Replenishment in SAP Warehouse Management

 Replenishment in WM

 

Source: https://wiki.scn.sap.com/wiki/display/ERPSCM/Replenishment+in+WM

Purpose

Consider the following example to understand the concept and need of replenishment.
Example : There is a rack with three compartments (Upper, middle and lower)

When the stock is manually picked by a worker in warehouse, it is always easier to pick it from the lower compartment than picking it from the middle or the upper compartment.

Now consider a scenario that the stock at the lowest compartment is consumed. And there is a new pick request for the stock. The person who would carry the stock now needs to take extra efforts to access the stock at the higher compartments. If this continues then it will be tedious and time consuming.

This is where the replenishment is important.

Whenever the stock in the lower compartment is minimum, we fill the compartment with the stock from middle/upper compartments.

Necessary Customization

The replenishment is configured by the following steps:

1. At material master, go to Warehouse management view 2 and under 'Storage bin stock', maintain the fields fixed bin, maximum quantity, minimum quantity and replenishment quantity.
   
   
   
   
   Minimum quantity - This the basis to trigger the replenishment. The replenishment is possible only when the current stock in the bin is less than this minimum quantity.
   where current stock in a bin = available quantity + pick quantity + putaway quantity (These values are taken from LQUA table)
   Maximum quantity - This is the quantity upto which the bin is to be filled or replenished.
   Note : As per the standard design, it is mandatory to maintain the positive value for the maximum quantity.
   Replenishment quantity - The bin is replenished with the multiples of this quantity.

2.     Under the path SPRO -> Logistics Execution --> Warehouse Management --> Activities -->Transfers --> Define movement types, use movement type 319 for replenishment.

3. Under SPRO -->Logistics Execution --> Warehouse Management --> Activities -->Transfers --> Define stock transfers and replenishment control, assign movement type 319 against Storage type with replenishment technique 1.

3. Run transaction LP21 to create TR if the Stock < Min Quantity  (or schedule batch job on program RLLNACH1). LP21 shows the available quantity in the bin and the requested quantity. The TR can be created for this requested quantity.

Note : If you require that the replenishment TO's are created automatically after the immediate confirmation of the removal TO(such that the bin quantity is less than minimum), this would have to be handled with user exits and WM enhancements. WM enhancement MWMTO001 can be used where there is a call to function L_REP_TO_CREATE_FROM_USEREXIT.

Enhancements

The following enhancements can be used by the customers to make the other customization as per the business requirement.

Enhancement :  MWMRP001
Short text : Customer Exit for Fixed Bin Replenishment.: Delivery Item Selection

Enhancement :  MWMRP002
Short text : Customer Exit for Fixed Bin Replenishment: TR Quantity Distribution

Enhancement :  MWMRP003
Short text : Customer Exit for Replenishment using RLLNACH1

Case Scenario

Consider a bin which has current stock of 5 PC. At material master level, the minimum quantity is 10 PC, maximum quantity is 100 and replenishment quantity is 10.
Now current stock (5 PC) < minimum quantity (10 PC)

Now when the replenishment is carried out via LP21, the requested quantity should be 90 (multiples of replenishment quantity 10). And if the replenishment is successful then the total quantity in the bin becomes 95 PC.

In case, if the requested quantity is less than 90(expected), then there might  be picked / putaway stock for the bin which can be seen by checking open Transfer requirements in LB11 and open Transfer orders in Tcode LT24.