Table Of Content

Warehouse Management Guide Release 4 .6C H E L P . L E W M Warehouse Management Guide SAP AG Copyright © Copyright 2001 SAP AG. All rights reserved. No part of this publication may be reproduced or transmitted in any form or for any purpose without the express permission of SAP AG. The information contained herein may be changed without prior notice. Some software products marketed by SAP AG and its distributors contain proprietary software components of other software vendors. ® ® ® ® ® ® ® Microsoft , WINDOWS , NT , EXCEL , Word , PowerPoint and SQL Server are registered trademarks of Microsoft Corporation. ® ® ® ® ® ® ® ® ® IBM , DB2 , OS/2 , DB2/6000 , Parallel Sysplex , MVS/ESA , RS/6000 , AIX , S/390 , ® ® ® AS/400 , OS/390 , and OS/400 are registered trademarks of IBM Corporation. ® ORACLE is a registered trademark of ORACLE Corporation. TM ® ® INFORMIX -OnLine for SAP and Informix Dynamic Server are registered trademarks of Informix Software Incorporated. ® ® ® ® UNIX , X/Open , OSF/1 , and Motif are registered trademarks of the Open Group. ® HTML, DHTML, XML, XHTML are trademarks or registered trademarks of W3C , World Wide Web Consortium, Massachusetts Institute of Technology. ® JAVA is a registered trademark of Sun Microsystems, Inc. ® JAVASCRIPT is a registered trademark of Sun Microsystems, Inc., used under license for technology invented and implemented by Netscape. SAP, SAP Logo, R/2, RIVA, R/3, ABAP, SAP ArchiveLink, SAP Business Workflow, WebFlow, SAP EarlyWatch, BAPI, SAPPHIRE, Management Cockpit, mySAP.com Logo and mySAP.com are trademarks or registered trademarks of SAP AG in Germany and in several other countries all over the world. All other products mentioned are trademarks or registered trademarks of their respective companies. 2 April 2001 SAP AG Warehouse Management Guide Icons Icon Meaning Caution Example Note Recommendation Syntax April 2001 3 Warehouse Management Guide SAP AG Contents Warehouse Management Guide ......................................................................13 Warehouse Structure in the Warehouse Management System.............................................. 17 Warehouse Number .................................................................................................................... 22 Storage Type................................................................................................................................ 23 Storage Section ........................................................................................................................... 26 Picking Area................................................................................................................................. 28 Storage Bin .................................................................................................................................. 29 Creating Storage Bins .............................................................................................................. 31 Editing Storage Bins................................................................................................................. 34 Blocking and Unblocking Storage Bins .................................................................................... 36 Displaying the Bin Status Report ............................................................................................. 38 Displaying Warehouse Capacity .............................................................................................. 39 Quant ............................................................................................................................................ 40 Door .............................................................................................................................................. 41 Staging Area ................................................................................................................................ 43 Warehouse Management with Lean WM................................................................................... 44 Setting Up Lean WM................................................................................................................ 46 Basic Functions........................................................................................................................... 48 Number Ranges........................................................................................................................... 49 Foreground/Background Processing........................................................................................ 51 Bar Code Use............................................................................................................................... 52 Authorization Checks ................................................................................................................. 53 Displaying Authorization Groups and Table Views.................................................................. 55 Archiving and Reorganization ................................................................................................... 56 Warehouse Controlling............................................................................................................... 58 Displaying Material Movement Data ........................................................................................ 61 Function Modules and Customer Exits in WMS....................................................................... 62 WM in the SAP Retail System .................................................................................................... 66 Planning and Monitoring ............................................................................................................ 67 Rough Workload Estimate.......................................................................................................... 68 Wave Picks................................................................................................................................... 70 Wave Picks with Capacity Restrictions .................................................................................... 72 Creating Wave Picks - Delivery Time ...................................................................................... 74 Processing Wave Picks............................................................................................................ 77 Subsequent Functions for Wave Picks .................................................................................... 78 Warehouse Activity Monitor....................................................................................................... 81 Unconfirmed Transfer Orders .................................................................................................. 84 Open Transfer Requirements................................................................................................... 85 Open Posting Change Notices................................................................................................. 87 Open Deliveries........................................................................................................................ 88 Critical Stock ............................................................................................................................ 89 Critical TRs for Production Supply ........................................................................................... 91 Using the Warehouse Activity Monitor ..................................................................................... 92 Example: Displaying Unconfirmed Transfer Orders ........................................................... 95 4 April 2001 SAP AG Warehouse Management Guide Basic Stock Management ........................................................................................................... 97 Material Master Data ................................................................................................................... 98 Defining Warehouse Data in the Material Master .................................................................... 99 Displaying the Material Master Record .................................................................................. 101 The Quant and Stock Management in WM.............................................................................. 102 Changing Quant Data ............................................................................................................ 105 Displaying Quant Information................................................................................................. 106 Types of Stock........................................................................................................................... 