”, you ensure that materials with the fewest days remaining before the expiration date are removed from storage first. A report is also available to select and list materials in the warehouse that respond to a user-defined remaining time before a given expiration date. This is known as the shelf life expiration date (SLED) control list. For materials that are managed in batches, the processing of materials that are to be removed from stock can be handled using the general batch search task.
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7.15 Stringent FIFO (***)
Storage Type Search: WH Act TypIn 100
A
100
A
FIX
100
A
REG
C S
Class
WPC
Ref SL 001 002 003 (Stor Types) 001 002
***
005 ***
SAP AG 1999
It is generally assumed that only one picking strategy is allocated to each storage type. However, a strategy based on the storage type is not usable in all sectors of industry.
In WM, it is possible to remove stock according to the FIFO principle by taking into account all quants within a warehouse. In this case, the system does not scan individual storage types in sequence but it proposes the oldest quant in the entire warehouse as the quant to be removed from the warehouse. The system does not take into account the picking strategies specified for the individual storage types. This would lead to inconsistencies.
Some storage types should be excluded from the stringent FIFO strategy, otherwise incorrect picks would result. For example, the interim storage area for differences should be excluded from the stringent FIFO strategy. The stringent FIFO strategy is set or switched off in the table Exclusion of storage types from Stringent FIFO.
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7.16 Goods Issue: Summary
You are now able to: Customize the goods issue activity so that the Transfer Order in the Warehouse is created in the foreground, immediately following the Inventory Management process and the goods are picked from the optimal location.
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7.17Goods Issue - Exercises Unit: Goods Issue Topic: Customizing the Goods Issue At the conclusion of this exercise, you will be able to: • Customize the goods issue activity so that the TO creation progrm is called immediately following the Inventory Management transaction A Goods Issue to a Cost Center is often referred to as a ‘Miscellaneous Issue’. Typically, these types of issues are done in the warehouse when other departments are requesting materials outside of regular production or maintenance; for example, materials that are stocked in the warehouse, but not consumed by the production process. These materials are issued from the warehouse and expensed to a cost center. When you process a goods issue, you want to be able to combine the Inventory Management and Warehouse Management activities so that immediately following the IM transaction, the Transfer Order program comes into the foreground. During the stock removal, you want the system to look first in your storage type 015 for available inventory. If there is no stock in storage type 015, then you want the system to search throughout the other storage types for the oldest quant. The user will make the final decision about which quant to select.You want to process the TO online in the foreground and then confirm the TO as a separate step. It is your responsibility to configure and test this business process. Remember to work only within your warehouse!! 1-1
When materials are requested from outside departments, you first process the issue in IM and then follow through with the WM transactions. You want to customize the system to follow the business scenario outlined above. You will be testing with material T-BW04-##. 1-1-1 Check the material master record and verify the Stock Removal indicator. Stock Removal: _________________
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1-2
Now configure the system to match the process. 1-2-1 First, you must find the Reference Movement Type for the Goods Issue 201. IM Movement 201 – Reference Movement: ____ 1-2-2 Add an entry in the LE-WM Interface table for your warehouse and movement type 201 – Goods Issue to a Cost Center so the TO program is called to the foreground when the IM transaction is run. You want to find an existing entry in this table, copy it and modify it for your warehouse only. 1-2-3 Now you want to modify the storage type search sequence so that the system will search first in storage type 015 for an available quant. If there is no material available in 015, then you want to search throughout the warehouse for the oldest available quant. Customize the storage type search sequence for stock removals to fit this scenario.
1-3
Now test your configuration. 1-3-1 Before you begin, check your stock situation for T-BW04-##.
Material
StorType
Available
For Putaway
Pick Quantity
T-BW04-## 1-3-2 Issue 100 of material T-BW04-## to cost center 1000. 1-3-3 Process the TO in the foreground. During the processing of the TO, list the quants and choose one from the list. 1-3-4 Confirm the TO as a separate step. 1-3-5 Check your stock situation once again. Material
StorType
Available
For Putaway
Pick Quantity
T-BW04-##
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7.18Goods Issue - Solutions Unit: Goods Issue Topic: Customizing the Goods Issue
1-1 1-1-1 Logistics → Logistics Execution → Master Data → Material → Material → Display → Display Current Status. Enter material T-BW04-##. Select the Warehouse Management 1 view for your warehouse number 1##. Stock Removal BLANK 1-2 1-2-1 Tools → AcceleratedSAP → Customzing → Edit Project → Goto → SAP Reference IMG → Logistics Execution → Warehouse Management → Interfaces → Inventory Management → Define Movement Types → Assign WM movement type references to IM movement types. Position on Movement Type 201, Quantity Updating (X), Value Updating (X). IM Movement 201 – Reference Movement: 201 1-2-2 SAP Reference IMG → Logistics Execution → Warehouse Management → Interfaces → Inventory Management → Define Movement Types → LE-WM Interface inventory management. Position on Warehouse number ***, Reference movement type 201. Select the row and enter Copy As. Specify the target entry by entering your warehouse number 1##, and in the column IM ->, enter X. Enter and Save. 1-2-3 SAP Reference IMG → Logistics Execution → Warehouse Management → Strategies → Activate Storage Type Search → Determine Search Sequence. Position on warehouse 1##, activity A. Modify the storage type sequence of the first entry to read: W…
Oper
1##
A
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TyIn
S S Stor…
W…
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S.
1 ST
2 ST
015
***
3 ST
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1-3 1-3-1 Favorites → Warehouse Management Stock Overview 1-3-2 Logistics → Logistics Execution → Outbound Process → Goods Issue for Other Transactions → Enter Goods Issue. Field Name or Data Type
Values
Movement Type
201
Plant
1000
Storage Location
01##
Cost Center
1000
Material
T-BW04-##
Quantity
100
1-3-3
When you save, you are now in the TO Processing screen. Select Enter. Choose Stock Figures. Enter the quantity for removal from each quant and Save.
1-3-4
Favorites → Confirm TO, One Step
1-3-5
Favorites → Warehouse Management Stock Overview
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8 Posting Changes
Contents: Stock Transfer: Logical vs Physical Bin to Bin Movements Change in Stock Category Material to Material/Batch to Batch Transfer Initiate Post Change from WM
SAP AG 1999
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8.2 Posting Changes: Course Overview Diagram
Course Overview
1
Goods Issue
7
Logistics Execution Overview
2
Post Changes Posting in Chan g ges
8
Warehouse Management Structure
3
Production Integration
9
Master Data
4
Delivery Processing
10
Integration with Inventory Management
5
Replenishment
11
Goods Receipt
6
Physical Inventory
12
Conclusion
13
SAP AG 1999
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8.3 Posting Changes: Business Scenario
In day-to-day warehouse activity, it is often necessary
for warehouse workers to move inventory from one bin to another, whether combining inventory, rearranging shelves or correcting errors. For this activity, we need to be able to move quants from one bin location to another. There are also processes in IM which create posting
change notices in the warehouse. These scenarios include release from Quality Inspection or Blocked Stock, material identification changes and corrections to batch-managed materials. Warehouse workers need to be able to process these activities, using posting change notices.
SAP AG 1999
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8.4 Posting Changes: Objectives
At the conclusion of this unit, you will be able to: Recognize when an inventory movement will
create a posting change notice in WM Process bin to bin movements within the
warehouse Demonstrate how to process a posting change
notice in WM in the foreground Demonstrate how to configure the
system so that posting change notices can be initiated in WM
SAP AG 1999
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8.5 Stock Transfer / Transfer Posting
Stock Transfer
Distribution Center
Materials Warehouse Physical movement
Unrestricted Use
Transfer Posting In quality inspection
“Logical” movement
SAP AG 1999
Although postings are made in both cases, simple “transfer postings” differ from “stock transfers” in that transfer postings do not usually also involve a physical material movement; instead, simply the stock type, batch number, or material number is changed. Further examples of transfer postings are postings recording release from quality inspection or the transfer from blocked material into unrestricted stock, a change in the stock category of the material
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8.6 Bin to Bin Transfer
Trans. order without reference
Transfer order
Confirm TO
Material available
SAP AG 1999
To transfer stock from one storage bin to another storage bin within the same warehouse, you manually create and confirm a transfer order for the material to be moved. A transfer requirement is not needed. Since the total quantity of stock in the warehouse remains the same, stock movements that take place within the same warehouse number do not require the use of the Inventory Management system.
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8.7 Create TO from Stock List
Clear Bins / Bin areas Group together Supply to Pick Areas
Transfer when capacity reached
Transfer for change in classes in storage type
SAP AG 1999
The new report ”Stock Transfer” allows the creation of Transfer Orders from a list of bin stock. The following tasks can be performed from this report: Clear bins or bin (for example, because of maintenance work or for other reasons). Group together stocks that are dispersed throughout the warehouse (consolidation). Supply stocks to a picking area. Transfer stock as soon as a specified capacity has been reached. Transfer stock when there has been a change in the storage classes in a storage type.
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8.8 Material to Material / Change in Batch
1994
“Sharp Cheese”
“Mild Cheese”
A
A
Batch
Batch
SAP AG 1999
A stock transfer from material to material requires that both materials are managed in the same base units of measure. A stock transfer from material to material can be necessary if a material changes over the course of time. It no longer matches the data defined in the material master, but rather fits the criteria of another material master number. This typically occurs in the chemical and pharmaceutical industries. Use the same transaction to change the batch identification of a material. Enter the same material number, but change the batch information.
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8.9 Posting Change: Material Number
Transfer posting in Inventory Management Material A to Material B (100 pcs) Posting change area
Quant A 100 Quant B 100 +
Example:
Posting change notice
Material A to Material B
Storage type 001
Item 1 A 100 Item 2 B 100 + Posting change transfer order Item 1
Mat.
A
Src Dest
001 922
001 01-01-01 001 PC area
Item 2
Mat.
B
Src Dest
922 001
001 PC area 001 01-01-01
SAP AG 1999
A posting change or stock transfer is first posted in the Inventory Management system as a “transfer posting”. As a result, the system creates a posting change notice and two quants in the posting change area (a logical interim storage area). You process the posting change in the WM system by creating a transfer order for the posting change notice. You can post the posting change quantity to the original bin or to another storage bin.
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8.10 Stock Transfer/Transfer Posting (II)
Company code
Company code
Plant
Plant
Storage Location
Storage Location
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Physical stock transfers can occur at three different levels: Company code to company code Plant to plant Storage location to storage location Such a stock transfer consists of a goods issue from the issuing point and a goods receipt at the receiving point. You can post stock transfers in one step or two. To transfer material company code to company code, you use the transaction plant to plant, but the plants are assigned to different company codes. In this instance, two accounting documents are generated, one for the sending plant and one for the receiving plant.
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8.11 Stock Transfer / Posting Change: Plant to Plant
Plant 1
Plant 2
Plant 1
0088
0088
Storage location
0099
001
Warehouse
002
Stock Removal
Storage location
Warehouse
Stock Placement
Plant 2
0099
001
Posting Change
SAP AG 1999
A plant-to-plant transfer posting in the Inventory Management system can result in a posting change within a warehouse number. If stocks for two separate plants are managed within the same warehouse number, a transfer posting in the Inventory Management system results in a posting change within the warehouse number (in the WM system). However, if the two plants are managed in two separate warehouse numbers, the transfer posting results in a stock removal from the one warehouse number and a stock placement into the second warehouse number.
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8.12 Posting Changes During Stock Placement
Tr. requirement 50 pieces Reserve storage
GR area 50 pcs GR posting
A Q 50 pcs A Q
Posting changes (Release from quality inspec.) Material A 100 pcs
Posting change area A Q -100 A +100
SAP AG 1999
To release materials from quality inspection, you can carry out a transfer posting in the Inventory Management system or make a usage decision for an inspection lot in the Quality Management System. Afterwards, you create a transfer order for the posting change notice in the WM system. This is used to convert the material quants (possible on a material document basis) with stock category Q. If a transfer requirement for the stock placement is still open, this is also updated by the posting change. Depending upon the set-up, it is possible for the system to create transfer orders automatically in the background. Again, the posting change quantity can be posted to the original bin or to another storage bin.
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8.13 Transfer Posting: Initiated in WM
WM
IM
Posting Change
Posting Change
Automatic Update
SAP AG 1999
The transaction “Transfer Posting in WM and IM” will process posting changes for quants entirely from within WM. The entire quant must be selected.The system then performs all necessary processes in Inventory Management. With this program, no posting change notice is created in Warehouse Management so you can carry out certain posting changes directly as a one-step process.
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8.14 Customizing Posting Changes WM/IM Stock WM Movement Type
IM Movement Type
B B
B
C
A
Stock Category Source
Stock Category Destination
Special Stock Source
Quality to Unrestricted
Special Stock Destination
Consignment to Own
SAP AG 1999
The transaction is possible for the following posting change transactions: Convert stock category between quality inspection, blocked stock and unrestricted-use stock Convert special stock consignment to own restricted stock and back Convert individual customer stock to own stock and back Convert special stock returnable transport packing to own stock and back Convert project stock to own stock and back For active Quality Management components, posting changes (transfer postings) are still carried out first in Inventory Management and subsequently processed as posting change notices in Warehouse Management.
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8.15 Posting Changes: Summary
You are now able to: Recognize when an inventory movement will create a posting change notice in WM Process bin to bin movements within the warehouse Demonstrate how to process a posting change notice in WM in the foreground Demonstrate how to configure the system so that posting change notices can be initiated in WM
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8.16Posting
Changes - Exercises 1 Unit: Posting Changes Topic: Bin to Bin Movements At the conclusion of this exercise, you will be able to: • Process bin to bin movements within the warehouse
In day to day warehouse activity, it is often necessary for warehouse workers to move inventory from one bin to another, whether combining inventory, rearranging shelves or correcting errors. For this activity, we need to be able to move quants from one bin location to another. Within the warehouse, there is a movement type ‘999’ defined for bin to bin movements. This movement type allows you to move freely from one bin to another without reference to any other document and without affecting IM. This first section of this exercise is two-part. In the first part, you will move one material within the warehouse from one bin to another. In the second part, you will move several materials from one bin to another using a list. When you use the list, you want to create a variant for the display for your use in the future. 1-1
Move a quant from a bin in storage type 007 to a bin in storage type 001 by creating a TO without reference. 1-1-1 Look at the Bin Stock per Material for material T-BW08-##. Note several of the quants in Storage Type 007. Storage Type
Storage Bin
Total Stock
1-1-2 You want to move one quant from storage type 007 to storage type 001 (high rack storage). Create a Transfer Order without reference and move the material from storage type 007 to storage type 001 into an available bin. 1-1-3 Confirm the TO.
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1-1-4 Display the Bin Stock per Material and note the change. Storage Type
1-2
Storage Bin
Total Stock
You have just been notified that the maintenance department needs to fix some of the shelving in Storage Type 007 Section 002 area. You must select all materials in the Storage Type 007 Section 002 and move them to Storage Type 007 Section 001 while this maintenance occurs. 1-2-1 Look at the function Create Transfer Orders from List. You want to select those materials that are in Section 002, but the Section is not visible from the current list display. Change the display list format so the section is visible. You can remove other information that is not relevant as you wish (for example, Special Stock Number). Save the new display format as a variant with the name Group-##. 1-2-2 Using the Create Transfer Orders from List function, create the appropriate Transfer Orders to move the material in Storage Type 007, Section 002 to Section 001 of the same storage type. Transfer the quants in the foreground and choose to confirm the TO immediately. 1-2-3 Refresh the list to see the effect of the movements.
