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Required Configuration for Replenishment

Configuring a Replenishment Wave requires the following steps:

  1. Setting up locations for replenishment
  2. Setting up replenishment rules
  3. Setting up task templates
  4. Creating a Replenishment Template

Step 1: Setting up Replenishment and Allocation Zones

Replenishment requires two types of locations: replenishment and allocation zones. Replenishment zones are locations that you replenish to, while allocation zones are locations that you pick from for replenishment.

To Configure the Replenishment Zone:

  1. Go to the “Replenishment Zone” screen.
  2. Define the different replenishment zones for the warehouse using the Create button.
  3. Once the replenishment zones are created, go to the “Locations” screen.
  4. Choose a location to replenish to by assigning it a replenishment zone. To do this, select the location and click Edit.
  5. Scroll down to the “Replenishment Zone” field and select the appropriate zone from the drop-down.
  6. Locations with replenishment zones also require item assignments. Item assignments tell the system what item this location is replenished with. To do so, change the location’s “Item Assignment Type” to “Permanent” and populate the SKU code in the “Item” field.
  7. Click “Save”.

Configuring the Allocation Zone:

  1. Go to the “Locations” screen.
  2. Select the location that you will replenish from and click Edit.
  3. Scroll down to the “Alloc zone” field and populate an allocation zone. This value is used in the replenishment template for defining which allocation zone will provide the replenishment.
  4. Click “Save”.

Step 2: Create the Replenishment Template

Next, you need to create the Replenishment template and define the parameter:

  1. Go to the “Replenishment Template” screen.
  2. Click Create () to create a new template.
  3. Fill in the desired parameters.
  4. Click Save.

Description of Fields

  • Area: Configures WMS to exclusively look at the populated area to replenish to.
  • Template Name: Enter the template name.
  • Replenishment Zone: Determines which replenishment zones the template searches for.
  • Replenishment Rule: Allows you to select which rule to use for the current template.
  • Task Creation Template: Allows you to select which task template to use for the current template.
  • Replenishment Trigger Mode: Determines the trigger mode (see replenishment modes described in section 5.1).
  • Wave Search - Wave Search Templates are used as filters for selecting specific Orders during a wave. Each search template has a set of fields that are configurable.
  • Percentage of Max: Triggered when the volume of items in the location goes below the location’s pre-configured percentage of maximum volume. Additional configurations:
    • Locations with Replenishment Zones need the Length, Width, and Height fields populated.
      • Locations with Replenishment Zones require Min/Max Volumes populated.
      • You should populate the “Percentage of Max” field in the replenishment template. This percentage value is used as criteria for triggering a location based on the location’s maximum volume.
        • For example, say that Location A’s Max Volume = 100 and Percentage of Max = 20%. If the location’s total volume goes below 20 (100*0.2 = 20), the location is triggered for replenishment.
  • Allow Expired Inventory: If the flag is enabled, the system allows you to replenish inventory that exceeds the expiry date.

Step 3: Setting up Task Templates

  1. Go to the “Task Creation Template” screen.
  2. Click “Create” () to create a new Task Template.
  3. Select this template and click on Details () to view its details.
  4. Click “Create” () to create the appropriate task types and their ordering/selection criteria.
    • For LPN replenishment, select “Full LPN Replenishment”.
    • For Cases replenishment, select “Cases Replenishment”.
    • For Units replenishment, select “Consolidate Replenish”.
  5. Click Save

Step 4: Setting up Replenishment Rules

Much like the Wave Template’s “Allocation Mode”, the Replenishment Template uses Replenishment Rules to define the types of allocations that are used for replenishment.

  1. Go to the “Replenishment Template” screen.
  2. Click on the “Replenishment Rule” button to access the rules.
  3. Click Create to create a new rule. To access its details, select it and click Details.
  4. To create a new allocation UOM, from the Replenishment Rule Sequence screen click Create and populate the appropriate fields.
  5. Click Save.
Note: To create a Secondary Allocation Method for Replenishment Waves: (Allocations created for Replenishment to Reserve or Active):
  1. Go to the Replenishment Template>Replenishment Rules>>Replenishment Rule Sequence.
  2. Populate the secondary allocation method.

Replenishment and Round Up One UOM

Note: The 'Round Up One UOM' and 'Ignore Capacity for Last Permanent Location' options can be used only for order-based replenishment and movement requests, and are not intended for standalone replenishment.