107 Stock Category .......................................................................................................................... 109 Displaying Stock in the Warehouse ....................................................................................... 111 Blocking Stock in the Warehouse .......................................................................................... 112 Units of Measure ....................................................................................................................... 113 Batch Management ................................................................................................................... 116 Shelf Life Expiration Date......................................................................................................... 118 Displaying Materials with a Shelf Life Expiration Date (SLED).............................................. 119 Storing Materials in the Warehouse ........................................................................................ 120 WM Interface to Inventory Management (IM).......................................................................... 121 Interim Storage Bins............................................................................................................... 123 Creating Interim Bins with Predefined Coordinates.......................................................... 125 Order of Postings in Integrated WM....................................................................................... 126 Posting First in IM ............................................................................................................. 127 Posting First in WM........................................................................................................... 128 Comparing Stock Quantities in WM and IM...................................................................... 129 Hazardous Materials Management .......................................................................................... 130 Hazardous Material Records.................................................................................................... 132 Creating and Using Hazardous Material Records.................................................................. 133 Hazardous Material Evaluation Reports ................................................................................. 135 Displaying the Fire Department Inventory List ....................................................................... 136 Checking for Proper Storage of Hazardous Material ............................................................. 137 Displaying Stock with Hazardous Substances....................................................................... 138 Warehouse Movements ............................................................................................................ 139 Basics for Goods Movements.................................................................................................. 143 Movement Types in WM............................................................................................................ 144 Using Special Movement Indicators....................................................................................... 147 Transfer Requirement ............................................................................................................... 150 Creating Transfer Requirements............................................................................................ 152 Creating Transfer Requirements ...................................................................................... 154 Processing Transfer Requirements .................................................................................. 156 Transfer Order ........................................................................................................................... 159 Creating Transfer Orders ....................................................................................................... 161 Automatic Creation of TOs for Transfer Requirement ...................................................... 163 Using a Transfer Order as a Pick Order in Lean WM....................................................... 164 Displaying Transfer Orders .................................................................................................... 165 Print Transfer Orders and Labels........................................................................................... 166 Printing Transfer Orders and Labels................................................................................. 170 Evaluating Transfer Orders .................................................................................................... 172 Confirming Transfer Orders ................................................................................................... 173 Confirming Transfer Orders .............................................................................................. 175 April 2001 5 Warehouse Management Guide SAP AG Packaging Notification to Shipping ................................................................................... 177 Cancelling Transfer Orders .................................................................................................... 178 Transfer Order Split................................................................................................................ 179 Performance Data .................................................................................................................. 181 Planned Data .................................................................................................................... 182 Entering of Actual Data ..................................................................................................... 183 Handling Differences ................................................................................................................ 185 Clearing Differences............................................................................................................... 187 Storage of Pre-Picked Handling Units .................................................................................... 188 Putting Away, Picking, and Transferring Pre-Packed HUs .................................................... 191 Goods Receipt ........................................................................................................................... 193 Creating Transfer Orders Immediately at the IM Posting...................................................... 195 Manual Creation of Transfer Orders for Putaway .................................................................. 197 Posting a Goods Receipt Based on a Purchase Order ......................................................... 200 Posting Returns for Deliveries................................................................................................. 201 Goods Receipt for Inspection .................................................................................................. 202 Releasing Material from Inspection Stock.............................................................................. 204 Releasing Stock in IM from Inspection................................................................................... 205 Goods Receipt Without a Previous Posting in IM.................................................................. 206 Example: Sample ABAP to Follow-up Postings in IM............................................................ 208 Creating a TO in WM without a Previous Posting in IM......................................................... 209 Negative Stock Check............................................................................................................... 211 Stock Placement Using Storage Unit Types........................................................................... 212 Example: Using Storage Unit Types ...................................................................................... 213 Cross-Docking........................................................................................................................... 214 Stock Placement with Active Bypass ..................................................................................... 215 Setting up Active Bypass for Putaway ................................................................................... 216 Adding Goods to Existing Stock ............................................................................................. 217 Goods Issue............................................................................................................................... 