Replenish Primary Locations Overview
What is replenishing primary locations? The Replenish Primary Locations function, initiated through Working with Replenishment Control (MSRP), is used to determine whether inventory should be moved from secondary or bulk locations to the primary picking locations. The replenishment program:
1. Analyzes the inventory level in the primary location to determine if additional inventory is needed.
2. Analyzes the secondary and/or bulk locations to determine the quantity to transfer and the location from which to transfer.
3. Provides a report detailing the transfer information, and, optionally, several reports which sort or consolidate information.
4. Creates a request that can be used to process the inventory transfer transactions for approved quantities and locations.
You can specify which location types will be used to replenish the primary locations, and the quantities to replenish.
You can run the Replenish Primary Locations program at any time, and multiple times throughout the day.
Replenishment and radio frequency: If you are using radio frequency and you have the LPN Tracking (E16) system control value selected, the system will not generate a Replenishment Control request. When you create a replenishment control request, the system will analyze the inventory level in both the primary and secondary/bulk locations and generate a Replenishment Detail by 'From' Location Report. The request you create will not generate and will clear from the screen. See Radio Frequency Overview.
Let down replenishment: Let down replenishment is automatic restocking of primary locations initiated by the system when you generate pick slips. The system can recommend, or recommend and immediately process, a replenishment transfer, to ensure that inventory quantities in primary locations will be adequate for the pick slips you have generated. The Let Down Replenishment (C36) system control value determines whether the system initiates replenishment when you generate pick slips, and whether the system completes the replenishment transfer, or recommends but does not complete the transfer.
• If the Let Down Replenishment (C36) system control value is set to RPT/EXEC, the system generates the Replenishment Detail by 'From' Location Report during pick slip generation, creates the Replenish Control record, and immediately processes the item transfers. The Replenish Control record is automatically deleted once the process is complete.
• If the Let Down Replenishment (C36) system control value is set to REPORT, the system generates the Replenishment Detail by 'From' Location Report during pick slip generation and creates the Replenish Control record; however:
• If the LPN Tracking (E16) system control value is unselected, you must use the Working with Replenishment Control (MSRP) menu option to process the item location transfers.
• If the LPN Tracking (E16) system control value is selected, the system resets the Pending quantity for the item locations back to what it was before Let Down Replenishment was run and deletes the Replenishment Control request in Working with Replenishment Control (MSRP). You must perform RF transactions to move the recommended replenishment quantity to the primary location; see Radio Frequency Overview.
See Let Down Replenishment for more information on the processing that occurs during let down replenishment.
In this topic:
• Primary Location Replenishment Setup
• Primary Location Replenishment Processing
• Processing a Primary Location Replenishment
• Determining the Locations to Replenish
• Primary Location Replenishment Example
Primary Location Replenishment Setup
Before you can process a primary location replenishment, you must complete the required setup. Setup includes:
You can determine how the Primary Location Replenishment process will be used by completing the following system control values.
Note: The following system control values settings relate to Primary Location Replenishment. To view the system control value settings required for Let Down Replenishment, see Let Down Replenishment.