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8.17Posting Changes - Solutions 1 Unit: Posting Changes Topic: Bin to Bin Movements 1-1 1-1-1 Logistics → Logistics Execution → Internal Whse Processes → Bins and Stock → Bin Stock per Material 1-1-2 Logistics → Logistics Execution → Internal Whse Processes → Stock Transfer → Create Transfer Order → No Source Object. Field Name or Data Type
Values
Movement Type
999
Material Number
T-BW08-##
Requested Quantity
(from 1-1-1)
Enter. Enter the Source information from 1-1-1 (Source Storage Type and Bin) and enter 001 in the Destination Storage Type and press enter again to let the system find an appropriate bin for placement. 1-1-3 From the Create Transfer Order: Initial Screen, select Transfer Order → Confirm → Transfer Order. Alternatively, select Favorites → Confirm TO, One Step. 1-1-4 Logistics → Logistics Execution → Internal Whse Processes → Bins and Stock → Bin Stock per Material 1-2 1-2-1 Logistics → Logistics Execution → Internal Whse Processes → Stock Transfer → Create Transfer Order → From Stock List. Field Name or Data Type
Values
Warehouse Number
1##
Storage Type
007
Material Number
T-BW08-##
Movement Type
999
Select Current Display Variant. Select Storage Section from the right side of the display and choose the single arrow pointing to the left. Select any fields as you wish from the left and move to the right to remove them from the display. When you have finished, select Copy. Select Save Display Variant and save your changes under Group-##, TO List Display. Exit the list.
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1-2-2 Execute the TO from Stock List again as above, but this time enter Group-## in the Display Variant field. Select all the lines from storage type 002 then select Stock Transf.frgrnd. Field Name or Data Type
Values
Storage Type
007
Storage Section
001
Confirm Immediately
Select
1-2-3 Refresh
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8.18Posting Changes - Exercises 2 Unit: Posting Changes Topic: Transfer Posting – Material to Material At the conclusion of this exercise, you will be able to: • Process a Material to Material Posting Change
Transfer Postings are movements within the warehouse that can be either ‘physical’ (moving a material from one place to another) or ‘logical’ (changing the identification or characteristic of a material). These Inventory Management Transfer Postings cause Posting Change Notices to be created within the warehouse. Examples of IM Transfer Postings that cause posting change notices include inventory releases from Quality Inspection or Block Stock, material revision changes that change the identification of a material, or changes and corrections to a batch managed material. In this exercise, you will change the identification of a material and process the resulting posting change notice in the foreground. 2-1
You have a quantity of 100 pumps material number T-BW-## in your warehouse. Engineering notifies you that 25 of these pumps have been retested and are now to be identified as T-MS-## pumps. 2-1-1 Look at the stock balances for the materials T-BW-## and T-MS-##. Material
Stor Type
T-BW-##
015
Material
Stor Type
Available
For Putaway
Pick Qty
Available
For Putaway
Pick Qty
T-MS-##
2-1-2 Execute the Transfer Posting – Material to Material to change 25 pumps from material number T-BW-## to T-MS-##.
2-1-3 Display the Stock Overview again for both materials.
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Material
Stor Type
T-BW-##
015
Available
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For Putaway
Pick Qty
20
922 TOTAL Material
Stor Type
T-MS-##
922
Available
For Putaway
Pick Qty
TOTAL 2-1-4 Process the Posting Change that was created in the warehouse. 2-1-5 Confirm the TO. 2-1-6 Display the WM Stock Overview again. Material
Stor Type
T-BW-##
015
Available
For Putaway
Pick Qty
Available
For Putaway
Pick Qty
TOTAL Material
Stor Type
T-MS-##
005
TOTAL
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8.19Posting Changes - Solutions 2 Unit: Posting Changes Topic: Transfer Posting – Material to Material
2-1 2-1-1 Favorites → Warehouse Management Stock Overview. (Note: While you do have an inventory balance for T-BW-##, there is no inventory yet for TMS-##.) 2-1-2 Logistics → Logistics Execution → Internal Whse Processes → Post Change → Via Inventory Management → Enter Posting Change. Field Name or Data Type
Values
Movement Type
309
Plant
1000
Storage Location
01##
Receiving Material
T-MS-##
Material
T-BW-##
Quantity
25
2-1-3 From the Enter Transfer Posting: Initial Screen select Environment → Stock Overview → Stock Material. To see the WM inventory, select the line, then select Environment → WM Stocks. 2-1-4 Logistics → Logistics Execution → Internal Whse Processes → Post Change → Via Inventory Management → Transfer Order → Create → From List of Posting Change Notices. Display the posting change notices for your warehouse. Select the line and choose Create trans.order. Select the line for Stock in Storage Types, then choose Quant List. Select quants as appropriate up to the quantity of 25 and indicate that quantity in the field provided. Then choose Process in the foreground. Choose enter (for each quant) and save. 2-1-5 Favorites → Confirm TO, One Step 2-1-6 Favorites → Warehouse Management Stock Overview
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8.20Posting Changes - Exercises 3 Unit: Posting Changes Topic: Posting Changes Initiated in WM At the conclusion of this exercise, you will be able to: • Customize a WM movement type to initiate a posting change in WM • Perform a Posting Change in WM and have the system create the required IM documents Occasionally in the warehouse, you have the requirement to change the status of a quant--for example, to change a quant from Unrestricted Status to Blocked Stock. You want to configure SAP to allow you to move materials to Blocked Stock from within the warehouse without creating a posting change notice in WM. 3-1
You want to process movements into and out of Blocked Stock, initiating those movements from within the warehouse. You will create two new WM movement types and customize the IM interface for posting changes to allow this transaction to occur within the warehouse. 3-1-1 Create two new WM Movement Types (943, 944) by copying 309 with the following changes: Allow manual TO creation Allow TO to be confirmed immediately Propose Confirmation 3-1-2 Define the control for the posting change activity from Blocked Stock (S) to Unrestricted Use (Blank). Also define the control from Unrestricted Use to Blocked Stock.
3-2
Test your configuration by converting a quant from Unrestricted Use to Blocked Stock from the WM Posting Change Bin Stock function. 3-2-1 Before you begin, note your stock situation. Material
StorType
Available
For Putaway
Pick Quantity
T-BW-## 3-2-2 Now execute the transfer posting from within WM, converting a quant of the T-BW-## pumps from Unrestricted to Blocked Stock. 3-2-3 What TO number is generated? ____________ 3-2-4 (C) SAP AG
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Material
StorType
Available
For Putaway
Pick Quantity
T-BW-##
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8.21Posting Changes - Solutions 3 Unit: Posting Changes Topic: Posting Changes Initiated in WM 3-1 3-1-1 SAP Reference IMG → Logistics Execution → Warehouse Management → Activities → Transfers → Define Movement Types. Position on your warehouse, movement type 309. Select 309 and choose Copy As. (Repeat for movement type 944.) Field Name or Data Type
Values
Movement Type
943; 944
Manual TO Creation Not Allowed
Not selected
TO Item can be confirmed immediately
Selected
Propose Confirmation
Selected
3-1-2 SAP Reference IMG → Logistics Execution → Warehouse Management → Interfaces → Inventory Management → Define Posting Changes. Select New Entries. Field Name or Data Type
Values
Warehouse
1##
WM Movement Type
943
IM Movement Type
343
Stock Category Source
S
Stock Category Destination
(Blank)
Warehouse
1##
WM Movement Type
944
IM Movement Type
344
Stock Category Source
(Blank)
Stock Category Destination
S
Field Name or Data Type
Values
3-2
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Warehouse Number
1##
Movement Type
944
Material
T-BW-##
Plant
1000 3.2.1
Favorites → Warehouse Management Stock Overview
3-2-2 Logistics → Logistics Execution → Internal Whse Processes → Post Change → Bin Stock → Other Posting Changes. Select a quant and choose Post Change. 3-2-3 Display Log to see the TO that was created. 3-2-4
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9 Production Integration
Contents: WM Staging Customizing Production Integration Kanban Replenishment
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9.2 Production Integration: Course Overview Diagram
Course Overview
1
Goods Issue
7
Logistics Execution Overview
2
Posting Changes
8
Warehouse Management Structure
3
Prod uc Integration Production Integ tion ratio n
9
Master Data
4
Delivery Processing
10
Integration with Inventory Management
5
Replenishment
11
Goods Receipt
6
Physical Inventory
12
Conclusion
13
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9.3 Production Integration: Business Scenario
In your company, you replenish the production
area from the warehouse. You need to examine different possibilities for accomplishing this replenishment.
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9.4 Production Integration: Topic Objectives
At the conclusion of this topic, you will be able to: Describe the replenishment strategy for
WM Staging Set up master data and customizing for
processing WM Staging
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9.5 Scenario for WM Staging
WAREHOUSE STRUCTURE R E C E I V I N G
902
003
0xx
002
001
005 100
PRODUCTION LINES -->
901
916 Warehouse 100 Storage Location 0100
Shipping
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In this example, the Production Area is managed within a WM-relevant Storage Location.
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9.6 Production Order Process Review Production Planning
Warehouse Management
Inventory Management
Create Production Order Release Production Order Stage Components
Transfer Requirement Transfer Order Confirm TO
Confirm Production Order
Backflush Components Transfer Requirement Transfer Order
Goods Receipt for Finished Assembly
Confirm TO
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The production order process has many steps from the creation of the production order through the putaway of the finished assembly or sub-assembly. Typically, many people are involved in the process. It is possible to automate several of these steps. It is important that the company’s business process is understood so that the appropriate steps are automated.
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9.7 Production Supply Area PSA = WM001
Work Center B3 Work Center A1 Production Supply Area
Work Center Master
Storage Location
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Production supply areas (PSAs) are used for material replenishment and are situated directly on the shop floor in the production department. The PSA groups work centers near production storage bins based on the material staging methods. The PSA is defined for the storage location and assigned in the work center master data.
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9.8 Control Cycle
Material Plant
Supply Area
Control Data:
Destination Data:
Number of KANBANs Kanban Quantity
Warehouse Number Storage Type Storage Bin Staging Indicator Storing Position
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The control cycle record is made up of the plant, production supply area and material and determines for the WM-PP interface the production storage bin and the type of material staging that is used. The production storage bin is defined by the whole key: warehouse number, storage type and bin.
You can also define a control cycle without specifying the material. This general entry is valid for all materials in the supply area for which no control cycle has been defined.
The control cycle establishes how and to where a material is to be supplied within a production supply area.
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9.9 Material Staging Indicators
Pick Parts
Production Order
Crate Parts
Release Order Parts
Manual Staging SAP AG 1999
Pick parts are provided in the quantities requested as specified in the production order. These parts can be provided in a physical storage bin or in the dynamic storage bin for the Production Order. For this type of material staging, transfer requirements can be created: automatically when the production order is released manually. Crate parts are ordered manually when a crate is almost empty. For Release Order parts, the transfer quantity is calculated based on the planned quantities of components of selected, released orders. The stock situation in the production area and the replenishment storage types are included in this calculation. Set the indicator to Manual Staging if you want to handle the process manually.
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9.10 Production Storage Bins
PR Bin-1001
PO 6000378 A
B
You can define the dynamic storage bin “PRODUCTION ORDER” in the control cycle for pick parts.
A separate storage bin for production supply is defined for each material and control cycle. SAP AG 1999
For production supply, you can define a storage bin as a physical or dynamic location. Production storage bins that are used for material staging are determined based on the control cycle.
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9.11 Material Supply
Transfer Requirement Production Order
Transfer Order
Components
Materials Staged
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Planning function The transfer requirement (TR) does not block materials, but notifies warehouse management that a particular material is needed on a certain date in a specified quantity at a specified production storage bin. Request for Material Staging Production workers request the needed materials with a transfer requirement. The TR can be created from within the Production Order function (Goto > WM Picklist or Functions > WM Material Staging > Proceed ) or from within Logistics Execution (Outbound Process > Goods Issue for Other Transactions > Prepare Production Supply > For Production Order/Crate Part/Release Order Part). Warehousing personnel transfer the material based on a transfer order created from the TR. The availability check in the production order ensures the availability of materials at the storage area level. You can control automatic transfer order creation within the Production Scheduling Profile in Customizing.
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9.12 Decreasing the Quantity during TO Creation
You can only decrease the quantity for pick parts.
4711 / 300 lbs
When you create a TO, the available quantity is calculated and the TO quantity is optionally decreased by the same amount.
01/01
TRANSFER REQUIREMENT
Mat: 4711 900 lbs To: 100 01/01
-
TRANSFER ORDER Mat: 4711 600 lbs From: 001 01-01-01 To: 100 01/01
Examples: - minimum use - material change - workstation change - previous overdelivery
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The unrestricted available quantity can be established dynamically. This later point in time allows more current information than if it were determined at the time of the request for materials. In the Production Scheduler Profile, you can set the indicator “Confirmed Quantity for TR Creation”. Setting this indicator will cause the TR to be created for the confirmed quantity instead of the requirement quantity of the component.
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9.13 Supply to Production Storage Bins
4711 / 300 lbs 4711 / 300 lbs
Storage
01/01
TRANSFER ORDER Material: 4711 600 lbs From:
001 01-01-01
To:
811 01/01
WP 1
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A transfer order is created based upon the transfer requirement. The transfer order: determines the source bin based upon the strategy used to select the needed material is the actual instruction for the physical stock transfer moves the quantities in the system determines whether the quantity will be decreased (optional). After the TO is confirmed, the material becomes available at the destination bin.
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9.14 Usage posting
4711 / 300 lbs 4711 / 300 klgs
03/01
01/01
PSA1
WS 1
WS 3
05/01
PSA2
PSA3
WS 5
WS 6
WS 2
WS 4
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The final step in the material staging process is to post a goods issue for consumption. When a production order is completed, the materials have been removed from the production storage bins in the warehouse and the final product has been fully assembled, it is still necessary to balance the stock quantities in the IM and WM systems. You post the use of materials to the database either by "backflushing" with the completion confirmation or directly in the IM system. This posting is necessary to reduce the stock quantities in the production storage bins of the WM and IM systems. Since the transfer requirement for the production order was created far in advance of this goods issue posting, the materials are delivered in a timely manner to the production storage bins. You post the actual goods issue in the IM system (or in the PP system) after the product has been assembled in production. Since the production storage bin was noted in the production order when it was released, the material usage posting reduces the quantity in the production bins (in the system) and no further action is required in the WM system.
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9.15 System Definition Define a Production Storage Type Create the Production Supply Area Define a Movement Type Assign Movement Type to the Production Storage Type Create the Production Storage Bins Define the Control Cycle Records Warehouse Management Customizing
Activate the PP Switch Customize the Production Profile (Optionally)
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The physical production bins are defined in the Warehouse Management system. If all materials are staged as pick parts to a collective storage bin or dynamic coordinates are used, generally, only one material-independent control cycle per production supply area is sufficient.
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9.16 Distinctive Features for RepetitiveOrders
No defined release time. The request is made from the removal list.
The usage posting is based on the release of the current bill of materials.
There are no dynamic coordinates.
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The high flexibility of the processes necessary to pick materials directly for serial orders requires extremely complex organization. The timing of material supply should be organized as follows: Early enough to carry out the physical supply using the WM system on time Late enough to avoid charges that are relevant to material supply (location, material, etc.) Especially when many changes must be made, it is recommended that you use “crate parts” as a material staging type.
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9.17 Standard Reports
Material Stock at Production Storage Bin
List of Control Cycles WM-PP Evaluation Report (Storage Bin Selection)
Analysis of Production Orders
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Evaluation of the Production Storage Bins per Storage Type: List of Control Cycles (RLLS4100): Provides a list of control cycles assigned to your warehouse based on your selection criteria. Material Stock at Production Storage Bin (RLWMPPC1): Overview of quantity situation in Production Storage Bins. WM-PP Evaluation Report (RLWMPPC3): This report provides an overview of the production storage bins. A traffic light icon displays the status of the respective storage bins depending on the stock situation. This makes it possible to identify critical situations more quickly. More detailed information is available in the report documentation. Analysis of Production Orders (RLWMPPC4): This report evaluates PP orders from the WM view. A traffic light icon displays critical situations that result from discrepancies between reservations and the corresponding transfer requirements. More detailed information is available in the report documentation.