218 Goods Issues Based Upon a Delivery..................................................................................... 220 Random Picking Using Transfer Orders ................................................................................ 222 Pick-and-Pack During Picking........................................................................................... 224 Picking from a Fixed Bin without a Transfer Order ................................................................ 226 Picking Quantities Based on Size .......................................................................................... 227 Goods Issue for a Delivery..................................................................................................... 228 Creating a Delivery ........................................................................................................... 229 Automatic Creation of Transfer Orders for Outbound Delivery......................................... 230 Confirming a Transfer Order for a Delivery....................................................................... 232 Processing Differences for a Delivery............................................................................... 233 Partial Picking ................................................................................................................... 234 Creating a TO for a Cancelled Delivery ............................................................................ 235 Goods Issue Based on an IM Posting ..................................................................................... 236 Goods Issue to a Cost Center................................................................................................ 238 Posting a Goods Issue to a Cost Center .......................................................................... 239 Creating a Transfer Order for a Material Document ......................................................... 240 Manual Creation of Transfer Orders for Picking.................................................................... 241 Goods Issue for Production Supply........................................................................................ 242 6 April 2001 SAP AG Warehouse Management Guide Pick Part ................................................................................................................................. 245 Crate Part ............................................................................................................................... 246 Release Order Part ................................................................................................................ 247 Setting up the Interface between PP and WM....................................................................... 248 Production Supply Areas .................................................................................................. 249 Creating a Control Cycle................................................................................................... 250 Production Storage Bins ................................................................................................... 251 The Material Staging Process................................................................................................ 252 Creating a Production Order ............................................................................................. 253 Displaying a Production Order .......................................................................................... 254 Releasing a Production Order........................................................................................... 255 Automatic Staging for WM ................................................................................................ 256 Displaying TRs for Material Staging ................................................................................. 258 Creating TRs for Material Staging Manually ..................................................................... 259 Processing TRs for Material Staging ................................................................................ 261 Posting a Goods Issue for Material Usage ....................................................................... 263 Kanban Replenishment.......................................................................................................... 264 Handling Cancelled Kanbans............................................................................................ 267 Material Staging for Repetitive Manufacturing ....................................................................... 269 Staging Release Order Parts for Repetitive Manufacturing.............................................. 272 Multiple Processing .................................................................................................................. 273 Selecting TRs for Multiple Processing ................................................................................... 275 Selecting Deliveries for Multiple Processing .......................................................................... 277 Sample Report: Multiple Processing Selection................................................................. 278 Creating Transfer Orders for a Group.................................................................................... 279 Releasing Groups .................................................................................................................. 280 Confirming TOs for a Group................................................................................................... 281 Partial Processing of TRs and Deliveries............................................................................... 282 Analysis of Groups ................................................................................................................. 283 2-Step Picking............................................................................................................................ 285 2-Step Picking Process .......................................................................................................... 287 Work Method 1: Delivery to Goods................................................................................... 288 Work Method 2: Goods to Delivery................................................................................... 292 How to Carry Out 2-Step Picking ........................................................................................... 294 Using the Analysis Tool for 2-Step Picking ............................................................................ 297 Bestandsfindung ....................................................................................................................... 298 WM Interface to Quality Management ..................................................................................... 300 How the QM Interface Process Works .................................................................................... 301 Making Stock Placements Using the QM Interface ............................................................... 302 Examples: Making a Usage Decision .................................................................................... 305 Finding an Inspection Lot in the Warehouse ......................................................................... 308 Examples for the Putaway of Inspection Stock ..................................................................... 309 After Usage Decision: Sample Stored ................................................................................... 310 After Usage Decision: Stock Returned to Vendor.................................................................. 311 After Usage Decision: Sample Destroyed.............................................................................. 312 Before Usage Decision: Sample Stored ................................................................................ 313 Before Usage Decision: Stock Returned to Vendor............................................................... 314 Before Usage Decision: Sample Destroyed........................................................................... 315 Stock Transfers and Replenishment....................................................................................... 316 April 2001 7 Warehouse Management Guide SAP AG Plant/Storage Location to Plant/Storage Location ................................................................ 317 Internal Stock Transfers ........................................................................................................... 319 Moving Stock from One Storage Bin to Another .................................................................... 