System Control Value |
Description |
Allows you to determine the location types from which inventory will be pulled to replenish the primary picking locations. • BULK = The system replenishes from bulk locations only. • SECONDARY = The system replenishes from secondary locations only. • SEC/BULK = The system replenishes from bulk and secondary locations. When both location types are used, the system will replenish from bulk locations first in earliest placement date/item location creation sequence, then from secondary locations in earliest date/item location creation sequence. |
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Allows you to include the number of units needed to fulfill printed pick tickets in the replenishment calculation. By using this option, the system reduces the on-hand quantity in the primary location by the number of units that are to be picked before determining the quantity to replenish. The system also reduces the quantity on-hand in the location that will be used to replenish the primary location by this amount, before determining the quantity available to move. |
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Allows you to determine whether replenishments will be initiated when you generate pick slips, and whether the replenishments will be immediately processed based on the system-recommended inventory transfers, or will be recommended but not processed. If this system control value is set to REPORT, the system creates the Replenish Control record and details; however, inventory transactions are not processed and a report is not generated automatically. You can use the Working with Replenishment Control (MSRP) menu option to print Replenishment Detail reports for each replenishment request, or print consolidated replenishment reports for several replenishments generated on the same day. You can then confirm and process the item transfers after reviewing the reports. See Let Down Replenishment for more information on the processing that occurs during let down replenishment. |
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Defines the print program used to print consolidated replenishment reports: • Consolidated Replenishment Report by From Location • Consolidated Replenishment Report by Item/SKU • Consolidated Replenishment Report By To Location You can use these reports to consolidate replenishment information from multiple let down replenishment transactions processed on the same day. To print consolidated replenishment reports, the following system control values must be set to these values: • Replenish from Location Type (A66): BULK, SECONDARY, or SEC/BULK. • Check Location Quantities During Pick Generation (C54): Selected • Let Down Replenishment (C36): REPORT Leave this field blank if you do not want to print consolidated reports. Regardless of the setting of this system control value, you can print detailed replenishment reports using the Working with Replenishment Control (MSRP) menu option: • Replenishment Detail by 'From' Location Report |
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Defines the print program used to generate Replenishment Transfer Labels during Primary Location Replenishment. The base print program name is FLR0382. |
Type: Identifies which locations can be replenished, and which locations will be used to replenish. Valid location types are primary, secondary, bulk, and temporary. Primary locations are the only locations that will be replenished; secondary and bulk locations are the only location types that can be used to replenish the primary location.
Freeze: The freeze status of the location indicates whether the location is on hold. If the primary location is frozen, it cannot be replenished. If the secondary or bulk location is frozen, inventory in the location cannot be used to replenish a primary location.
Note: Locations can be automatically flagged for Physical freeze during physical inventory. See Resetting the Freeze Flags (RPFF).
The following fields must be completed for the replenishment calculation to be performed.
Min qty: The minimum number of units of the item/SKU that should be kept in the item location. When the on-hand quantity of the item in the location falls below this number, the item/location is eligible for replenishment.
Max qty: the maximum number of units of the item/SKU that should be kept in the item location. If a Reorder quantity is not specified, the system will attempt to replenish the location until the on-hand quantity reaches the amount defined in the Max qty field.
Reservation freeze: Indicates whether the item location is frozen. If the item in the primary location is frozen, it cannot be replenished. If the item in the secondary or bulk location is frozen, inventory in the location cannot be used to replenish a primary location. In addition, Pick Slip Generation does not print pick slips for an item/location that is frozen.
Physical freeze: If the item location’s physical freeze status is selected, the inventory in the location will not be available to replenish the primary location. The physical freeze status of the primary location being replenished is not evaluated in the replenishment process.
Placement date: The system uses the placement date to determine the order in which bulk and secondary locations are used to stock the primary locations. The system will replenish from bulk locations first in earliest placement date/item location creation sequence, then from secondary locations in earliest placement date/item location creation sequence.
Reservation freeze: Indicates whether the item warehouse is frozen. If the item is frozen at the warehouse level, it will not be evaluated for replenishment at any location.
Primary Location Replenishment Processing
Purpose: The Replenish Primary Locations program uses values in the System Control table, the Item Location table, the Location table, and the Item Warehouse table to determine the locations to replenish and the locations used to replenish them.
Let down replenishment: Let down replenishment is automatic restocking of primary locations initiated by the system when you generate pick slips. The system can recommend, or recommend and immediately process, a replenishment transfer, to ensure that inventory quantities in primary locations will be adequate for the pick slips you have generated. The Let Down Replenishment (C36) system control value determines whether the system initiates replenishment when you generate pick slips, and whether the system completes the replenishment transfer, or recommends but does not complete the transfer. See Let Down Replenishment for more information on the processing that occurs during let down replenishment.
Processing a Primary Location Replenishment
Use the following steps to process a Primary Location Replenishment.
1. Create the Primary Location Replenishment.
Use the Working with Replenishment Control (MSRP) menu option to create the Primary Location Replenishment.
• Select Create at the Work with Replenish Control Screen to advance to the Create Replenish Control Screen.
• At the Create Replenish Control Screen, define the warehouse and optionally, zone(s) and aisles you wish to replenish and select OK.