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9.18 Production Integration: Topic Objectives
At the conclusion of this topic, you will be able to: Describe the replenishment strategy for KANBAN within WM Set up master data and customizing for KANBAN processing in WM
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9.19 Scenario for KANBAN Replenishment
KANBAN 1 Storage Location 0001 KANBAN 2
R E C E I V I N G
WAREHOUSE STRUCTURE 003
901
150
001
002
902 200
007
005 916
Warehouse 100 - Storage Location 0100
Shipping
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In this example, KANBANs are managed in their own storage location that is not WM-relevant. The KANBAN storage location must be different from the WM storage location from which the replenishment materials are taken.
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9.20 KANBAN
Demand
Supply
f ul l f ul l
full
Material
empty
KANBANCard
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With KANBAN, the material flow is organized by containers that are located at the work centers. They contain the amount of material that the workers need at their work center for a certain period of time. If the container is emptied by the demand, KANBAN replenishment is triggered. Supply source for the requested material can be another production unit, the warehouse, or a vendor. Since the container arrives at the work center, the worker can help himself from further containers.
The goal is that production controls the production process itself and the effort for the worker in production is reduced. Stocks and lead times can be reduced by the self controlling and replenishment created close to actual requests (replenishment is started when the material is needed).
Material is staged in production where it is needed. It is available in small buffers; material staging doesn‘t have to be planned. Instead, material is replaced very soon by KANBAN.
As of release 4.5A, Warehouse Management (WM) is interfaced to the SAP Production Planning (PP) application component to replenish kanban stock to production supply areas. Prior to Release 4.5A, replenishment from a WM warehouse could only take place as a stock transfer between two storage locations. This stock transfer had to be started in Inventory Management. With the new process you can initiate replenishment directly from within WM.
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9.21 KANBAN Replenishment Strategy with WM
Warehouse
Set KANBAN to empty and create a Transfer Requirement in WM
Automatic or manual creation of a Transfer Order in WM
Empty
full
Confirmation of the TO sets KANBAN to full and posts stock transfer to KANBAN storage location
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To provide KANBAN replenishment from a WM warehouse to production, you need to carry out the following steps: 1. Request the KANBAN replenishment either manually using the PP system or by scanning a bar code. Set the container to “empty”. The system records the request in the form of a transfer requirement (TR). The WM transfer requirement number appears in the KANBAN itself. From the KANBAN information window, you can display the corresponding transfer requirement from within the WM system. 2. Process the transfer requirement (TR) like any normal TR in WM by creating a transfer order (TO) for it. 3. Confirm the transfer order. Once you confirm the TO, the system updates the KANBAN in PP by setting the status to "full". As an alternative to confirming the TO, the confirmation of the replenishment can take place in the KANBAN. If you set the status of the KANBAN to "full", the system confirms the corresponding TO automatically. 4. After the replenishment has been processed in WM, a stock transfer results between the WM storage location and the KANBAN storage location. The system can process this stock transfer automatically when the TO is confirmed or you can process it manually by selecting PostChange Inventory management Stor.loc. to stor.loc. from the WM menu bar.
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9.22 Setup of KANBAN Replenishment
Define KANBAN Storage location (must be different from WM storage location)
Define the replenishment strategy
Specify the replenishment strategy and replenishment storage location in the KANBAN control cycle Set up replenishment movement type Set up storage location control
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To activate KANBAN in WM, you need to take the following into consideration in the KANBAN control cycle: KANBAN replenishment must be defined using its own KANBAN storage location that must be different from the WM storage location. Change system parameters in customizing: You define the strategy for the KANBAN replenishment under Production KANBAN Replenishment strategies Define stock transfer strategies in the SAP Implementation Guide. Set the control type for the stock transfer stratgies to Transfer reqmts from a storage location controlled by WM. You need to specify this replenishment strategy which is specifically defined for KANBAN replenishment. For the replenishment storage location, you need to enter a WM-relevant storage location. This way, the system knows that it is dealing with a WM-relevant replenishment. In addition to the storage location, you need to enter the WM data to include the warehouse number, storage type as a KANBAN interface (storage type 150 in the standard system) and the storage bin.. Set up the appropriate replenishment movement type for KANBAN in WM (standard is movement type 350). Setup the storage location control for manual posting chnages or for automatic processing.
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9.23 Production Integration: Summary
You are now able to: Describe the replenishment strategy for KANBAN within WM Set up master data and customizing for KANBAN processing in WM Describe the replenishment strategy for WM Staging Set up master data and customizing for processing WM Staging
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9.24Production Integration - Exercises 1 Unit: Production Integration Topic: Setting Up Production At the conclusion of this exercise, you will be able to: • Set up master data and customizing for WM Staging.
In your company, you have materials that are supplied to the production line in three different ways. First, you have crate materials that are supplied to the line based on container quantities. When one container becomes empty, that container is refilled and returned to the line based on a visual cue. These parts are typically parts that are common to multiple assemblies and are often large, bulky materials. Second, you have materials that are picked specifically for a production order, depending on the product that you are building. These parts are typically more specialized, and may be high dollar inventory items that are supplied to the line only when you are building a particular product. Third, you have materials that are supplied to the line for several production orders at a time. These are typically floor stock type items like nuts, bolts and screws, where you want to have 3-6 months of inventory available on the production floor. In this exercise, you will define the process for production orders such that all three material staging types are utilized. Engineering has designed a new flywheel for an existing pump. It is your responsibility to set up the production line for this new material so that the new, revised pump can be manufactured on your existing production line. You want to set this material up to be stored at point of use on the production floor and replenished based on a visual cue. You will verify the supply area, create a control cycle for the new material, enter a production order for the new pump, stage all the required materials, complete the production order and stock the finished assembly. This exercise covers the full circle of events required for managing the entire production process. Keep in mind that the steps in this exercise are not necessarily all performed by warehouse personnel, but are generally performed by a combination of production, planning and warehouse personnel. As you work through the exercise, think about which personnel in your company might perform each task.
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2-1
In Part One of this exercise, you will set up the production supply process, verifying the configuration and creating or changing the necessary master data. 2-1-1 Look at the Production Supply Area PVB 1310## in the Warehouse Master Data. Which Storage Location is assigned to your supply area? _______ 2-1-2 The production supply area is linked in Production Planning to the Work Center. Go to the work center T-WM## Basic Data view and verify that the correct supply area is assigned. 2-1-3 Use Field Level help to determine where in R/3, other than WM, is the Supply Area Used? _______________________________________ 2-1-4 Display the Control Cycle and verify the following: In order to have pick parts staged by production order, there must be one material-independent control cycle. Does this control cycle exist? _____ For this material-independent control cycle, to which bin will the materials be delivered ? _________________ 2-1-5 There is a release order part T-BW07-## in your process. Verify the control cycle for this material. What is the staging indicator for this control cycle record? __________________ 2-1-6 The new flywheel, T-BW01-##, is a crate part and is delivered to the production line based on a visual cue. There are 2 Containers, each holding 20 flywheels. The container is stored on the production floor in storage type 100 in a bin labeled PROD-1310. When one container becomes empty, it is replenished from the warehouse. Based on this information, create a control cycle record for this flywheel. Field Name or Data Type
Values
No. of Kanbans Kanban Quantity Warehouse Number Storage Type Storage Bin Staging Indicator Why can’t you use a dynamic bin for a crate part? ________________ _________________________________________________________
2-1-7 For this control cycle, you must request the first lot of materials to be delivered to the floor. Perform WM Staging on the crate part to create a Transfer Requirement in the warehouse. (Note: Typically, this task is (C) SAP AG
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performed by either a production worker or a material handler in production when the materials need to be refilled. Since this is a new control cycle, this first request is to get the process started.) Create the TR, but do not process it yet. Transfer Requirement _____________ PART TWO: 3-1
Changing responsibilities, you now represent the Production Planner in your company. Engineering has determined that you are ready to build the pump with the new flywheel. You need to create and release a production order, and have the materials moved from the warehouse to support production. 3-1-1 Using the data provided below, create, release and stage a production order. Which materials are selected for staging? __________________________________________________ Why aren’t the rest of the materials selected for staging? ______________ ____________________________________________________________
Production Order Order Type:
PP01
Production Plant: 1000
Material
Quantity
T-MS-##
10
Delivery Date One week from Today
Production Order Number: _______________________
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4-1
Back in the warehouse, there are requirements to be processed from the warehouse to the production floor. 4-1-1 Display the Transfer Requirements that have been created by the WM Staging. What requirement type should you use to display production requirements? ______ Leave the Requirement Number blank so you see all requirements for production. 4-1-2 Process the TRs by converting them to Transfer Orders. TO Numbers ________ __________ 4-1-3 Confirm the Transfer Orders. 4-1-4 Look at the Stock Overview for materials T-BW01-## (Flywheel – Crate Part); T-BW03-## (Shaft – Pick Part); and T-MS-## (Finished Pump). Material
StorType
Available
For Putaway
Pick Quantity
T-BW01-## T-BW03-## T-MS-## 5-1
Confirming the Production Order confirms that the work has been completed and signals that you have consumed the materials from the production floor. It is possible to have the system complete the finished assembly at this point, delivering the finished pump to the warehouse for put away into stock. In our test system, the confirmation of the Production Order will consume all of the materials required to build the assembly and perform the receipt of the finished assembly into stock. 5-1-1 In PP, perform the Completion Confirmation. How many goods issues were processed? _______ Failed? ________ 5-1-2 Recheck your stock for the materials T-BW01-##, T-BW03-## and T-MS-##. Material
StorType
Available
For Putaway
Pick Quantity
T-BW01-## T-BW03-## T-MS-##
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6-1
The Production Order accomplished two functions: consumed the components and received the finished pump into the warehouse. Now you must process the finished pump to the fixed bin in the warehouse. 6-1-1 Process the finished pump to its final destination bin. Which storage type/bin is suggested by the TO you created? ________________________ Where does the system get that information? ________________________ 6-1-2
Confirm the TO.
6-1-3
Check stock on the T-MS-##.
Material
StorType
Available
For Putaway
Pick Quantity
T-MS-##
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9.25Production Integration - Solutions 1 Unit: Production Integration Topic: Setting up Production
2-1 2-1-1 Logistics → Logistics Execution → Master Data → Warehouse → Production Supply → Production Supply Area → Display. Enter Plant 1000. Select the line for PVB 1310##, and choose Details. Your storage location 01## is assigned to your supply area. 2-1-2 Logistics → Production → Master Data → Work Centers → Work Center → Display. Enter Plant 1000 and Work Center T-WM## and choose Basic Data. 2-1-3 Position on the field: Supply Area and Choose F1. The Supply Area is used in Kanban and in Warehouse Management. 2-1-4 Logistics → Logistics Execution → Master Data → Warehouse → Production Supply → Control Cycle Production Supply → Display. Field Name or Data Type
Values
Material
Blank
Plant
1000
Supply Area
PVB 1310##
Yes, there is a control cycle record that is material-independent for pick parts. Materials will be delivered to Storage Type 100 and will be stored in a Dynamic Bin. 2-1-5 Logistics → Logistics Execution → Master Data → Warehouse → Production Supply → Control Cycle Production Supply → Display. Field Name or Data Type
Values
Material
T-BW07-##
Plant
1000
Supply Area
PVB 1310##
The Staging Indicator for the control cycle for T-BW07-## is 3. 2-1-6 Logistics → Logistics Execution → Master Data → Warehouse → Production Supply → Control Cycle Production Supply → Create.
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Field Name or Data Type
Values
Material
T-BW01-##
Plant
1000
Supply Area
PVB 1310##
No. of Kanbans
2
Kanban Quantity
20
Warehouse Number
1##
Storage Type
100
Storage Bin
PROD-1310
Staging Indicator
2
You can’t use a dynamic bin for a Crate Part because Crate Parts are delivered to the production area without regard to the production order number. 2-1-7 Logistics → Logistics Execution → Outbound Process → Goods Issue for Other Transactions → Prepare Production Supply → For Crate Part. Enter the material T-BW01-## and select WM Material Staging. Select WM Material Staging again to create the TR and Save. Select Logistics → Logistics Execution → Internal Whse Processes → Transfer Requirement → Display → By Requirement. Use Requirement Type P and enter to see the Transfer Requirement that was created by the WM Staging Process. (Do not process it yet.) PART TWO: 3-1 3-1-1 Logistics → Production → Production Control → Order → Create → With Material. Field Name or Data Type
Values
Material
T-MS-##
Production Plant
1000
Order Type
PP01
Total quantity
10
Finish
One week from today
Functions → Release. Goto → WM PickList → Proceed. Select WM Material Staging. Save the order. The pick parts are selected for staging. The other materials are crate or release order parts and are not relevant for staging here. 4-1 4-1-1 Logistics → Logistics Execution → Internal Whse Processes → Transfer Requirement → Display → By Requirement. Use Requirement Type P and enter. You should see two TRs available for processing. (C) SAP AG
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4-1-2 Select the TRs from the list display above and choose TO in Background. 4-1-3 Favorites → Confirm TO, One Step 4-1-4 Favorites → Warehouse Management Stock Overview 5-1 5-1-1 Logistics → Production → Production Control → Confirmation → Enter → For Order. Enter the Production Order Number. Select Final Confirmation and save. If your setup is correct, you should have 8 transactions processed; 0 failed. 5-1-2 Favorites → Warehouse Management Stock Overview 6-1 6-1-1 Favorites → Display TR by Storage Type. Select the TR and convert it into a TO. The system should select your fixed bin Box-## as the final destination because that is what you have identified in the Material Master at the storage type level. 6-1-2 Favorites → Confirm TO, One Step 6-1-3 Favorites → Warehouse Management Stock Overview
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9.26Production Integration - Exercises
2
Unit: Production Integration Topic: Kanban (Optional Exercise) At the conclusion of this exercise, you will be able to: • Set up master data and customizing for KANBAN
In one area of your company, you are running a separate storage location using KANBAN as your method of resupply to production. You need to configure the system so that materials can be supplied from your warehouse to the production area using KANBAN methodology. In this exercise, you will configure the system and create the master data required for utilizing the KANBAN functionality. This exercise covers the full circle of events required for managing the entire production process. Keep in mind that the steps in this exercise are not necessarily all performed by warehouse personnel, but are generally performed by a combination of production, planning and warehouse personnel. As you work through the exercise, consider which personnel in your company might perform each task. 1-1
First you must define the control between Production and the Warehouse. In Production Customizing, verify the Stock Transfer Strategy. 1-1-1 In the Stock Transfer Strategy, verify that for plant 1200, strategy 0006 is configured as Stock Transfer with transfer requirement. The TO should be automatically created and no difference indicator is set. Be sure that From Different Plant movement is indicated.
1-2
1.1.2
The Storage Type for Kanban for your warehouse has been defined as 150. In WM Customizing under Interfaces → Define KANBAN, you must verify the assignment of WM movement type 350 to storage type 150 in your warehouse.
1.1.3
Verify the Storage Location Control from your warehouse to Plant 1200 Storage Location PL06. What movement type will be run in the background at the time of the TO Confirmation? ________________
Create the master data. 1.2.1
Create material K-1## to use for the KANBAN test by copying the material R-1270C. You need to create this material for both Plant 1200, Sloc PL06 and for Plant 1000, Warehouse 1##. The Industry Sector is M, and the Material Type is Raw Material.
Plant 1200 and storage location PL06, create the Basic Data, Purchasing, General Plant Data/Storage 1 and 2, and Accounting views with reference to R1270C, Plant 1200, Storage Location PL06. (C) SAP AG
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In Plant 1000, Storage Location 01##, create Purchasing, General Plant Data/Storage 1 and 2, Warehouse Management 1 & 2 and the Accounting 1 view with reference to R-1270C, Plant 1200, Storage Location PL06. In the Warehouse Management 2 View, set the pallet size to 80 pieces on an Industrial pallet. 1-2-2 Create a Bin KANBAN in Storage Type 150, Storage Section 001.