320 Replenishing Fixed Bins in the Warehouse ........................................................................... 321 Executing Replenishment for Fixed Bins ............................................................................... 322 Choose Logistics ( Logistics Execution ( Internal Whse Processes ( Stock Transfer ( Planning of Replenishments ( Based Upon Outb. Deliveries to be Selected from the SAP menu. ................................................................................................................................ 323 Creating a Replenishment TO During TO Confirmation........................................................ 324 Posting Changes in WM ........................................................................................................... 326 Processing Posting Changes................................................................................................... 327 Displaying Posting Change Notices....................................................................................... 328 Automatic Creation of TOs for Posting Change Notices........................................................ 329 Processing Posting Changes Entirely Within WM................................................................. 330 Example: Changing the Status of Consignment Stock .......................................................... 332 Processing Inspection Stock ................................................................................................... 334 Releasing Stock from Inspection............................................................................................ 336 Releases from More than One Storage Type ........................................................................ 338 Releasing Consignment Stock from Inspection .................................................................... 339 Processing Blocked Stock ....................................................................................................... 340 Converting Available Stock to Inspection Stock ................................................................... 341 Changing a Material Number.................................................................................................... 342 Dividing Materials into Two or More Batches ........................................................................ 344 Changing Stock Ownership from Plant to Plant .................................................................... 345 Storage Locations in TRs, TOs and Posting Changes.......................................................... 346 Possible Scenarios Based on Storage Locations .................................................................. 348 Example: Stock Movement from GR Area........................................................................ 350 Example: Material Staging for Production ........................................................................ 352 Putaway and Picking Strategies .............................................................................................. 354 Putaway Strategies ................................................................................................................... 355 Manual Entry .......................................................................................................................... 359 Strategy F: Fixed Bin Storage................................................................................................ 360 Strategy C: Open Storage...................................................................................................... 362 Strategy I: Addition to Existing Stock ..................................................................................... 363 Strategy L: Next Empty Storage Bin ...................................................................................... 365 Strategy K: Putaway near Picking Bin ................................................................................... 366 Strategy P: Storage Unit Type ............................................................................................... 367 Example: Optional SUT Check When Creating a TO....................................................... 370 Strategy B: Bulk Storage........................................................................................................ 371 Combined Placement........................................................................................................ 374 Partial Quantities............................................................................................................... 375 Blocking Transfers into a Row .......................................................................................... 376 Defining Time Limits for Block .......................................................................................... 377 Total .................................................................................................................................. 378 Round Off.......................................................................................................................... 379 Strategy Q: Dynamic Quant Number ..................................................................................... 380 Additional Factors that Affect Search Strategies .................................................................. 381 Cross-Line Stock Putaway..................................................................................................... 382 8 April 2001 SAP AG Warehouse Management Guide Capacity Checking ................................................................................................................. 385 Capacity Checking Based on a Neutral Indicator ............................................................. 387 Picking Strategies ..................................................................................................................... 390 Strategy F: FIFO (First In, First Out) ...................................................................................... 392 Strategy: Stringent FIFO Across All Storage Types............................................................... 393 Strategy L: LIFO (Last In First Out)........................................................................................ 394 Strategy A: Partial Quantities First ......................................................................................... 395 Strategy M: According to Quantity ......................................................................................... 396 Example: Rounding Off Requested Quantities ................................................................. 398 Strategy H: Shelf Life Expiration Date ................................................................................... 399 Strategy P: Fixed Storage Bin................................................................................................ 400 Stock Return Methods .............................................................................................................. 401 Storage Unit Management ........................................................................................................ 403 Warehouse Management at the Storage Unit Level............................................................... 405 SU-Managed Storage Types..................................................................................................... 407 Putaway using Storage Unit Management.............................................................................. 409 Creating Storage Units........................................................................................................... 410 Creating Homogeneous Storage Units ............................................................................. 412 Creating Mixed Storage Units for a TR............................................................................. 413 Adding Materials to an Existing Storage Unit ................................................................... 414 Creating Storage Units Manually ...................................................................................... 415 Automatic Bin Search............................................................................................................. 417 Confirming Transfer Orders for Storage Units ....................................................................... 418 Displaying the Contents of a Storage Unit ............................................................................. 419 Identification Point.................................................................................................................. 420 Using an ID Point .............................................................................................................. 