The system submits the RPLN_STK job, which:
• Evaluates the primary locations to replenish.
• Determines where to get the inventory (secondary, bulk, or both secondary and bulk, depending on the setting of the Replenish from Location Type (A66) system control value).
• Creates the Replenishment Control request.
• Generates the Replenishment Detail by 'From' Location Report, indicating the quantity the system recommends moving from secondary or bulk to the primary item locations.
• Generates the Replenishment Transfer Labels.
See Determining the Locations to Replenish for more information on the calculations the system performs to determine the locations to replenish.
As the system evaluates the primary locations to replenish and the quantities that will be moved from the bulk and/or secondary locations to replenish them, a record for each pending transfer transaction is added to the Replenishment Control request. When the request is generated:
• The Pending field in the Item Location table for the primary location is increased by the total quantity to transfer.
• The Pending field in the Item Location table for each bulk and secondary location that will be used to replenish the location is decreased by the quantity to transfer from that location.
2. Move the recommended replenishment quantity to the primary locations.
You can use the following reports as a worksheet when moving the stock:
• Replenishment Detail by 'From' Location Report (generated when you create the Primary Location Replenishment; also generated from the Work with Replenish Control Screen)
• Replenishment Detail Report by Item (generated from the Replenishment Confirmation by Item Screen)
• Replenishment Detail Report by 'To' Location (generated from the Replenishment Confirmation By To Location Screen)
Note: If you do not move the recommended replenishment quantity (you can move an amount less than the recommended quantity), make note of the amount actually moved so that you can update the Quantity moved field for the Replenish Control record.
3. Optionally, update the system recommended primary location replenishment transfers for the Replenish Control record.
You can review the system recommended replenishment transfers for the Replenish Control record at the following screens:
• Replenishment Confirmation By To Location Screen
• Replenishment Confirmation by Item Screen
• Replenishment Confirmation by From Location Screen
At these screens, you can update the Quantity moved field if you did not move the recommended replenishment quantity. However, the quantity you enter cannot exceed the recommended replenishment quantity. If you did not move any quantity of the item to the primary location, leave the Quantity moved field blank.
4. Confirm the replenishment.
Select Confirm for the Replenish Control record at the Work with Replenish Control Screen and select OK.
You can also confirm each record in the Replenish Control record individually at the following screens. You may wish to confirm each record in the Replenish Control record individually if you did not move the recommended replenishment quantity for all of the item locations.
• Replenishment Confirmation By To Location Screen
• Replenishment Confirmation by Item Screen
• Replenishment Confirmation by From Location Screen
5. Process the primary location replenishment.
Select Process for the Replenish Control record at the Work with Replenish Control Screen to process the primary location replenishment.
The system submits the RPLN_UPD job, which:
• Increases the on-hand quantity in the primary location by the transaction amount.
• Decreases the pending transfer quantity in the primary location by the transaction amount.
• Decreases the on-hand quantity in the location from which the inventory was transferred by the transaction amount.
• Decreases the pending transfer quantity in the location from which the inventory was transferred by the transfer amount.
• Updates the Inventory Transaction History table with the transaction activity.
• Deletes the processed replenishment control request from the system.
If an item/location is defined in multiple primary item location replenishments: A separate Replenish Control request is created each time you run the Replenish Primary Locations program, or each time the system initiates the Replenish Primary Locations program to perform Let Down Replenishment as a result of pick slip generation. Only one replenishment request for an item/location can exist. If a replenishment request has been generated for the item/location, the item/location will not be evaluated for further replenishment until the request is processed.
Determining the Locations to Replenish
Each primary location in the zones and aisles you select using the Working with Replenishment Control (MSRP) menu option is evaluated to determine if the location requires replenishment.
The system will replenish from bulk locations first in earliest placement date/item location creation sequence, then from secondary locations in earliest placement date/item location creation sequence.