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1-2-3 Create a Control Cycle Record in PP for this new material K-1##, Plant 1200 and Supply Area PVB_PC. Choose the Classic KANBAN and copy from R1270C, Plant 1200 and Supply Area PVB_PC. In the Stock Transfer tab of the control cycle record, establish the Issuing Plant as 1000, Storage Location 01##, use your warehouse number 1##, Storage Type 150 and Storage Bin KANBAN. 1-2-4 Do a goods receipt without reference to bring in 800 pieces of the K-1## material into Plant 1000, Storage Location 01##. Create a Transfer Order with reference to the Transfer Requirement that is created by the 501 transaction, and remember to confirm the Transfer Order. 1-3
Test the connection 1-3-1 Call the Kanban Board → Demand Source View and for Plant 1200 and supply area PVB_PC. 1-3-2 Choose one of the boxes that represent the KANBAN and set it to empty. Is a TR created? Select the box to see the TR that is created. 1-3-3 Set status to Full. 1-3-4 Display the stock overview from Inventory Management for the K-1## so you can see inventory for Plants 1000 and 1200. Plant
Storage Location
Unrestricted Use Stock
Be sure to leave the plant field blank so you can overview the inventory balances for both plants.
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9.27Production Integration - Solutions 2 Unit: Production Integration Topic: Kanban
1-1 1-1-1 Tools → AcceleratedSAP → Customizing → Edit Project → Goto → SAP Reference IMG → Production → Kanban → Replenishment Strategies → Define Stock Transfer Strategies. Select Plant 1200, Replenishment Strategy 0006. Select From diff plnt and verify Immed TO Crtn is selected. 1.1.2
SAP Reference IMG → Logistics Execution → Warehouse Management → Interfaces → Define Kanban→ Movement Type Assignment to Kanban Supply. Position on your warehouse and storage type 150.
1.1.3
SAP Reference IMG → Logistics Execution → Warehouse Management → Interfaces → Define Kanban→ Storage Location Control in Warehouse Mgmt. The movement type 301 (Plant to Plant) is the movement type that will be executed upon TO Confirmation.
1-2 1-2-1 Logistics → Logistics Execution → Master Data → Material → Material → Create → Immediately
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Field Name or Data Type
Values
Material
K-1##
Industry Sector
Mechanical Engineering
Material Type
Raw material
Copy From
R-1270C
Select Views
Basic Data, Purchasing, General Plant 1 and 2, Accounting 1
Plant
1200
Storage Location
PL06
Copy from Plant
1200
Copy from Storage Location
PL06
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Create the material a second time with the following data: Field Name or Data Type
Values
Material
K-1##
Industry Sector
Mechanical Engineering
Material Type
Raw material
Copy From
R-1270C
Select Views
Purchasing, General Plant 1 and 2, Warehouse Management 1 and 2, Accounting 1
Plant
1000
Storage Location
01##
Warehouse
1##
Copy from Plant
1200
Copy from Storage Location
PL06
Warehouse Management 2 View: Field Name or Data Type
Values
LE Quantity
80
UN
PC
SUT
IP
1-2-2 Logistics → Logistics Execution → Master Data → Warehouse → Storage Bin → Create → Manually
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Field Name or Data Type
Values
Warehouse
1##
Storage Type
150
Storage Bin
KANBAN
Storage Section
001
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1-2-3 Logistics → Production → KANBAN → Control Cycle → Create Field Name or Data Type
Values
Material
K-1##
Plant
1200
Supply Area
PVB_PC
Classic KANBAN
Select
Copy from Material
R-1270C
Plant
1200
Supply Area
PVB_PC
Select the Stock Transfer Tab: Field Name or Data Type
Values
Issuing Plant
1000
Storage Location
01##
Warehouse Number
1##
Storage Type
150
Storage Bin
KANBAN
1-2-4 Logistics → Logistics Execution → Inbound Process → Goods Receipt for Purchase Order, Order, Other → Goods Receipt for Other Activities Field Name or Data Type
Values
Movement Type
501
Plant
1000
Storage Location
01##
Material Number
K-1##
Quantity
800
Still under Inbound Process, select Putaway → Create Transfer Order → By Material Document. Generate the TO in the background. Save. Choose Transfer Order → Confirm →Input List. Save.
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1-3 1-3-1
1-3-2
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Logistics → Production → KANBAN → Control → Kanban Board → Demand Source View Field Name or Data Type
Values
Plant
1200
Supply Area
PVB_PC
Logistics → Logistics Execution → Internal Whse Processes → Bins and Stock → Display → Total Stock per Material (Inventory Management)
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10 Delivery Processing
Contents: Processing Delivery Notes Collective Processing Two-Step Picking
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10.2 Delivery Processing: Course Overview Diagram
Course Overview
1
Goods Issue
7
Logistics Execution Overview
2
Posting Changes
8
Warehouse Management Structure
3
Production Integration
9
Master Data
4
Deliv Delivery ry Proc eProcessing essin g
10
Integration with Inventory Management
5
Replenishment
11
Goods Receipt
6
Physical Inventory
12
Conclusion
13
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10.3 Delivery Processing: Business Scenario
In this unit, you will examine different possibilities for processing delivery notes and customizing the delivery function in the warehouse. You will create delivery notes and process them through shipping and post goods issue, using different techniques.
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10.4 Delivery Processing: Objectives
At the conclusion of this unit, you will be able to: Demonstrate the shipping process in WM
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10.5 Overview of Shipping Processand WM Create sales order Create delivery SD Pick list
Picking technique
Create transfer order
Print TO (or multiple TO list)
Confirm transfer order
Picking from fixed bin
no
Differences yes yes Post goods issue
?
Copy transfer data to the delivery
no
SAP AG 1999
Depending upon the picking technique, materials are picked from the fixed bin (with a picking list from the Sales and Distribution system) or a transfer order for a delivery is created. If picking takes place without a transfer order, the WM status in the delivery is set to “N” (not relevant for Warehouse Management). If picking takes place with a transfer order, the WM status in the delivery is set to “A” (relevant for Warehouse Management). The WM status is updated after each step during transfer order processing.
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10.6 Picking Process Transfer Order
Dely 80004092
4711 Mat. 4711
50
50
Updates Delivery
916 0080004092 4711 50 Post Goods Issue
Relieves Inventory
SAP AG 1999
When the picking technique is set to Random Picking, the system will always expect a Transfer Order to be created for the delivery item. Upon confirmation, the materials are delivered to the interim storage type and bin defined for the movement type (601). Upon post goods issue, the materials are relieved from the interim storage type and bin, and the order is available for billing.
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10.7 Transfer Order for Outbound Delivery
Transfer Order Delivery Source – Dest
Item 1 Item 2
Source – Dest Source – Dest Source – Dest
Item 3
Source – Dest Source – Dest GI- Area
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No transfer requirement is created for a delivery; instead, a transfer order is created on the basis of the delivery. If the requirement quantity of a delivery item is to be removed from several storage bins, several transfer order items are created for the delivery item.
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10.8 Creation of Groups in the Delivery Monitor Printout without Group
Selection and assignment of groups
Delivery Monitor: Creation of single TOs
Del 4711 Del 4720
Transfer Transfer auftrag auftrag Transfer order zur LF 4711 zur LF 4725 Transfer order zur LF 4720 for Del 4813
Del 4725 Del 4813
Group #23
Release/ Printout with group Collective Processing: Creation of TOs for the group
Picking list Group #23
Interface LSR IDoc Release Group #23 SAP AG 1999
With the Delivery Monitor, dialog processing of inbound and outbound deliveries is possible with SAP's Enjoy initiative. The delivery data is organized in process-oriented groups. Foreground navigation is possible with buttons and tabstrip controls. A status overview gives you a summary of the delivery document's processing status. You can switch from display to change mode without having to exit the application. It is possible to combine multiple delivery notes together to pick as a group, or have a Transfer Order for each delivery note.
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10.9 Two-Step Picking Stock removal based on materials
Delivery based distribution
2nd step: Allocation
1st Step: Picking Group
Picking TO for a Group
TO #250
Del 4813 Mat.01 3 Ea Mat.02 4 Ea
Del 4814 Mat.01 4 Ea Mat.02 5 Ea
Del 4815 Mat.01 3 Ea Mat.02 1 Ea
Item 1 Mat.01 10 Ea
Mat.01 3 Ea Mat.02 4 Ea
Srce: Dest:
Srce 001 Dest 200
200 916
TO #251 Mat.01 4 Ea Mat.02 5 Ea
Srce: Dest:
Item 2 Mat.02
10 Ea
Srce 001 Dest 200
200 916
TO #252 Mat.01 3 Ea Mat.02 1 Ea
Srce: Dest:
200 916
SAP AG 1999
Two-Step Picking is an extension of multiple processing. For Two-Step picking, the picking process is divided into 2 steps: First Step: The entire quantity of needed materials is picked to fill requests (for example, several deliveries) for the materials. Second Step: The total quantity is divided and allocated to match the individual requirements. The goal is to go once to a bin to pull materials, even if the requirements are from different deliveries. Two-Step picking was developed using the group number as a basis. The group number serves as a means to combine several deliveries. Additionally, you can carry out other functions associated with the group number, such as printing and confirmation.
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10.10 Transfer Order Splitting
DELIVERY Not fulfilled
Transfer Order
Split Criteria?
Fulfilled Transfer Order
Transfer Order
Transfer Order
SAP AG 1999
To achieve a balanced distribution of the workload of the warehouse, Transfer Orders can be split. Together with the splitting process, dynamic sorting of the TO items takes place. For this sorting process, you can use the sequence field in the storage bin. This field allows you to enter the exact sequence in which the storage bins are to be processed. Transfer Orders are split by a profile for the warehouse number. You can split the TOs by: Storage type and picking area Target time (header information) , volume and weight as value limits User exit (either for sorting or for splitting)
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10.11 Creation of TOs: WMTA Processing time
Condition Records
Delivery
Shp. point. 1200 Shipping Condition immediately
Del Type LF Shipping Condition Immediately
Message
Automatic TO-Creation
Job
RLAUTA20 BatchProgram
Transaction
Transaction: Messages from Deliveries
WMTA
Immediate TO-Creation immediately
Direct Processing with delivery creation SAP AG 1999
At the interface from SD Shipping to WM, you can set immediate or automatic transfer order creation for deliveries. Processing is controlled by the message control function of the shipping module. Via the condition technique, you can initiate the message type WMTA upon creation of the delivery. The requirement for this is that at least one item of the delivery is relevant for WM. The combination “Shipping point / Delivery type” is responsible for finding the message type. Depending on the processing of the message type “WMTA”, there are different processing type: Time 1-3 (processing later) In this case, the message is processed either via a batch program or manually via the transaction “Messages for delivery”. Since this processing type is executed separately from the delivery creation process, we refer to this as Automatic Transfer Order Creation. Time 4 (Processing Immediately) Here message processing is initiated immediately after the delivery has been created. Therefore, this is referred to as Immediate Transfer Order Creation. Transaction VOK2 Sales and distrib. Document --> Delivery --> Condition Type WMTA
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10.12 Delivery Processing: Summary
You are now able to: Demonstrate the shipping process in WM
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10.13Delivery
Processing - Exercises 1
Unit: Delivery Processing Topic: Processing Delivery Notes in WM At the conclusion of this exercise, you will be able to: • Create a delivery note with reference to a sales order • Create/confirm a Transfer Order with reference to a delivery • Post Goods Issue for a Delivery Your Order Processing Department has received sales orders for the pump number T-MS-##. In this exercise, you will create a delivery note with reference to an existing sales order and process that delivery note through shipping and post goods issue. Keep in mind that it is not always the warehouse person who performs each step in this process. Think about the business process in your own company and which departments or individuals perform which functions. 1-1
In this step, you will create a delivery note with reference to a sales order that has already been entered through the Order Processing Department. 1-1-1 Create a delivery with reference to a Sales Order. You are processing deliveries for shipping point 1000 that are due for shipment within the next week. (Add this function to your Favorites. Change the text to Create Delivery.) Using F4, search for the Sales Order Number using your group number as the Purchase Order Number. Note: You may be prompted for sales area data when you search. If so, the Sales Organization is 1000, Distribution Channel 10, Division 00. When the Sales Order is selected, press enter. Before you save the delivery, go to the Picking tab and verify that the material will be picked from stores location 01##. Notice that the line is relevant for Warehouse Management. WM Status _______ Picking Status _______ Save the delivery. Delivery Number _____________________ 1-1-2 Using the Delivery Monitor, create a Transfer Order with reference to the Delivery. (Add the Delivery Monitor to favorites. Change the text to Delivery Monitor.) Leave the Adopt Pick Quantity field blank. Transfer Order _________________
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1-1-3 Still using the delivery monitor before confirming the TO, check the WM Status and Picking Status within the Delivery Note to see how the system keeps track of what processes are going on within the warehouse. WM Status _______ Picking Status _______ 1-1-4 Confirm the Transfer Order. (Leave Adopt Pick Quantity field blank.) 1-1-5 Check the Stock Overview for material T-MS-##. Material
StorType
Available
For Putaway
Pick Quantity
T-MS-##
1-2
Posting goods issue is the step that actually removes the inventory from your warehouse, creating the material and accounting documents in IM. Following this step, the Sales Order is available for billing. 1-2-1 From the Delivery Monitor, Post Goods Issue against the delivery note. Before you exit the Delivery Monitor, verify that the Pick Quantity is now updated and recheck the WM and Picking Status. WM Status _______ Picking Status _______ 1-2-2 Look at the Document Flow. What is the material document number that was created for the goods issue? _________________________ 1-2-3 Check the stock overview to verify that inventory has been updated.
Material
StorType
Available
For Putaway
Pick Quantity
T-MS-##
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10.14Delivery Processing - Solutions 1 Unit: Delivery Processing Topic: Processing Delivery Notes in WM
1-1 1-1-1 Logistics → Logistics Execution → Outbound Process → Goods Issue for Outbound Delivery → Outbound Delivery → Create → Single Document → With Reference to Sales Order. Select Add to Favorites then Change Favorites to change the text. Use Shipping Point 1000. Set the selection date out one week. Search for the order number by selecting the match code and choose A:Sales document according to customer PO number. Search for PO of your group number. Select the item and enter. Select the Picking tab to overview picking. Save the delivery. 1-1-2 Logistics → Logistics Execution → Outbound Process → Goods Issue for Outbound Delivery → Outbound Delivery → Lists and Logs → Outbound Delivery Monitor. Select Add to Favorites then Change Favorites to change the text. Select For Picking. Field Name or Data Type
Values
Shipping Point/receiving pt
1000
Only WM Picking
Select
Warehouse Number
1##
Execute. Select your delivery and choose TO in backgr. Leave the Adopt Pick Quantity field blank. 1-1-3 From the Outbound Delivery Monitor select For confirmatn. Enter Shipping Point 1000 and execute. Select the line and choose Subsequent → Display outbound deliveries to see the WM and Picking status. 1-1-4 Still in Outbound Deliveries for Confirmation, select your delivery and choose Confirm in Background. Leave the Adopt Pick Quantity field blank. 1-1-5 Favorites → Warehouse Management Stock Overview.
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1-2 1-2-1 Favorites → Delivery Monitor → For goods issue. Shipping Point 1000. Select your delivery note and choose Post Goods Issue. Enter today’s date as the actual goods issue date. Select the line and choose Subsequent → Display outbound deliveries to see the pick quantity and the WM and Picking status settings. 1-2-2 From the delivery display, choose Environment → Document Flow. 1-2-3 Favorites → Warehouse Management Stock Overview.