The following are some example scenarios for when the Round up One UOM Flag is set to Yes:

Scenario Source Inventory LPNs Movement Request Need Destination Location Max Replenishment Result
Dynamic Location mentioned on Movement Request LineReplenishment UOM is "LPNs". Multiple LPNs of 60 units each 90 200 Replenishment to be created for 120 Units (Allocate Two LPNs of 60 units).
Dynamic Location mentioned on Movement Request LineReplenishment UOM is "LPNs". Multiple LPNs of 60 units each 90 100 Dynamic Location will be replenished to 60 units. Replenishment of another 60 units will take incoming inventory beyond location max.
Movement Request Line has Replenishment Zone mentioned which has multiple Dynamic locations Multiple LPNs of 60 units each 190 Loc-1: 100Loc-2: 100 Replenishment 60 Units to Location-1 and 60 Units to Location-2 as we do not want to go beyond max for dynamic location.
Permanent Location is mentioned on Movement Request line and Replenishment UOM is "LPNs". Multiple LPNs of 60 units each 90 100 Replenish only 60 Units, we will not go beyond locations Max.

These are some example scenarios for when the Ignore Capacity for Last Permanent Location flag is set to yes.

Round Up One UOM Flag Ignore Capacity for Last Permanent LocationFlag will have no bearing Result
Yes No

We replenish permanent locations by one excess UOM. Applicable for UOMs for LPNs, cases and packs. If the outstanding need is > combined location max. Replenishment will happen for one excess UOM and not satisfy the need.

Example: Location max is 1000 and Order need is 250 and LPN's of 60 units present. Replenishment will happen for 300 units. If Location Max is 200 and Order Need is 170 and we have LPNs of 70 Units each, we will replenish upto 140 and subsequent LPN will not be replenished as we go beyond the location's max.
No No

This is the defualt behavior. With this replenishment beyond locations, max is not supported.

Example: Location max is 1000 and Order need is 250 and LPNs of 60 units present. Replenishment allocation will created for 240 units, if the underlying movement request does not allow partial allocation.
No Yes

This is the defualt behavior. With this replenishment beyond locations, max is not supported.

Example: Location max is 1000 and Order need is 250 and LPNs of 60 units present. Replenishment allocation will created for 240 units, if the underlying movement request does not allow partial allocation.
Yes Yes

We replenish permanent locations by one excess UOM. Applicable for UOMs for LPNs, cases and packs. If the outstanding need is > combined location max. Replenishment will happen for one excess UOM and not satisfy the need.

Description of Fields

  • Replenishment Rule: allows you to select which rule to use for the current template.
  • Sequence Nbr: Sequence for creating task types, if there are more than one within the template.
  • Location Type: Locations in WMS represent storage locations in the warehouse. Locations have different types depending on how they are used within the warehouse.
  • Restrict area: populating this field tells WMS to exclusively look at the populated area to replenish from.
  • Restrict alloc zone: populating this field tells WMS to exclusively look at the populated allocation zone (which was defined earlier) to replenish from.
  • Allocation Method: defines the order in which LPNs are selected for replenishment.
  • Replenishment UOM: defines the UOM that is allocated for replenishment.
    • Note: Units replenishment only works for Active locations.
  • Consolidate and Distribute Replen: if this flag is checked, WMS allocates replenishment from multiple locations. This flag only works with Unit and Cases replenishment.
    • Note: Units replenishment only works for Active locations.
  • Consolidate and Distribute Replen: if this flag is checked, WMS allocates replenishment from multiple locations. This flag only works with Unit and Cases replenishment.
  • Round Up One Uom: The Round Up One UOM flag allows you to replenish beyond the need by one extra UOM (LPNs/cases/packs) for all of the eligible locations. When the Round Up One UOM flag is configured in the Replenishment Rule Header, the system replenishes by one extra UOM compared to the outstanding need of the location (see example below). When the Round Up one UOM flag is combined with the Ignore Capacity for Last Permanent Location Flag, the required need is replenished to the destination location when the replenishment UOM is LPNs/cases/packs. If the Ignore Capacity for Last Permanent Location Flag is set to no and the Round Up one UOM flag is enabled, then the destination location is replenished by one extra UOM when the need is not an integral multiple of the LPN/case/pack quantity.

Step 5: Wave Inquiry

The Wave Group Inquiry screen will show the status of the Wave run. Choose the Allocation View in this screen. Once Allocation completes, the wave will generate a Task. It will also create an internal order.