The freeze status of the location is evaluated. If any of the following fields is selected, the location will not be replenished:
Table |
Field |
Item Warehouse |
Reservation freeze |
Location |
Freeze |
Item Location |
Reservation freeze flag |
Calculating the replenishment quantity: The on-hand quantity in the primary location is evaluated to determine if the location requires replenishing. The on-hand quantity is adjusted if there are any pending transfers to or from the location, or if the printed quantity is to be included in the calculation. The following calculation is performed to determine the adjusted on-hand quantity:
On-hand qty + Positive pending transfer quantity - Negative pending transfer quantity - Printed quantity (if included) = Adjusted on-hand quantity
• The amount of any pending transfers to the location (a positive pending transfer quantity) is added to the on-hand quantity so that the location is not over-replenished.
• The amount of any pending transfers from the location (a negative pending transfer quantity) is subtracted from the on-hand quantity so that the location is not under-replenished.
• The Include Print Quantity in Available Calculations (A65) system control value determines whether the quantity on printed pick tickets can be included in the calculation so that the location will also be replenished for the items currently being shipped.
If the location's adjusted on-hand quantity is less than the minimum amount for the location (from the Min qty field in the Item Location record), the system evaluates the maximum quantity defined for the location (from the Max qty field in the Item Location record) and performs the following calculation to determine the quantity to replenish: Maximum quantity - Adjusted on-hand quantity = Replenishment Quantity
Determining where to get the inventory: Once the replenishment quantity required for the primary location is calculated, the system evaluates the locations from which the inventory can be moved and the quantities available to move before the replenishment request is complete.
For example, there may not be enough inventory in the warehouse to meet the replenishment requirements for a particular location, or the required amount may come from more than one secondary or bulk location.
The Replenish from Location Type (A66) system control value defines the location types from which stock can be moved. If both bulk locations and secondary locations are to be used, the system will replenish from bulk locations first in earliest placement date/item location creation sequence, then, if there is insufficient stock in the bulk locations to fulfill the replenishment requirement, from secondary locations in earliest placement date/item location creation sequence.
The freeze status of the location is evaluated. If any of the following fields is selected, the location will be ignored:
Table |
Field |
Item Location |
Reservation freeze flag |
Item Location |
Physical freeze |
Calculating the quantity to move: If the location is eligible to be used to replenish a primary location, the following calculation is performed to determine the available quantity to move from the secondary or bulk location:
On hand quantity - Printed quantity (if included) - Negative pending transfer quantity = Quantity to Move
• Negative pending transfer quantities indicate that inventory in the location is in the process of being transferred from the location, but the transfer is not yet reflected in the on-hand quantity. Because this inventory has already been marked for transfer, it is subtracted from the on-hand quantity so that it will not be included in multiple transfers.
• Positive pending transfer quantities indicate that inventory is in the process of being transferred to the location, but the transfer is not yet reflected in the on-hand quantity. Because the inventory may or may not be in the location, it is not included in the on-hand quantity.
• If the Include Print Quantity in Available Calculations (A65) system control value is selected, the quantity on printed pick tickets is included in the calculation.
All eligible locations are evaluated in earliest placement date/item location creation sequence until the optimum quantity to replenish is reached, or until all eligible locations have been evaluated.
Break a case? If you have specified a Pieces/case (Pieces per case) quantity for the item, the system avoids breaking a full case when calculating the replenishment quantity.
• Example 1: The item has a Pieces per case quantity of 70, and the primary location requires a replenishment quantity of 70. There are currently two item locations available to replenish the item: location BULK1 has a quantity of 5, and location BULK2 has a quantity of 70. The system selects the entire quantity in BULK1 and BULK2 for the replenishment, for a total replenishment quantity of 75, in order to avoid breaking the full case in BULK2.
• Example 2: The item has a Pieces per case quantity of 70, and the primary location requires a replenishment quantity of 50. There are currently 65 units of the item available to for replenishment in BULK1. Since the quantity in BULK1 does not constitute a full case of 70, the system selects a quantity of 50 to replenish the primary location.
Primary Location Replenishment Example
In this example, the Replenish from Location Type (A66) system control value is set to SEC/BULK. The Include Print Quantity in Available Calculations (A65) system control value is selected.
The following item locations exist for item VCS20PSB in warehouse 5.
