warehouse and dc management (lean wm)
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Warehouse and DC Management (Lean WM). SAP Best Practices for Retail. Purpose, Benefits, and Key Process Steps. Purpose - PowerPoint PPT PresentationTRANSCRIPT
Warehouse and DC Management (Lean WM)
SAP Best Practices for Retail
© 2012 SAP AG. All rights reserved. 2
Purpose, Benefits, and Key Process Steps
Purpose This scenario describes the processing of merchandise in the distribution center with
inventory management done at the level of storage location – Lean Warehouse Management.
Benefits Since storage procedures depend on space limitations, organization and the type of
merchandise being stored, this scenario should be seen as one example of an implementation. However, this example can be easily adjusted to fit the warehouse of SAP customer.
Key Process Steps Goods Receipt Processing Return Deliveries Goods Issue Processing Warehouse Physical Inventory Tools and Workbenches
© 2012 SAP AG. All rights reserved. 3
Required SAP Applications and Company Roles
Required SAP Applications SAP SAP enhancement package 6 for SAP ERP 6.0
Company Roles Retail Store Manager Retail Master Data Manager Retail Replenishment Planner Retail Warehouse Specialist
© 2012 SAP AG. All rights reserved. 4
Process Flow DiagramWarehouse and DC Management (Lean WM)
Create Purchase Order
Goods Receipt with Reference to Rough
Goods Receipt
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Posting Rough Goods Receipt
Create Inbound Delivery
© 2012 SAP AG. All rights reserved. 5
Process Flow DiagramWarehouse and DC Management (Lean WM) – Return Deliveries (Optional)
Article document for goods receipt
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Output of article document as goods
issue slip
Create Return Delivery
© 2012 SAP AG. All rights reserved. 6
Process Flow DiagramWarehouse and DC Management (Lean WM) – Goods Issue Processing
Create Outbound Delivery
Alternative 2: Confirmation with
fifference
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Alternative 1: Confirmation
without differences
Create transfer order as picking
document
Post goods issueMass processing of outbound deliveries
© 2012 SAP AG. All rights reserved. 7
Process Flow DiagramWarehouse and DC Management (Lean WM) – Warehouse Physical Inventory (Optional)
Create physical inventory document
Process physical inventory
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Clearing differences
Alternative 1: Manual creation of physical inventory
Alternative 2: Creation of physical inventory via batch-
input
Analyse physical inventory
© 2012 SAP AG. All rights reserved. 8
Document Flow in the Warehouse
GOODS ISSUEGOODS ISSUE
GOODS RECEIPTGOODS RECEIPT
FIXEDSTORAGEBIN
PUTAWAYTRANSFER ORDER
PUTAWAYTRANSFER ORDER
PICKINGTRANSFER ORDER
PICKINGTRANSFER ORDER
Outb. Del.Outb. Del.
POPO
Inb. DeliveryInb. Delivery
Rough GRRough GR
There is no stock keeping in Lean-WM, but just recordingof movements usingtransfer orders.
optional
optional
© 2012 SAP AG. All rights reserved. 9
Inventory Management - IM vs. WM
Storage LocationSite
Inventory Management on article level
Fixed storage bin can be maintained in the article master (text field)
No additional level of stock keeping below IM.
Warehouse number and type are just used for the recording of stock movements using the transfer order, but no stock posting is triggered when moving merchandise at this level.
Whose numberStorage type
© 2012 SAP AG. All rights reserved. 10
Using Lean WM
When you implement Lean WM, inventory management takes place solely at storage location level. The system does not update the stock data at storage bin level using the quants like the Warehouse-Management-System (WMS) .
You use Lean WM solely for processing goods receipts and goods issues. Using Lean WM, you process the warehouse movements in basically the same way as if using the Warehouse Management System: you work with deliveries, and you create transfer orders for these deliveries. These transfer orders serve as pick lists.
The use of transfer orders in Lean WM provides the following advantages:
• You can reprint transfer orders at any time. • You can split transfer orders and thus distribute the workload better among
the staff in your warehouse. • You can use mass processing functions based on the transfer order (for
example wave picks).
© 2012 SAP AG. All rights reserved. 11
Mass Processing of Deliveries
Manual creation in the outbound delivery monitor using selection by:
Shipping point Picking date Route, carrier ... Free selection
Automatic generation using selection by: Picking date / time Additional filter by several criteria (e.g. route, shipping point, ship-to-party ...)
Considering capacity restrictions: Weight, volume Maximum items on the picking list Working time ...
Group of Outbound Deliveries
orWave Pick
DeliveryDelivery
DeliveryDelivery
DeliveryDelivery
DeliveryDelivery
DeliveryDelivery
DeliveryDelivery
DeliveryDelivery
© 2012 SAP AG. All rights reserved. 12
Mass Processing of Deliveries
Collective Follow-On-Processing:
Create transfer order Confirm transfer order Post goods issue
Group of Outbound Deliveries
orWave Pick
DeliveryDelivery
DeliveryDelivery
DeliveryDelivery
DeliveryDelivery
DeliveryDelivery
DeliveryDelivery
DeliveryDelivery
© 2012 SAP AG. All rights reserved. 13
Rough Workload Estimate
Information on:
needed manpower needed transport capacity
Estimated Workload in:
Quantity Weight Volume Execution time
Calculation of workload using:
Logistics Load Category Unit of Measure Whse no. / storage type Warehouse process
Planned Goods Issue
DeliveryDelivery
DeliveryDelivery
DeliveryDelivery
DeliveryDelivery
DeliveryDelivery
© 2012 SAP AG. All rights reserved. 14
Processes Goods Receipt and Return Deliveries
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Processes Picking and Goods Issue
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Process Physical Inventory
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