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10.15Delivery Processing - Exercises 2 Unit: Delivery Processing Topic: Two-Step Picking (Optional Exercise) At the conclusion of this exercise, you will be able to: • Process multiple delivery requirements with 2-step picking
When picking for multiple sales orders, it is your goal to go once to a bin to pick the required materials, regardless of the number of sales order requirements you may have. It is your process to pick all materials required for shipment within a given period, then deliver those materials to an area to be sorted for shipment against the specific requirement. Therefore, you move material from the warehouse to an intermediate area, then from that area to the shipping area where requirements are matched to the specific delivery note. 2-1
In this scenario, you have three sales orders with products due to ship for various combinations of materials that are stored in your warehouse. You want to process these deliveries using two-step picking functionality, where you want to go once to a bin to pick all of the requirements, then redistribute those materials back to the original delivery notes for shipping. 2-1-1 Go to customizing interfaces in Warehouse Management to verify that your warehouse is relevant for 2-Step Picking. What is the WM movement type configured for removal 2-Step Picking? __________ 2-1-2 Look at WM Movement Type 850 in your warehouse. What is the Destination Storage Type for movement type 850? _________ 2-1-3 Look at Storage Type 200 in your warehouse. Is this an Interim Storage Type? ____________ How can you tell? _____________________________________________ 2-1-4 Now look at the Storage Type Search Sequence. Is there a special entry in your warehouse for 2-step picking? ______
2-2
In this exercise, you are processing delivery notes that are required for service parts for your pump. Your order processing department has received orders that are due for processing today. The delivery notes have already been created for you. You have 3 delivery notes with various combinations of materials T-BW04-## and TBW05-##. 2-2-1 In the first step, you must group together the deliveries and assign a group number for further processing. Use the grouping functionality in the Outbound Delivery process to group together the deliveries. Group Number _______ 2-2-2 Create the first TO that will move the material from the warehouse to the I intermediate area – Storage Type 200.
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2-2-3 Confirm your Transfer Order. 2-2-4 Check your inventory for the T-BW04-## and T-BW05-## materials. Your inventory for the deliveries now shows in storage type 200. Material
StorType
Available
For Putaway
Pick Quantity
T-BW04-##
T-BW05-##
2-2-5 In this step, you want to allocate the materials that you picked back against the original delivery notes. You will create 3 Transfer Orders, one for each delivery, to move the materials from 200 to 916. You will complete the process via the 2-Step Picking Analysis function. The Transfer Orders will be confirmed automatically. 2-2-6 Check again your inventory for the T-BW04-## and T-BW05-## materials. Material
StorType
Available
For Putaway
Pick Quantity
For Putaway
Pick Quantity
T-BW04-## T-BW05-##
2-2-7 Post Goods Issue for your delivery notes. 2-2-8 Check your inventory balances. Material
StorType
Available
T-BW04-## T-BW05-##
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10.16Delivery Processing - Solutions 2 Unit: Delivery Processing Topic: Two-Step Picking
2-1 2-1-1 Tools → AcceleratedSAP → Customizing → Edit Project → Goto → SAP Reference IMG → Logistics Execution → Warehouse Management → Interfaces → Shipping → Two-Step Picking. Two step picking is relevant for your warehouse and is determined by material. The WM movement type for removal is 850. 2-1-2 SAP Reference IMG → Logistics Execution → Warehouse Management → Activities → Transfers → Define Movement Types. Position on your warehouse 1## and Movement Type 850. Select the line and choose Details. The destination storage type for movement type 850 is Storage Type 200. 2-1-3 SAP Reference IMG → Logistics Execution → Warehouse Management → Master Data → Define Storage Type. Position on your warehouse 1## and Storage Type 200. Storage Type 200 is not an interim storage type because it has a placement and a removal strategy. In both cases, the strategy is R, which will cause the system to use the Reference Number as the dynamic coordinate. 2-1-4 SAP Reference IMG → Logistics Execution → Warehouse Management → Strategies → Activate Storage Type Search → Determine Search Sequence. Position on your warehouse 1##. Activity 2 is relevant only for 2-Step Picking.
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2-2 2-2-1 Favorites → Delivery Monitor. Choose Picking. Use shipping pt/receiving pt 1000. Select Only WM Picking for your warehouse. Select your deliveries, then choose Subsequent Functions → Group → Create with WM Reference. Field Name or Data Type
Values
Group Type
K
Description
Group ##
Warehouse Number
1##
2-2-2 Logistics → Logistics Execution → Outbound Process → Goods Issue for Outbound Delivery → Picking → Create Transfer Order → Via 2-Step Picking. Enter your Group Number and choose enter then Generate TO. 2-2-3 Favorites → Confirm TO, One Step 2-2-4 Favorites → Warehouse Management Stock Overview 2-2-5 Logistics → Logistics Execution → Outbound Process → Goods Issue for Outbound Delivery → Picking → Wave Picks → 2-Step Picking → Analysis. Enter your Group Number that was previously assigned and execute. Select the Allocation line, then choose Create TOs. Enter your Warehouse 1## and Group Number, set control to Background, and choose Start Multiple Processing. Select your Group Number and Display Details. Return to the analysis and Refresh Data. You should now show all Green lights! 2-2-6 Favorites → Warehouse Management Stock Overview 2-2-7 Favorites → Delivery Monitor → For Goods Issue. Select only your deliveries and Post Goods Issue, using today’s date. 2-2-8 Favorites → Warehouse Management Stock Overview
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11 Replenishment
Contents: Various Replenishment Techniques
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11.2 Replenishment: Course Overview Diagram
Course Overview
1
Goods Issue
7
Logistics Execution Overview
2
Posting Changes
8
Warehouse Management Structure
3
Production Integration
9
Master Data
4
Delivery Processing
10
Integration with Inventory Management
5
ReReplenishment pleni shme nt
11
Goods Receipt
6
Physical Inventory
12
Conclusion
13
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11.3 Replenishment: Business Scenario
In this area of the warehouse, you store materials
in fixed bins to be picked for delivery from this storage type and then replenished from other areas of the warehouse. You would like to experiment with different approaches to this strategy and automate the process as much as possible.
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11.4 Replenishment: Objectives
At the conclusion of this unit, you will be able to: Execute two methods of fixed bin
replenishment Explain different possibilities to
execute replenishment within the warehouse
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11.5 Replenishment for Fixed Storage Bins
SAP AG 1999
When you use fixed bin replenishment, the system calculates the replenishment quantities that are necessary to maintain appropriate stock levels based on information that you provide. You first must define a WM movement type for storage types that use the fixed bin stock placement strategy. In the standard WM system, movement type 319 was created for this purpose. Link the movement type with the fixed bin storage type. You must maintain the material master record for the fixed bin storage type. You must enter data in the Storage bin, Maximum bin quantity, Minimum bin quantity and Replenishment Quantity data fields at the Storage Type level in the Warehouse Management view of the Material Master record.
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11.6 Replenishment for Fixed Bins: Batch Report
RL LN AC H 1
min. storage bin quantity 3 ctn replenishment quantity 8 ctn
Transfer requirement
Transfer order
SAP AG 1999
You can process a report (RLLNACH1) in batch to replenish fixed bin storage types at regular predefined time intervals or online as required. When you run RLLLNACH1, the system will recommend a Transfer Requirement if your stock falls below the minimum bin quantity you have defined. The Transfer Requirement will be recommended in increments of the Replenishment Quantity up to the Maximum Bin Quantity. Afterwards, you process the transfer requirements to create transfer orders according to the normal procedures you would use to carry out stock movements within WM.
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11.7 Planned Replenishment
Firma Firma
Firma Firma
Firma Rechnung Firma Rechnung
Firma Rechnung Firma Rechnung
Firma Rechnung Firma Rechnung
Rechnung Rechnung
Firma Rechnung Firma Rechnung
Rechnung Rechnung
Planned Replenishment
RLLNACH2
SAP AG 1999
This report creates transfer requirements for fixed bin replenishment where stock removals are allowed to take place before put aways because of the respective deliveries. This report takes into account, in addition to the stock situation, planned stock removals and replenishment transfer requirements. Using this report, you can create all the replenishment transfer requirements for supplying the fixed bins based on delivery requirements and rounded to the replenishment quantity. Use this report to create the transfer requirement which can then be processed according to normal procedures you use to carry out stock movements within WM.
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11.8 Creating TOs Automatically for TRs
IM Document
PP System
Manual
Transfer requirement Batch
RLAUTA10 Transfer order
Mail
SAP AG 1999
For certain classes of transfer requirements, it is possible to set up the Warehouse Management system to create transfer orders automatically as a background process. You set up the system to carry out this process by setting an indicator in each movement type. When you create a transfer requirement manually, the system copies this indicator into the transfer requirement header. To activate the automatic creation of transfer orders for these transfer requirements you must start the report RLAUTA10 as a batch job. For this process you define a variant for each different indicator. This makes it possible for you to define different starting times and time spans to repeat each task periodically
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11.9 Replenishing Random Bin Management: TR/TO 4.6C
min. storage bin quantity 6 ctn replenishment quantity 8 ctn
Transfer requirement
O r: TO imme cre d ati o i a te n
RL
4 CH A LN
Transfer order
SAP AG 1999
As of this release, you can take care of internal warehouse replinishment at the time of transfer order confirmation. This replenishment can be triggered for random bin managed storage types and for fixed bin storage types.
For random bin managed storage types, you define the minimum bin quantity for the storage type view in material master as minimum quantity in the storage type.
For random bin management replenishment, you can use the report RLLNACH4 to create a TR. This processing is similar to the processing of RLLNACH1 and RLLNACH2. Else, you have the possibility to use immediate TO creation for replenishing the whole storage type.
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11.10 Replenishment: Summary
You are now able to: Execute two methods of fixed bin replenishment Explain different possibilities to execute
replenishment within the warehouse
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11.11Replenishment
- Exercises 1
Unit: Replenishment Topic: Replenishment for Fixed Bins At the conclusion of this exercise, you will be able to: • Create the appropriate master data to run fixed bin replenishment • Run the fixed bin replenishment process in the warehouse You have a process in the warehouse where you establish a minimum quantity, together with a maximum and a replenishment quantity for a fixed bin. You would like to run a replenishment program that would, when your minimum is exceeded, create a requirement to replenish your bins based on the replenishment quantity up to the maximum. 1-1
Set up the appropriate data for fixed bin replenishment, using minimum, maximum and replenishment data. Run the replenishment report and process the resulting TRs to restock the bins. 1-1-1 Storage type 005 is your fixed bin storage type. Verify the WM movement type for replenishment is assigned to storage type 005. Movement Type _____ 1-1-2 The material master T-BW20-## already exists in the system, but the replenishment data has not been defined. Create the material T-BW20-## for your warehouse number 1## and storage type 005. Assign the material to fixed bin 400-##. When your inventory dips below 100, you would like to replenish the stock in increments of your pallet size, up to 5 full pallets. Also make sure that the material is set up to be picked from the fixed bin. 1-1-3 Check your stock situation for T-BW20-##.
Material
StorType
Available
For Putaway
Pick Quantity
T-BW20-## 1-1-4 Create the TR by running Replenishment for Fixed Bins (Acc to Bin Situation). 1-1-5 Convert your TR to a TO and confirm the TO.
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1-1-6 Recheck your stock situation for T-BW20-##. Material
StorType
Available
For Putaway
Pick Quantity
T-BW20-##
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11.12Replenishment - Solutions 1 Unit: Replenishment Topic: Replenishment for Fixed Bins
1-1 1-1-1 SAP Reference IMG → Logistics Execution → Warehouse Management → Activities → Transfers → Define Stock Transfers and Replenishment Control → Define Replenishment Control for Storage Type.. (4.6B Menu Path: SAP Reference IMG → Logistics Execution → Warehouse Management → Activities → Transfers → Define Stock Transfers and Replenishment Control → Assign replenishment mvt type to stor. Type.) Position on your warehouse and storage type 005. Movement type 320 is assigned as the replenishment movement type for storage type 005. 1-1-2 Logistics → Logistics Execution → Internal Whse Processes → Master Data → Material → Material → Create → Immediately. Field Name or Data Type
Values
Material
T-BW20-##
View
Warehouse Management 1 & 2
Warehouse
1##
Stock Removal
FIX
Storage Type
005
Storage Bin
400-##
Maximum Quantity
500
Minimum Quantity
100
Replenishment Quantity
100
1-1-3 Favorites → Warehouse Management Stock Overview
1-1-4 Logistics → Logistics Execution → Internal Whse Processes → Stock Transfer → Planning of Replenishments → Acc to Bin Situation (C) SAP AG
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Field Name or Data Type
Values
Plant
1000
Storage Location
01##
Warehouse number
1##
Storage Type
005
Requirement Type
N
Requirement Tracking Number
FB##
Execute. Select the line and choose Material Staging. Save. 1-1-5 Favorites → Display Transfer Requirements by Storage Type. Select the TR and choose TO in backgr. Favorites → Confirm TO, One Step 1-1-6 Favorites → Warehouse Management Stock Overview
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11.13Replenishment - Exercises 2 Unit: Replenishment Topic: Planning Replenishment At the conclusion of this exercise, you will be able to: • Create the appropriate master data to run planning replenishment • Run the planning replenishment in the warehouse In this scenario, you want the system to consider TRs open for replenishment to the fixed bin as supply and delivery notes as demand. You want to create Transfer Requirements to cover deliveries for a period, in increments of the replenishment quantity.
2-1
In planning replenishment, you want to cover tomorrow’s demand in your fixed bin area. 2-1-1 Change the material master view for storage type 005, material T-BW21-##. Assign the bin 401-##. Modify the material if necessary to have a replenishment quantity equal to the pallet size. No minimum or maximum quantity is required. 2-1-2 There are 3 sales orders that exist for T-BW21-##. Create delivery notes for them. Search for the sales orders using the Purchase Order LO530-##. You will need to set the Selection Date out one week to select the deliveries. Also, choose the three sales orders with the highest sales order numbers.
2-1-3 Check the Delivery Monitor. How many are scheduled for delivery? ____ 2-1-4 Run Planning Replenishment. 2-1-5 How many TRs are created by the replenishment program? _____ What is the quantity of the TR generated by the planning replenishment program? _______
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11.14Replenishment - Solutions 2 Unit: Replenishment Topic: Planning Replenishment
2-1 2-1-1 Logistics → Logistics Execution → Internal Whse Processes → Master Data → Material → Material → Create → Immediately. Field Name or Data Type
Values
Material
T-BW21-##
View
Warehouse Management 2
Warehouse
1##
Storage Type
005
Storage Bin
401-##
Replenishment Quantity
100
Minimum Quantity
100
Maximum Quantity
500
2-1-2 Favorites → Create Delivery. Enter Shipping Point 1000. Select the matchcode and search for sales orders with the Purchase Order Number LO530-##. Create a delivery note for each sales order. 2-1-3 Favorites → Delivery Monitor → For Picking. Enter Shipping Point 1000 and your warehouse number. Choose Item View to see the quantity on the deliveries. 2-1-4 Logistics → Logistics Execution → Internal Whse Processes → Stock Transfer → Planning of Replenishments → Based Upon Outbound Deliveries to be Selected. Field Name or Data Type
Values
Plant
1000
Storage Location
01##
Warehouse
1##
Storage Type
005
Requirement Type
N
Requirement Tracking Number
PL##
2-1-5 One TR for a quantity of 100 is created for the replenishment.
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12 Physical Inventory
Contents: Inventory Methods The Physical Inventory Process
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12.2 Physical Inventory: Course Overview Diagram
Course Overview
1
Goods Issue
7
Logistics Execution Overview
2
Posting Changes
8
Warehouse Management Structure
3
Production Integration
9
Master Data
4
Delivery Processing
10
Integration with Inventory Management
5
Replenishment
11
Goods Receipt
6
Phys icInventory Physical Inven al tory
12
Conclusion
13
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12.3 Physical Inventory: Business Scenario
You must decide which inventory method your company will use. You must configure and test at least one inventory method.