Location |
Type |
Max |
Min |
On Hand |
Printed |
Pending |
Date |
B1 |
Bulk |
120 |
12 |
120 |
0 |
-108 |
4/06 |
B2 |
Bulk |
120 |
12 |
24 |
0 |
0 |
4/05 |
S1 |
Secondary |
60 |
12 |
60 |
0 |
0 |
4/04 |
S2 |
Secondary |
60 |
12 |
60 |
0 |
0 |
4/03 |
M1 |
Primary |
60 |
12 |
6 |
2 |
2 |
4/02 |
M2 |
Primary |
60 |
12 |
13 |
0 |
-6 |
4/01 |
When you create a Primary Location Replenishment for warehouse 5, the system:
• Calculates the Adjusted on hand quantity for the primary item locations: On hand quantity + Positive pending quantity - Negative pending quantity - Printed quantity = Adjusted on hand quantity.
Location |
On Hand Qty |
Pending Qty |
Printed Qty |
Adjusted On Hand Qty |
M1 |
6 |
2 |
2 |
6 |
M2 |
13 |
-6 |
0 |
7 |
• If the Adjusted on hand quantity is less than the Minimum quantity for the primary item location, the system calculates the Replenishment quantity for the primary item locations: Maximum quantity - Adjusted on hand quantity = Replenishment quantity.
Location |
Min Qty |
Max Qty |
Adjusted On Hand Qty |
Replenishment Qty |
M1 |
12 |
60 |
6 |
54 |
M2 |
12 |
60 |
7 |
53 |
Total quantity to move to replenish the primary item locations: |
107 |
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• Calculates the available quantity to move from bulk and secondary locations: On hand quantity - Printed quantity - Negative pending transfer quantity = Quantity available to move.
Location |
On Hand Qty |
Printed Qty |
Pending Qty |
Available Qty to Move |
B1 |
120 |
0 |
-108 |
12 |
B2 |
24 |
0 |
0 |
24 |
S1 |
60 |
0 |
0 |
60 |
S2 |
60 |
0 |
0 |
60 |
Total quantity eligible to replenish primary locations: |
156 |
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• Determines the sequence in which to take stock from the eligible locations. The system first looks at bulk locations in Earliest placement date/Item location creation sequence. If the bulk locations cannot fulfill the replenishment quantity, the system then looks at secondary locations in Earliest placement date/Zone/Aisle sequence. In this example, the sequence is:
• B2: Bulk location; Placement date 4/05
• B1: Bulk location; Placement date 4/06
• S2: Secondary location; Placement date 4/03
• S1: Secondary location; Placement date 4/04
• Creates the Replenish Control record and generates the Replenishment Detail by 'From' Location Report, indicating the recommended replenishment quantity to move from bulk and secondary locations to the primary locations.
From Location |
From Location Type |
To Location |
Replenishment Qty |
B1 |
Bulk |
M1 |
12 |
B2 |
Bulk |
M1 |
24 |
S2 |
Secondary |
M1 |
18 |
S1 |
Secondary |
M2 |
11 |
S2 |
Secondary |
M2 |
42 |
• Updates the Pending quantity for the item locations, based on the recommended replenishment quantities:
Location |
Type |
Max |
Min |
On Hand |
Printed |
Pending |
B1 |
Bulk |
120 |
12 |
120 |
0 |
-120 |
B2 |
Bulk |
120 |
12 |
24 |
0 |
-24 |
S1 |
Secondary |
60 |
12 |
60 |
0 |
-11 |
S2 |
Secondary |
60 |
12 |
60 |
0 |
-60 |
M1 |
Primary |
60 |
12 |
6 |
2 |
56 |
M2 |
Primary |
60 |
12 |
13 |
0 |
47 |
• Once you confirm and process the Primary Location Replenishment, the system updates the On hand quantity and Pending quantity for the item locations:
Location |
Type |
Max |
Min |
On Hand |
Printed |
Pending |
B1 |
Bulk |
120 |
12 |
108 |
0 |
-108 |
S1 |
Secondary |
60 |
12 |
49 |
0 |
0 |
M1 |
Primary |
60 |
12 |
60 |
2 |
2 |
M2 |
Primary |
60 |
12 |
66 |
0 |
-6 |
Note: The system deleted item locations B2 and S2 because the system reduced the on hand quantity to 0.
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