Replenishment

DATASCOPE WMS has two main replenishment systems.

  • Simple Replenishment System
  • Directed Replenishment
  • Replenishment mass check
  • Mass Based Inventory Adjustment

The first is a simple replenishment process that monitors all pick face bin stock levels and compares these to the reorder level set against each bin. Depending on the replenishment setting selected on the bin the module will:

  1. Replenish to the bin max level based on reorder level
  2. Replenish to the bin min level based on reorder level
  3. Replenish to the bin max level plus SYSPRO sales order demand in the next X days (where X days is a warehouse setting) or picking slip demand (based on reorder level)
  4. Replenish a set replenishment qty (based on reorder level)
  5. Replenish to the reorder level plus SYSPRO sales order demand in the next X days (where X days is a warehouse setting) or picking slip demand

Replenishments generated in this program automatically load a mobile device task to have the stock pulled from the correct source warehouse (as set against the pick face setup). The TrackID to fetch stock from can be selected by the user or forced by the system based on FIFO or smaller quantity TrackIDs.

Certain lines will be flagged as critical automatically if there is not enough stock in the pick face bin to satisfy demand for the pick face (bearing in mind some orders will be split over pick face and bulk). Additionally, lines can be flagged as urgent from the sales order allocation screen if the user is unable to release picking slips to the floor due to pick face shortages. Both urgent and critical lines can be viewed separately by scanner operators on the floor to action immediately.

Users can select specific pick face zones to replenish allowing for easy work load distribution. The stock can be replenished in a single step mode where the users scans the stock from the bulk bin location and directly to the pick face or in a two-stage replenishment mode where a pallet is built up and then moved to the pick face to put away. Several screens are available for eth put away process depending on the level of stock control required – carton level replenishment, item by item scanning or quantity entry.

This replenishment mode allows for advanced requirement calculations and then makes use of the wave release option to generate the replenishments in the format of a picking slip.

Demand Calculations

There is not one magic rule for calculating replenishment orders. Some calculations can be quite simply yet others can be very complex. Some may be a movement to a Pick face bin others may be a replenishment to another bulk location. In some warehouses, the replenishment system is used to generate a consolidate order pick to move stock to the floor for detailed order picking. Due to this the DATASCOPE WMS system allows for custom scripted replenishment calculations to be embedded into the software. Typically, when using this module, a custom rule would be discussed, written and applied to the site.

Once the replenishment orders have been loaded, the module has a full wave release screen to review the replenishments and then release that as picking slips in logical groupings. For instance, you may review all replenishment order and then sort them by bulk warehouse bin zones. You could then release a separate picking slip per zone or Aisle in a zone. This helps to optimize the picking of replenishment orders.

In another scenario, you may want to release the picking slips by pick face zone. Here you will be less efficient when picking in the bulk area but your replenishment order will be easy to put away into the pick face.

Yet another scenario would be to generate a replenishment by bulk warehouse zone to optimize the bulk picking and then release a second replenishment order from the staging area to the pick face where the pick is grouped by pick face zone.

The release of replenishment picking slips works in the same way as all picking in the DATASCOPE WMS software in that the picking slip is assigned to a picker and all detail is tracked including what was picked from where to where at what time by whom.

This module performs a mass check on a replenishment pallet. For many companies, this is not a requirement but in some mass driving operations this is important. One such example is in a food manufacturing operation. Here we may call for a replenishment of a food or chemical ingredient which must be weight to confirm that mass before it is issued to production.

This function is like the mass check above but it has been designed to correct any mass variance of lot controlled product going into a pick face warehouse. Here a replenishment may call for 40 pounds of a product to be placed into a pick face. A single bag of the product is picked and delivered to the pick face warehouse entrance. Before simply scanning this into the pick face the back can be placed on a conveyor that integrates to this software to process a weight check. The screen then processes any small positive or negative stock adjustment to get the mass correct. Ensuring the mass is correct before moving the stock into a pick face bin helps to ensure that we do not get picking errors later where the picking transacts 2.34 pounds to a job but DATASCOPE WMS only has 2.1 pounds in the bin.