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12.4 Physical Inventory: Objectives
At the conclusion of this unit, you will be able to: Execute the basic physical inventory process
in the warehouse Customize settings in the warehouse to allow
different inventory methods
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12.5 Inventory Methods
Inventory Methods Annual inventory Continuous inventory Cycle counting Inventory Based on First Placement Zero Stock Check Inventory sampling procedure
SAP AG 1999
The description of the inventory methods refer only to the technical prerequisites that are necessary to set up and carry out the different inventory methods. These notes can be used to supplement and check the company-specific inventory requirements. The inventory method is assigned at the storage type level with the exception of cycle counting. All of the inventory methods are executed within the storage type. If cycle counting is the chosen inventory method, it can be run above the storage type level, provided all storage types involved have cycle count assigned as the inventory method.
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12.6 Inventory Process Inventory Inventory planning planning Create Create system system inventory inventory record record Activate Activate system system inventory inventory record record
Storage Storage bins bins blocked blocked
Print Print out out inventory inventory list list Count, Count Count,, weigh, weigh, measure, measure measure,, estimate estimate
123
Take Take physical physical inventory inventory count count Start Start differences differences // control control list list Clear Clear differences differences in in the the Warehouse Warehouse Management Management system system
Storage Storage bins bins unblocked unblocked
Clear Clear differences differences in in the the Inventory Inventory Management Management system system SAP AG 1999
The process for taking inventory is the same, whether you are doing annual or continuous inventory. When you take annual inventory, the entire storage type is blocked for movement and all bins are counted. With continuous inventory and cycle counting, only the affected bins are blocked for movement. When you select continuous inventory, you are counting the bin and you must count all quants within that bin. When you select cycle count, you are counting the material, wherever that material is within the storage type(s) selected. In the case of mixed storage, all quants within the bin must be counted. When you clear differences in WM, any discrepant amount is written to the interim storage type for differences and the bins are unblocked. You then clear differences in IM to adjust the inventory balance and create the accounting document. Warehouse inventory data is year-dependent and must be reset at the beginning of a new inventory period. The program RLREOLPQ is provided for this purpose.
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12.7 Enjoy in Warehouse Management Inventory
Table controls replace step loops
SAP AG 1999
With the Enjoy release, the physical inventory was changed to Table Controls. Effected transactions are Create System Inventory Record, Change System Inventory Record,Display System Inventory Record, Enter Inventory Count,Change Inventory Count, and Display Inventory Count. For the transactions Create, Change, and Display Inventory Record, the processing logic is such that with the creation of an inventory record, new items are visible on the same screen where you enter the new item. The transactions Create, Change, and Display Inventory Record use per default the latest recount version. If you wish to work with a prior version, you must specify it. There is one central function module L_COUNT_DATA_PROCESS that ensures the necessary data verification. This is also used for IDOC processing instead of processing the inventory screens in the background.
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12.8 Continuous Inventory
Only the selected bins are blocked Inventory Document x x x
SAP AG 1999
With the continuous inventory method you take inventory on a selected number of storage bins in a storage type. The inventory can take place at any time during the fiscal year.
Compared to the annual inventory count at the end of the fiscal year, the continuous inventory has some advantages: The effort for the inventory is not concentrated on a certain day or days but is distributed over the entire year. This can result in a better leveling of the workload in the warehouse. Inventory can be conducted during slow times in the warehouse, for example, during summer vacation. With a reduction in the effort required at the end of the fiscal year, a company can respond better to problems that might arise during an end-of-year closing. When an inventory is carried out on a continuous basis, up-to-date information about the correspondence between the warehouse stock and the book inventory is always available..
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12.9 Cycle Counting
Goal: Goal:
Count Count Material Material Based Based on on Cycle Cycle Count Count Indicator Indicator
Continue normal WM inventory process:
Print Print
A A Items Items 12 12 times times // year year B B Items Items 6 times times // year year C C Items Items 1 time time // year year
Count Count
Record Record results results Assign CC Indicator: RMCBIN00
Recount Recount
Clear Clear differences differences
SAP AG 1999
Cycle counting in the Warehouse Management system makes it possible for you to separate materials into classes (such as A, B, C) and take inventory for each class separately several times throughout the year. You define the count frequency by class. It is possible to cycle count within a storage type or count across storage types as long as all storage types are set with cycle counting as the inventory method. In the Inventory Management IMG under Physical Inventory, you define the cycle counting indicators and the number of times per year that inventory counts are to be taken for each class. Then you enter the cycle count indicator (A, B, C) into the Storage View of the material master record for each material that will be counted using the cycle counting task. This can be set manually or by using the report RMCBIN00.
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12.10 Cycle Counting Time Interval
Starting the selection report for a time interval February
March
Mat. 4711
April
Mat. 4711
May
Mat. 4711
Mat. 4711
10 - 24 March Mat. 4712
Mat. 4712
Mat. 4713
Selection displays Selection displays: displays:: 123
Material Material 4711 4711 12 12 times times // year year Material Material 4712 4712 66 times times // year year Material Material 4713 4713 11 time time // year year
Stor.Bin .Bin Mat Stor Stor.Bin Mat 01-0701 07-03 01-07-03 01-0701 07-04 01-07-04 01-0601 06-09 01-06-09
Comments Comments
4711 4711 to to be be counted counted 4711 4711 to to be be counted counted 4713 4713 overdue overdue (was (was not not counted February counted in in February) February))
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The system searches for all materials in the storage type(s) that are marked for cycle counting within a given date interval and creates a list of storage bins for which inventory is to be taken.
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12.11 Inventory Based on First Stock Placement Create TO
Inventory already taken at destination bin? no
123
Print TO with inventory data Storage bin
Confirm TO
Inventory data Book quantity = Counted quantity
1 2 3 Difference in interim storage area Clear differences in Inventory Management
SAP AG 1999
Inventory based on stock placement: the system sets the inventory indicator for the storage bin the first time goods are placed in the storage bin for that fiscal year. The indicator is set when the transfer order is confirmed. Transfer orders provide proof of movement following the inventory. Because all movements to this bin must be individually identifiable throughout the fiscal year, you need to archive the transfer orders when you reorganize the data base. With this method, bins that are not occupied during the fiscal year are not counted; therefore, you should also set the annual inventory method for this storage type so that you can conduct an annual inventory for these storage bins.
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12.12 Zero Stock Check Create transfer order Print TO Note: Check bin
Bin empty?
Physical stock removal Confirm TO Verify zero stock check Bin empty
Bin occupied Enter counted qty Zero stock check message returned
Zero stock check confirmed
Correct qty in source bin (diff. calculated automatically) Post difference in Inventory Management SAP AG 1999
The zero stock check is activated by the system if during transfer order creation it is determined that the source bin will become empty by the stock removal. The transfer order for stock removal is printed with a notice that zero stock check is active for a specific bin. The zero stock check must be verified when the transfer order is confirmed. If the warehouse worker determines that the storage bin is not empty, the actual quantity remaining is entered at confirmation of the transfer order. The system carries out the correction of stock using the interim storage type for differences. The difference must be cleared from WM and recorded in IM. If a bin is empty although there should be stock you can request the zero stock check manually.
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12.13 Zero Stock Check as Inventory Confirm TO Zero stock check confirmed or requested manually
Bin occupied
Bin empty
Enter counted quantity
Zero stock check returned confirmed
Correct qty in source bin (diff. calculated automatically) Inventory data
Inventory data
Bin
Bin
Quant
SAP AG 1999
The zero stock check can also be defined as an inventory method for the storage type. In this case, an inventory record is made each time a zero stock check is carried out, not only in the case of a difference. When the transfer order is confirmed, the system updates the physical inventory data for the bin. Zero stock check is not applicable for all storage types (ie mixed storage).
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12.14 Inventory Sampling Procedure Random selection Stock mgmt unit to be counted
Physical inventory documents
Strata .....
Complete-count area
Inventory 1000 2317 L-Bin A L-Bin B
Updating
Extrapolation
Actual value of selected stock management units Estimation Estimated actual value of all stock units
Comparison
Book value of all stock units
SAP AG 1999
The inventory can be carried out with periodic sampling (at a given date) or continuous (over an extended period of time). A stock management unit is the Storage Type. You must assign stock levels by assigning which stock management units are to be included in the sampling. The Stock Population is divided in a complete count area and a sampling area, which is divided into several classes. (This is done automatically.) After the stratification, the Random Selection is generated (the system determines the stock management units to be counted for each stratum). The inventory documents are created. These documents are required for all stock management units drawn during random selection and for all that were allocated to the complete-count areas. You then count, weight, and measure your stocks. Carry out the update: During this process, the system reads the count results and reads any changed book inventory balances and book values. Extrapolation: The system estimates the physical inventory value on the basis of the latest counting results. The inventory is successful if the total physical inventory value deviates from the book inventory value by no more than 2% (in the standard system).
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12.15 Physical Inventory: Summary
You are now able to: Execute the basic physical inventory process in
the warehouse Customize settings in the warehouse to allow
different inventory methods
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12.16Physical Inventory Processes with WM - Exercises Unit: Physical Inventory Processes with WM Topic: Continuous Inventory and Cycle Counting At the conclusion of this exercise, you will be able to: • Customize settings in the warehouse to allow different inventory methods • Execute the basic physical inventory process in the warehouse You must decide which inventory method your company will use in the warehouse. You must configure and test at least one inventory method. With the continuous inventory method, you take inventory on a selected number of storage bins in a storage type at any time during the fiscal year. Cycle Counting in the warehouse allows you to separate materials into classes (such as A, B, C) and take inventory for each class separately several times throughout the year. With either inventory method, the basic inventory process remains the same once the inventory document is created. In this exercise, you can choose whether you would like to process an inventory using Continuous or Cycle Count as the inventory method. 1-1
You must make the appropriate entry in customizing to run the inventory method of your choice. 1.1.1
Remember that the inventory method is set in customizing at the storage type level. Decide whether you want to use Continuous or Cycle Count as your inventory method and set the method for storage type 002 appropriately.
1.1.2
If you chose Continuous as your inventory method, proceed to step 12.
1-1-3 If you chose Cycle Count as your inventory method, proceed to step 1-3.
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1-2
Continuous Inventory 1.2.1
Create an inventory document for continuous inventory in storage type 002. Select some empty bins and select at least one bin that contains a material. When you go to create the inventory document, all of the bins are initially selected. Choose Edit → Deselect All, then choose the bins you wish to include in your inventory document.
1.2.2
Activate the document immediately. Inventory document ____________
1.2.3
Print the inventory document.
1.2.4
Enter the results of the count. You can enter any quantities you like. If you enter a 0 quantity, be sure to select the Zero Count indicator.
1.2.5
Initiate a recount document.
1.2.6
Enter the results of the recount.
1.2.7
Look in the Information System for Warehouse Management and run the Differences List. Modify the report to show the Goods Receipt Date, Count Date, Total Stock, and Counted Quantity. Save your changes as a variant (Group-##).
1.2.8
Clear differences in the Warehouse Management system. Note the items that are to be cleared. Check the stock overview for one of the materials. Has the inventory balance been updated?
Material
StorType
Available
For Putaway
Pick Quantity
002 999 Total 1.2.9
Clear differences in Inventory Management. Material document number: _________________. Select the material document to view the transaction.
1.2.10 Display again the stock overview for one of the materials to verify the inventory balance has now been updated and your 999 storage type is clear. Material
StorType
Available
For Putaway
Pick Quantity
002
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1-3
Cycle Count 1.3.1
The cycle count indicator is set in the storage view of the material master. Run the CC Indicator Report to see the system recommendations for this indicator. Choose your area to analyze (Plant 1000) and look at all stock materials. Under Key Figures, choose Consumption/Usage and set the period to cover the last 3 months. You can override the CC Percentages that are set in customizing if you select the Change CC Percentages box (Note: this does NOT change customizing settings!). Under processing, select Display list first.
At the end of the report you will find a summary. Note the breakdown of ABC indicators: CC Indicator
Materials
Phys Inventories
Counts
A B C D 1.3.2
Look at the storage location view for the material T-BW02-##. What is the Cycle Count Indicator for this material? ____________
What does the CC fixed indicate? _________________________________ 1.3.3
Create a Cycle Count worksheet. If you are using a 4.6C System, you may choose to create the document by material or by quant. If you generate the inventory by quant, enter a range of materials from TBW-## to T-BW99-##. DeSelect all, then select 2 or 3 materials to count. Activate the document immediately.
Document Number: ________________ When you go to create the inventory document, all of the bins are initially selected. Choose Edit → Deselect All, then choose the bins you wish to include in your inventory document.
1-3-4 Print the inventory document. 1-3-5 Enter the results of the count. You can enter any quantities you like. If you enter a 0 quantity, be sure to select the Zero Count indicator.
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1.3.6
Initiate a recount document.
1.3.7
Enter the results of the recount.
1.3.8
Look in the Information System for Warehouse Management and run the Differences List. Modify the report to show the Goods Receipt Date, Count Date Total Stock and Counted Quantity. Save your changes as a variant (Group-##). LO530
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1.3.9
Clear differences in the Warehouse Management system. Note the items that are to be cleared. Check the stock overview for one of the materials. Has the inventory balance been updated?
1.3.10 Clear differences in Inventory Management. Material document number: _________________. Select the material document to view the transaction. 1.3.11 Display again the stock overview for one of the materials to verify the inventory balance has now been updated and your 999 storage type is clear. Material
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StorType
Available
LO530
For Putaway
Pick Quantity
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12.17Physical Inventory Processes with WM - Solutions Unit: Physical Inventory Processes with WM Topic: Continuous Inventory and Cycle Counting
1-1 1-1-1 Tools → Accelerated SAP → Customizing → Edit Project → Goto → SAP Reference IMG → Logistics Execution → Warehouse Management → Activities → Physical Inventory → Define Types per Storage Type Position on your warehouse 1## and storage type 002. If you choose to use the Continuous Inventory, set the inventory method to PZ. If you choose to use Cycle Counting, set the inventory method to ST and set the indicator for Cycle Count. 1-2 1-2-1 Logistics → Logistics Execution → Internal Whse Processes → Physical Inventory → In Warehouse Management → Physical Inventory Document → Create → Continuous Inventory Field Name or Data Type
Values
Warehouse Number
1##
Storage Type
002
Count Date
Today’s Date
Only bins not yet counted
Selected
1-2-2
Edit → Deselect all. Manually choose a few bins then select Physical Inventory Document → Activate. Save.
1-2-3
Logistics → Logistics Execution → Internal Whse Processes → Physical Inventory → In Warehouse Management → Physical Inventory Document → Print Whse Inventory List. System → Services → Output Controller. Execute. Select the report and choose Display.
1-2-4
Logistics → Logistics Execution → Internal Whse Processes → Physical Inventory → In Warehouse Management → Physical Inventory Document → Count Results → Enter.
1-2-5
Logistics → Logistics Execution → Internal Whse Processes → Physical Inventory → In Warehouse Management → Physical Inventory Document → Count Results → Recount.
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1-2-6
Logistics → Logistics Execution → Internal Whse Processes → Physical Inventory → In Warehouse Management → Physical Inventory Document → Count Results → Enter.
1-2-7
Logistics → Logistics Execution → Information System → Warehouse → Physical Inventory → With bin Inventory Management → Different List of Open Inventory Documents. Execute the report. Choose the Current Display Variant. Identify the fields you wish to add to the report, then select the arrow Show selected fields. Choose the Save Display Variant icon to save your changes.
1-2-8
Logistics → Logistics Execution → Internal Whse Processes → Physical Inventory → In Warehouse Management → Clear Differences → Warehouse Management → Display List. Select the lines to be cleared and choose Clear. When you check the stock balance (Favorites → Warehouse Management Stock Overview), you will notice that the inventory balance has not yet been updated. You can see that the bin is no longer blocked and the quantity at the bin is corrected, but there is an offsetting entry in the 999 Differences Storage Type.
1-2-9
Logistics → Logistics Execution → Internal Whse Processes → Physical Inventory → In Warehouse Management → Clear Differences → Inventory Management. Enter the storage type to clear (999) and execute. Select the line and choose clear.
1-3-1
Logistics → Materials Management → Physical Inventory → Special Procedures → Cycle Counting → Set CC Indicator
1-3-2
Logistics → Logistics Execution → Master Data → Material → Material → Display → Display Current Status. Enter your material number, then select the Storage Location View for Plant 1000, Storage Location 01##.
1-3-3
Logistics → Logistics Execution → Internal Whse Processes → Physical Inventory → In Warehouse Management → Physical Inventory Document → Create → Cycle Counting (Or choose Cycle Counting Quantwise). Execute the report, then Edit → Deselect all. Select what you wish to count then Activate the document.
1-3-4
Logistics → Logistics Execution → Internal Whse Processes → Physical Inventory → In Warehouse Management → Physical Inventory Document → Print Whse Inventory List.
1-3
System → Services → Output Controller. Execute. Select the report and choose Display. 1-3-5 Logistics → Logistics Execution → Internal Whse Processes → Physical Inventory → In Warehouse Management → Physical Inventory Document → Count Results → Enter. 1-3-6 Logistics → Logistics Execution → Internal Whse Processes → Physical Inventory → In Warehouse Management → Physical Inventory Document → Count Results → Recount.
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1-3-7 Logistics → Logistics Execution → Internal Whse Processes → Physical Inventory → In Warehouse Management → Physical Inventory Document → Count Results → Enter. 1-3-8 Logistics → Logistics Execution → Information System → Warehouse → Physical Inventory → With bin Inventory Management → Different List of Open Inventory Documents. Choose the Current Display Variant. Identify the fields you wish to add to the report, then select the arrow Show selected fields. Choose the Save Display Variant icon to save your changes. 1-3-9 Logistics → Logistics Execution → Internal Whse Processes → Physical Inventory → In Warehouse Management → Clear Differences → Warehouse Management → Display List. Select the lines to be cleared and choose Clear. The inventory balance has not yet been updated. You can see that the bin is no longer blocked and the quantity at the bin is corrected, but there is an offsetting entry in the 999 Differences Storage Type. 1-3-10 Logistics → Logistics Execution → Internal Whse Processes → Physical Inventory → In Warehouse Management → Clear Differences → Inventory Management. Enter the storage type to clear (999) and execute. Select the line and choose clear.
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13 Conclusion
Course Overview
1
Goods Issue
7
Logistics Execution Overview
2
Posting Changes
8
Warehouse Management Structure
3
Production Integration
9
Master Data
4
Delivery Processing
10
Integration with Inventory Management
5
Replenishment
11
Goods Receipt
6
Physical Inventory
12
Conclusion
13
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13.2 Course Objectives
You are now able to: Perform basic WM functions such as putaway and retrieval of stocks and process posting changes Customize the integration with Inventory Management, Production Planning and Delivery Processing Discuss customizing options and settings within the Warehouse Management system
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13.3 Recommended Follow-up Courses
LO531 Additional Topics in Warehouse Management LO610 Shipping LO611 Transportation
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13.4 Recommended Follow-up Activities
Go through the exercises using IDES data or your own data Read on-line documentation Read IMG documentation Read release notes
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13.5Warehouse Management Structure - Exercises 2 Unit: Warehouse Management Structure Topic: Storage Location Control At the conclusion of this exercise, you will be able to: •
Copy an existing warehouse •
Create two Storage Locations and assign them to your warehouse.
• Set up a Storage Location as the standard. • Set up the Storage Location to Storage Location Transfer Posting to be automatic when the Transfer Order confirmation for putaway occurs. • Send a mail message to the person confirming the Transfer Order if an error should occur. Your Delivery process is such that you want materials in the Goods Receipt area to be excluded from availability until they are put away to their final destination. Your delivery process considers materials in storage location 11## as available inventory. You want to create a new storage location 22## for your GR area. When you process materials from 22## to 11##, you want the storage location to storage location transfer to happen automatically upon Transfer Order confirmation. If an error should occur during the TO confirmation, you want to send a mail message to the person confirming the Transfer Order. 2-1
In your company, you want to structure your warehouse such that received materials are not available for sales order delivery notes until those materials are put away to their final storage type. Your delivery notes are created to ship from storage location 11##. You want to create a new warehouse (2##) with two storage locations (11## and 22##). 11## will be your standard storage location. 2-1-1 Copy warehouse 001 to your new warehouse 2##. 2-1-2 Create new Storage Locations 11## and 02## in Plant 1000. 2-1-3 Assign the new Storage Locations 11## and 22## to your Plant 1000, Warehouse 2##. 2-1-4 Establish Storage Location 11## as the standard storage location in Plant 1000 warehouse 2##. 2-1-5 In the same table, set up the new Storage Location 22## so it is not copied into the transfer requirement from the reference document. This allows the system to use the standard storage location (11##) when creating a Transfer Order from the Transfer Requirement. 2-1-6 Set up the Storage Location to Storage Location Transfer to be automatic upon confirmation of the Transfer Order used to move the goods from the
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interim GR area Sloc 22## into the main warehouse (Sloc. 11##) using a 311 movement type. In addition, send a message to the person confirming the Transfer Order in case an error should occur. 2-1-7 You will need some storage bins in storage type 001. Create 2 storage bins (Bin 01, Bin 02) manually. These bins are bin type P1, storage section 001. 2-2
Now test your configuration settings. 2-2-1 Create the Warehouse Management view for material T-BW08-## for warehouse 2##. You want this material to be directed to high rack storage upon receipt. There is a placement indicator HRL defined for this purpose. Set the Stock Placement and Stock Removal indicators to HRL for plant 1000, warehouse 2##. 2-2-2 Create a Purchase Order for material T-BW08-##. Note: Leave the storage location field blank. Standard PO Vendor:
1000 C.E.B Berlin
Purchasing Org.: 1000 IDES Deutschland Purchasing Grp.: 001 LO530 Company Code: 1000 SAP AG
Item Material 0001 T-BW08-##
Quantity
Dely
Plant
Price
100
Today
1000
15 UNI
PO Number: _______________________
2-2-3 Receive the goods into your warehouse and storage location 22## with reference to the above Purchase Order. Material Document
________________________
2-2-4 Display the Stock Overview for the material T-BW08-##. Plant (C) SAP AG
Sloc
StorType
Available LO530
For Putaway
Pick Qty 6
1000
2200
902
2-2-5 Create a Transfer Order with reference to the above Transfer Requirement. TO Number __________ 2-2-6 Display the Stock Overviews for the material T-BW08-##. Plant
Sloc
StorType
1000
1100
001
1000
1100
902
1000
2200
902
Available
For Putaway
Pick Qty
2-2-7 Confirm the Transfer Order. 2-2-8 Display the Stock Overview for the material T-BW08-##. Plant
Sloc
StorType
1000
1100
001
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Available
LO530
For Putaway
Pick Qty
7
13.6Warehouse Management Structure - Solutions 2 Unit: Warehouse Management Structure Topic: Storage Location Control
2-1 2-1-1 Tools → Accelerated SAP → Customizing → Edit Project → Goto → SAP Reference IMG → Enterprise Structure → Definition → Logistics Execution → Define, copy, delete, check warehouse number → Copy/Delete/Check Warehouse Number. Choose Copy org object. Field Name or Data Type
Values
From Warehouse Number
001
To Warehouse Number
2##
2-1-2 SAP Reference IMG → Enterprise Structure → Definition → Materials Management → Maintain Storage Location. Enter the plant value below, then choose New Entries. Field Name or Data Type
Values
Plant
1000
Sloc
11##
Description
Standard
Sloc
22##
Description
GR Location
2-1-3 SAP Reference IMG → Enterprise Structure → Allocation → Logistics Execution → Assign warehouse number to plant/storage location. Select New Entries.
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Field Name or Data Type
Values
Plant
1000
Storage Location
11## LO530
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Warehouse
2##
Plant
1000
Storage Location
22##
Warehouse
2##
2-1-4 SAP Reference IMG → Logistics Execution → Warehouse Management → Interfaces → Inventory Management → Define Storage Location Control → Control of Assignment “Plant/Stor.Loc – Whse Number”. Find your Storage Location 11## /Warehouse 2## combination and select Choose. Set the Standard stor loc field to On.
2-1-5 In the same table find the Storage Location 22## for your warehouse and set the Stor loc not in TR field to On.
2-1-6 SAP Reference IMG → Logistics Execution → Warehouse Management → Interfaces → Inventory Management → Define Storage Location Control → Stor Location Control in Warehouse Mgmt. Select New Entries.
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Field Name or Data Type
Values
Warehouse
2##
Storage Type
902
Plant
1000
Storage Location
22##
Movement Type
311
Combine post changes
Blank
Mail
A
Receiving Plant
Blank
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2-1-7 Logistics → Logistics Execution → Master Data → Warehouse → Storage Bin → Create → Manually
Field Name or Data Type
Values
Warehouse Number
2##
Storage Type
001
Storage Bin
Bin-01; Bin-02
Storage Section
001
Storage Bin Type
P1
2-2 2-2-1 Logistics → Logistics Execution → Master Data → Material → Material → Create → Immediately. Field Name or Data Type
Values
Material View
Warehouse Management 1
Plant
1000
Warehouse Number
2##
Storage Type
Blank
Stock Removal
HRL
Stock Placement
HRL
LE Quantity
50
Unit
PC
SUT
IP
2-2-2 Logistics → Materials Management → Purchasing → Purchase Order → Create → Vendor/Supplying Plant known.
2-2-3 Logistics → Logistics Execution → Inbound Process → Goods Receipt for Purchase Order, Order, Other → Enter Goods Receipt for Purchase Order. Enter your purchase order and line item number. Select the Where tab, enter Storage Location 22##, Select OK and Save.
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2-2-4 Favorites → Warehouse Management Stock Overview
2-2-5 Favorites → Display Transfer Requirement By Material Field Name or Data Type
Values
Warehouse
1##
Material
T-BW08-##
Plant
1000
Storage Location
Blank
Select the appropriate TR line item and choose TO in foregr. Choose Putaway background and save the TO.
2-2-6 Favorites → Total Stock per Material (Warehouse Management)
2-2-7 Favorites → Confirm TO, One Step. Enter the TO Number and choose Input List. Save. 2-2-8 Favorites → Total Stock per Material (Warehouse Management)
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14 Appendix
Contents: This section contains supplementary material to be used as reference This material is not part of the standard course Therefore, the instructor might not cover this during the course presentation
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14.2Frequently-used Menu Paths Activity
Menu Path
Master Data Create Storage Bin
Logistics → Logistics Execution → Master Data → Warehouse → Storage Bin → Create → Manually
Change Storage Bin
Logistics → Logistics Execution → Master Data → Warehouse → Storage Bin → Change → Single Bin
Display Storage Bin
Logistics → Logistics Execution → Master Data → Warehouse → Storage Bin → Display
Create Material Master
Logistics → Logistics Execution → Master Data → Material → Material → Create → Immediately
Change Material Master
Logistics → Logistics Execution → Master Data → Material → Material → Change → Immediately
Create Production Supply Area
Logistics → Logistics Execution → Master Data → Warehouse → Production Supply → Production Supply Area → Create/ Change
Create Control Cycle
Logistics → Logistics Execution → Master Data → Warehouse → Production Supply → Control Cycle Production Supply → Create
IM Processing Goods Receipt for Purchase Order
Logistics → Logistics Execution → Inbound Process → Goods Receipt for Purchase Order, Order, Other Transactions → Post Goods Receipt → Enter Goods Receipt for Purchase Order
Goods Receipt for Production Order
Logistics → Logistics Execution → Inbound Process → Goods Receipt for Purchase Order, Order, Other Transactions → Post Goods Receipt → Enter Goods Receipt for Production Order
Goods Receipt without Reference
Logistics → Logistics Execution → Inbound Process → Goods Receipt for Purchase Order, Order, Other Transactions → Post Goods Receipt →
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Activity
Menu Path Enter Goods Receipt for Other Activities
Display Material Document
Logistics → Logistics Execution → Inbound Process → Goods Receipt for Purchase Order, Order, Other Transactions → Post Goods Receipt → Display Material Document
Goods Issue for Cost Center
Logistics → Logistics Execution → Outbound Process → Goods Receipt for Other Transactions → Enter Goods Issue
Display Stock Balances (IM Perspective)
Logistics → Logistics Execution → Internal Whse Processes → Bins and Stock → Display → Total Stock per Material (Inventory Management)
Display Stock Balances (WM Perspective)
Logistics → Logistics Execution → Internal Whse Processes → Bins and Stock → Display → Total Stock per Material (Warehouse Management)
SD Processing Delivery Monitor
Logistics → Logistics Execution → Outbound Process → Goods Issue for Outbound Delivery → Outbound Delivery → Lists and Logs → Outbound Delivery Monitor
WM Processing Display Transfer Requirement
Logistics → Logistics Execution → Internal Whse Processes → TransRqmt → Display …
Create TO following Goods Receipt process
Logistics → Logistics Execution → Inbound Process → Goods Receipt for Purchase Order, Order, Other Transactions → Putaway → Create Transfer Order …
Confirm TO
Logistics → Logistics Execution → Inbound Process → Goods Receipt for Purchase Order, Order, Other Transactions → Putaway → Confirm Transfer Order → Single Item → In one step …
Display Stock Balances (WM Perspective)
Logistics → Logistics Execution → Internal Whse Processes → Bins and Stock → Display → Total Stock per Material (Warehouse Management)
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Activity
Menu Path
Display Posting Change Notice
Logistics → Logistics Execution → Internal Whse Processes → PostChange → Via Inventory Management → Posting Change Notice → Display → Single Document
Block/Unblock Storage Bins
Logistics → Logistics Execution → Internal Whse Processes → Bins and Stock → Block …
Mass Change Storage Bins
Logistics → Logistics Execution → Master Data → Warehouse → Storage Bin → Change → Selectively
Create Physical Inventory Document
Logistics → Logistics Execution → Internal Whse Processes → Physical Inventory → In Warehouse Management → Physical Inventory Document → Create …
Differences List
Logistics → Logistics Execution → Information System → Warehouse → Physical Inventory → With Bin Inventory Management (2nd one) → Different List of Open Inventory Documents
Clear Differences (WM)
Logistics → Logistics Execution → Physical Inventory → In Warehouse Management → Clear Differences → Warehouse Management
Clear Differences (IM)
Logistics → Logistics Execution → Physical Inventory → In Warehouse Management → Clear Differences → Inventory Management
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14.3 Warehouse Structure WAREHOUSE STRUCTURE R E C E I V I N G
902
003
0xx
002
001
005
100
PRODUCTION LINES -->
901 916
STORAGE TYPES 001 002 003 005 0xx
High-rack storage Shelf storage Open storage Fixed bin / Picking Temperature Controlled
901 902 916 100
SHIPPING
GR area from production GR area from external source Shipping area deliveries Production supply areas
SAP AG 1999
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14.4Case Study
R/3 System Release 4.0
LO530 Warehouse Management
Case Study
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Unit: Case Study
15Objective This case study has been created to challenge you and reinforce the concepts of the warehouse management application and customizing that you learned this week. The task is to customize a warehouse from a presented business scenario, then test the configuration using standard business processes. This week, you have been introduced to basic warehouse management processes within the R/3 system. At the beginning of the week, we looked at the application and focused on processing transactions in a warehouse that was already customized for this purpose. Later in the week, we made changes to that existing warehouse configuration and tested some transactions. Now, you will create a new warehouse using an existing warehouse structure as a model, and test your configuration using standard business transactions.
16Business Scenario Your company has decided to build a new warehouse because the existing warehouse has exceeded its capacity. This new warehouse will be used mainly for storage and shipping of finished pumps. Your team is responsible for creating and customizing this new warehouse so that standard business processes can be carried out using the SAP R/3 system.
On the following pages, you are given the information required to set up the structure and master data for this new warehouse. A description of the business processes and a rough layout of the new warehouse are included. Read through this information carefully before you proceed to the activities that follow.
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17Materials You will store the materials T-MS-##, T-BW-##, and T-BW20-## in the new warehouse. The following chart describes the palletization data for these materials. Use this chart when you are ready to enter the material master data later in the exercise. Material
Palletization
UoM
Pallet
T-MS-##
15
PC
IP
10
PC
E1
15
PC
IP
10
PC
E1
25
PC
E1
T-BW-## T-BW20-##
18Warehouse Structure You will have three different types of storage: a fixed bin storage area for picking, a shelf storage area for smaller amounts and partials, and a pallet storage area for full pallets. You will need to create some bins in each of these storage types. You can create the bins manually or automatically for each storage type. In your shelf storage, you will create some bins with bin type E1 and some with bin type P1.
19Processes For each material listed above, you want to carry a minimum quantity in the fixed bin of at least 10 PC. Upon goods receipt of these materials, you want them first to be placed in pallet storage, then in the shelf area if the pallet area is full. The fixed bins will be resupplied from the shelf storage area, then the pallet area. You will then test your configuration with goods receipts and goods issue for delivery. It is your process that goods issue in small quantities (less than 100) should be issued from the fixed bin storage type, while large quantities (greater than 100) are picked from the other storage areas. One way to consider your processes is to think about each movement type and how the business process in your company works with each movement type in the warehouse. The following matrix example is intended to help you make the decisions that are relevant to each movement type. In the first column, you would list the movement types that are necessary to support your business processes. In the second column, you can decide whether you need for that movement type to create a TR, not create a TR, or cancel an existing TR. In the TO column, indicate whether you want to create the TO manually, create it in the background automatically or using a batch process, or do you want to have the IM transaction call the TO creation. In the next column, should confirmation happen automatically or is confirmation of the TO a required step. Printing options to consider include whether you want to print one item on a page, multiple items on a page, multiple processing, or no printing at all. Once you have completed the matrix, you have the information you need to customize the warehouse movements according to your business requirements. The first line is provided as an example. It is not necessary for you to complete the table at this time. The table is provided here only as a reference. (C) SAP AG
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Reference Movement Type matrix: Movement Type
Transfer Requirement
Transfer Order
Confirmation
Printing (TO)
101
Create TR
Manual
Manual
Single item
102 122 201 311 312 501 561 601
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Warehouse Drawing
New Warehouse
Pallet Storage
Shelf storage
Goods Receipt
Fixed Bin Storage
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19.2.2Warehouse Configuration Structure In customizing under Enterprise Structure, create a new storage location: Copy storage location 01## as 02##. Remember that the storage location is the link between IM and WM. Still under Enterprise Structure, create the new warehouse by copying an existing warehouse. Warehouse 001 is delivered to you to use as a template for customizing your own warehouse. Copy warehouse 001 as 2##. 2## becomes your new warehouse number. Remember that the warehouse structures are copied, but master data for the warehouse is not, so you still need to create the master data records required for this warehouse. Still within the Enterprise Structure, assign your new warehouse to plant 1000 / new storage location 02##. (This activity activates the warehouse.) Moving to Warehouse management customizing, define the control parameters for warehouse number:
Change unit of weight if desired from KG to LB Allow Storage Unit management
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Number ranges definition: Verify that your new warehouse has an entry in each of the number range fields. If not, select the number ranges from your warehouse 1## and enter Copy As. NR-quant
NR-TO
NR-TR
NR-PstChg
NR-RefNo
NR-SU VA
01
01
01
01
01
01
2
Note: VA= Method of Assignment. Storage Type Definition: When you copied your warehouse, all of the standard storage types for warehouse 001 copied over to your new warehouse. You can create new storage types for the three storage areas defined in your business scenario, or you can use the standard storage types 002 for Shelf Storage, 005 for Fixed Bin Storage, 007 for Pallet Storage. If you create new storage types, use the standard storage type to copy from. In either case, verify that the storage types have the following characteristics:
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Shelf Storage SU Mgmt not active Stock placement control: Stock placement strategy: Next Empty Bin Stock placement requires confirmation SUT Check active Storage section check/search: Storage section determination and check Retain over deliveries Stock removal control: Stock removal strategy: FIFO Stock removal requires confirmation
Fixed Bin Storage SU Mgmt not active Stock placement control: Stock placement strategy: Fixed Bins Stock placement requires confirmation Addition to stock permitted Capacity check method based on maximum quantity per bin in storage type Stock removal control: Stock removal strategy: Fixed bin from material master Allow negative stock
Pallet Storage SU Mgmt not active Stock placement control: Stock placement strategy: Storage Unit Type Stock placement requires confirmation Mixed storage allowed without limitation Addition to stock permitted SUT Check active Stock removal control: Stock removal strategy: FIFO Complete removal active Return storage type 002
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Storage section definition: When you copied the warehouse, the storage sections were copied for the existing storage types. If you are not using the standard storage types, you need to create the following storage sections. If you are using the standard storage types, verify that the following sections exist: Shelf Storage:
Storage sections
001 - Fast moving items 002 - Slow moving items
Fixed Bin:
Storage section
001 - Total Section.
Pallet Storage:
Storage section
001 – Total Section
20Strategies Storage type indicators: Storage type indicators can be used to influence the storage type search sequence. If you would like to create a storage type indicator, make sure that you have an entry in the storage type search table for each storage type indicator that you create. Then tie that storage type indicator to the material master record for placement or removal. The material then will be directed to the storage type indicated in the storage type search table for that entry. Activate the new storage type search according to specifications described in the business process. Use the following table for reference.
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In the ”Storage Type Search” table above, for warehouse 200, when material with no storage type indicator is received (activity E) into unrestricted use or quality stock, it is placed into storage type 001, then 002. On removal (activity A), materials with no storage type indicator in unrestricted use or quality stock is picked from storage type 001, then 002. If material with a storage type indicator of FIX comes in for placement (activity E), it will be placed first in storage type 007 (pallet storage), and then in storage type 002 (shelf storage). For removal, (activity A) those materials will be picked from storage type 005, unless the reference movement type = 320 (replenishment), in which case the material will be resupplied from storage type 002, then 007. Storage Section Indicators: Storage section indicators can also be added to the material master record to direct specific materials into specific sections. In this case, we have said that in the storage type for fixed bins and pallets, there is only one section. In the shelf storage area, we have defined two sections: fast and slow moving. Be sure that there is an entry in the storage section search table for a blank storage section indicator.
The ”Storage Section Search” table above specifies that if material is received into storage type 002 with no storage section indicator, it will be directed first to storage section 001, then storage section 002. Materials with a storage section indicator of 001 will also be directed first into section 001, then 002. Materials with a storage section indicator of 002 will be directed first into section 002, then 001. Storage Unit Type definition: In the storage types for shelf storage and pallet storage, you indicated that the SUT Check was active. This means that the system will check the bin type against the storage unit type before allowing a putaway into a stoage bin. You will be working with pallet sizes E1 (Europallets) and IP (Industrial pallets). A Europallet will fit in either an E1 or P1 bin. The Industrial pallet will only fit in the P1 size bin. Under Definitions, you first verify that the bin types E1 and P1 and storage unit types E1 and IP exist. Under Assignments, specify that the storage unit types are allowed in the storage types for shelf and pallet storage. Storage Type (C) SAP AG
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Unit Type Shelf (002)
E1
IP
Pallet (007)
E1
IP
Check the assignment of storage unit type to storage bin type. The chart below indicates that pallet size E1 can go into bin sizes E1 or P1, and that IP can only go into storage bin type P1. Storage Unit Type
Storage Bin Type
E1
E1
IP
P1
P1
20.2.2Activities 20.3Movement Types Verify WM movement types were copied for your warehouse number. There are no changes to make to the standard WM movement types at this time.
20.4Inventory Define the Inventory method for each storage type. Continuous Inventory method (PZ) will be used for all three storage types.
20.4.2Interfaces 20.5Inventory Management - Movement Types Verify MM-WM Interface to inventory management. There are no changes to make to this table at this time. If you make any changes to this table based on the movement type matrix provided above, be sure to affect only your warehouse number.
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20.5.2Master Data Storage Bins
Storage Bin Definition: Storage bins will need to be created in all 3 storage types. These bins can be created manually or generated automatically using a template. Shelf and Pallet Storage: Create according to the structure: St. Type
Storage Section
Maximum Weight
Bin Type
Shelf
001
1000
E1
01-01-01 01-05-05
Shelf
002
2000
P1
02-01-01 02-05-05
Pallet
001
2000
P1
A-01
BIN
Begin
Material
Fixed Bin Storage: FIX-1##
Bin Structure End
A-10
Max Qty
T-MS-##
FIX-2##
T-BW-##
150
FIX-3##
T-BW20-##
250
150
You will also need to create the pre-defined storage bins for the interim storage types.
Remember that these bins are master data and are created from the WM menu. Add the material master warehouse view to the three materials you are testing with.
Use the information given to you in the business scenario to determine how to fill in the material master data below. Then, create the material master records/warehouse view as required for your new warehouse.
Warehouse 2## (Warehouse level data) Material
Palletization (LE Quantity)
U N
SUT
Stock Removal
Stock Placement
Addn to Stock
T-MS-## T-BW-## T-BW20-##
Fixed Storage Area (Storage Type level data) Material
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Minimum quantity
Maximum quantity
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Control quantity
Replenishment quantity 17
T-MS-## T-BW-## T-BW20-##
20.5.3Test your warehouse configuration 20.5.4 Goods Receipt Because you are creating the new warehouse to off load inventory from your existing warehouse, you will be moving material from the old warehouse into the new one using movement type 311, Storage location to storage location. Transfer the following quantities of materials from storage location 01## to storage location 02##: Material
Total
Industrial Pallets (IP)
Europallets (E1)
T-MS-##
65
3 pallets of 15
2 pallets of 10
T-BW-##
50
2 pallets of 15
2 pallets of 10
Goods Issue (Note: contact instructor if you are not familiar with the SD process)
Create a sales order for 5 pieces of T-BW20-##. Before saving the order, add storage location 02## to the line item‘s shipping detail. Create a Delivery Note with reference to the Sales Order you created. Create a Transfer Order with reference to the delivery note. Was the quantity picked from your fixed bin picking area? If so, confirm the TO and post goods issue. (Note: remember that you can post the goods issue by putting a 2 in the Adopt pick qty field from the TO confirmation screen.) Customer
1400
Sales Org.
1000
Dist. Channel
10
Division
00
Stor. Location
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20.5.5OPTIONAL: Additional set-up Change the movement type 101 in the MM – WM movement type table to create transfer orders automatically. Be sure to work only in your warehouse! (You will need to copy the entry provided for warehouse *** to your own warehouse number.) In addition, have a mail message sent to your user-id if there are any errors. Step 1: Copy the appropriate 101 entry in the MM-WM movement type table and set the field IM WM to A. Step 2: Look at the Mail column and select the appropriate entry. (To verify that customizing, look under Activities Transfers Setup automatic TO creation for TRs and posting change notices.) Step 3: Test your configuration. Create a Purchase order for 50 pieces of T-BW20-## data: Vendor
using the following
1000
Purchasing Org.
1000
Purchasing Group 001 Plant
1000
Stor. Location
02##
Step 4: Receive 10 pieces into your warehouse. Your TO should be created automatically and you will need to confirm it. Step 5: Create a pre-allocated stock entry for 10 pieces of the material. Step 6: Receive the remaining 40 pieces into your warehouse. (Your TO will not be created automatically and you will get an express message in your inbox describing the error).
Set-up a special movement indicator, so that a goods receipt (101) for material T-BW-## will be placed directly in Fixed bin storage (005). Change the MM-WM table so that a TR and a TO are not created for movement type 101. Again, please be sure to affect only your warehouse! Step 1: Create a special movement indicator in customizing (master data). Step 2: Create a new WM movement type. (Copy 101. Change the source storage type to 005 and Fixed Bin.) Step 3: Copy the appropriate 101 entry in the MM-WM table. Enter your warehouse number, the new special movement indicator, reference the new WM movement type you created to the 101 Reference movement type and remove the TR create flag.
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Step 4: You can tie the special movement indicator to the material master record for T-BW-##, or you can enter the special movement indicator at the time of the goods receipt by clicking on WM parameters. Step 5: Test. Create a Purchase Order for 10 pieces of T-BW20-##. Receive the goods. Check the WM parameters.
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Menu Path Aid for Case Study Customizing: Create Storage Location: Enterprise Structure Maintain Structure Definition Materials management Maintain storage location. Select New Entries.
Copy a Warehouse: Enterprise StructureMaintain Structure Definition Materials management Define, copy, delete, check warehouse number. Select the ‘Copy Warehouse’ icon.
Change Warehouse Description: Enterprise Structure Maintain Structure Definition Materials management Define, copy, delete, check warehouse number. Select ‘New Entries’. Assign Warehouse to Storage Location and Plant: Enterprise Structure Maintain Structure Assignment Materials management Assign warehouse number to plant / storage location. Select New Entries. Define / Change Control Parameters for warehouse: Materials Management Warehouse Management Master Data Define control parameters for warehouse number.
Define / Change Number Ranges: Materials Management Warehouse Management Master Data Define number ranges Assignment. Define / Change Storage Types: Materials Management Warehouse Management Master Data Define storage type.
Define / Change Storage Sections: Materials Management Warehouse Management Master Data Define Storage Sections. Storage Type Indicators / Search Sequence: Materials Management Warehouse Management Strategies Activate storage type search.
Storage Section Indicators / Search Sequence: Materials Management Warehouse Management Strategies Activate storage section search. Storage Unit Type Search: Materials Management Warehouse Management Strategies Activate storage bin type search.
Define Special Movement Indicator: Materials Management Warehouse Management Master Data Material Define Special Movement Indicator. (C) SAP AG
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Master Data: Create Storage Bins Manually: Logistics Materials management Warehouse management Master data Storage bin Create Manually. Create Storage Bins Automatically: Logistics Materials management Warehouse management Master data Storage bin Create Automatically.
Create Storage Bins for Interim Storage: Logistics Materials management Warehouse management Master data Storage bin Create For interim storage. Create Material Master: Logistics Materials management Warehouse management Master data Material Create.
Change Material Master: Logistics Materials management Warehouse management Master data Material Change.
IM Processing: Storage Location to Storage Location: Logistics Materials management Inventory management Goods movement Transfer posting.
Display Stock Balances from IM: Logistics Materials management Inventory management Environment Stock Stock overview.
SD Processing: Create a delivery note: Logistics Sales and distribution Shipping Delivery Create.
WM Processing: Display Transfer Requirement: Logistics Materials management Warehouse management TransRqmt Display By storage type (leave storage type blank for all TRs to display).
Display Transfer Order: Logistics Materials management Warehouse management TransOrder Display List Create Transfer Order from Transfer Requirement: From TR display, select a TR and ‘TO in foregr.’ Select ‘Palletization’; ‘Stock plcmnt foregrnd’; ‘Enter’; ‘Generate+next mat.’ (C) SAP AG
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‘Save’.
Confirm Transfer Order: Logistics Materials management Warehouse management TransOrder Confirm Transfer Order Display Stock Balances from WM: Logistics Materials management Warehouse Management Master data Material Stock Stock Overview (or Stock Bin Stock). Create a TO for a delivery: Logistics Materials management Warehouse management TransOrder Create For delivery.
Create entry for Pre-Allocated Stock: Logistics Materials management Warehouse management TransOrder Pre-allocated stock
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