422 Example: Putaway Using an ID Point.......................................................................... 423 Transferring a Storage Unit from the ID Point ............................................................. 424 Stock Picking Using Storage Unit Management .................................................................... 425 Partial Stock Removals .......................................................................................................... 428 Pick Point ............................................................................................................................... 429 Picking Using a Pick Point ................................................................................................ 431 Example: Returning Stock from a Pick Point............................................................... 432 SU-managed Bulk Storage ....................................................................................................... 435 System Controls..................................................................................................................... 437 Transfer Order Processing for Stock Removals .................................................................... 440 Confirming SU-Neutral Transfer Order Items ................................................................... 441 Partial Storage Unit Processing ............................................................................................. 443 Example: Optimization in Bulk Storage ............................................................................ 445 Storage Unit Documents .......................................................................................................... 446 Printing SU Documents Manually .......................................................................................... 448 Storage Unit Preplanning ......................................................................................................... 449 Preplanning Storage Units via an ID Point............................................................................. 451 Receiving Preplanned Storage Units ..................................................................................... 452 Handling Differences for Preplanned Storage Units .............................................................. 453 Blocking Storage Units............................................................................................................. 454 Multiple Processing for SU Management ............................................................................... 455 Inventory .................................................................................................................................... 456 April 2001 9 Warehouse Management Guide SAP AG Controlling the Inventory Process........................................................................................... 458 Take Continuous Inventory ...................................................................................................... 460 Selecting Storage Bins........................................................................................................... 462 Creating the System Physical Inventory Document............................................................... 463 Activating/Changing the Physical Inventory Document ......................................................... 464 Printing the Physical Inventory Document ............................................................................. 465 Closing the Inventory ............................................................................................................. 466 Processing Inventory Differences in WM............................................................................... 467 Entering the Inventory Results in WMS ................................................................................. 470 Using Batch Input for Inventory Count Results................................................................. 472 Take Annual Inventory.............................................................................................................. 473 Executing the Cycle Counting Inventory Method .................................................................. 475 Cycle Counting at Quant Level .............................................................................................. 477 Take Continuous Inventory Based on Putaway..................................................................... 479 Run a Zero Stock Check ........................................................................................................... 482 Example: Automatic Zero Stock Check ................................................................................. 485 Example: Manual Zero Stock Check...................................................................................... 486 Interfaces to External Systems................................................................................................ 487 Automated Warehousing Systems.......................................................................................... 488 Mobile Data Entry (MDE)........................................................................................................... 490 R/2-R/3 Link................................................................................................................................ 491 General Communication Process............................................................................................ 495 Link from Storage Location to R/3 Warehouse Number ........................................................ 496 Master Data............................................................................................................................ 498 When Does Communication Take Place? ............................................................................. 500 Communication Process R/2 -> R/3....................................................................................... 502 Communication Process R/3 -> R/2....................................................................................... 503 Technical Communication Process .................................................................................. 504 Terms that Apply to the Communication Process ............................................................ 506 Record Types.................................................................................................................... 507 Communication Technique ............................................................................................... 510 Error Prevention Mechanisms .......................................................................................... 511 R/2 -> R/3 Processes................................................................................................................. 512 Overview of R/2 -> R/3 Processes ........................................................................................... 513 Material Master Maintenance................................................................................................. 514 Creating the Material Master Record in R/2........................................................................... 516 Goods Receipt / Goods Issue ................................................................................................ 522 Posting Changes in R/3 ......................................................................................................... 528 Stock Transfers in R/3............................................................................................................ 530 Cancellation Posting .............................................................................................................. 532 R/3 -> R/2 Processes................................................................................................................. 534 Overview of R/3 -> R/2 Processes ........................................................................................... 535 Stock Transfers from R/3 to R/2............................................................................................. 537 Recording Differences............................................................................................................ 543 Cumulative Transmission of Differences R/3 -> R/2............................................................. 546 Set-up for Inventory Differences Storage Type 999 ......................................................... 549 Example: Set-up for Cumulative Postings ........................................................................ 551 Bi-directional Processes .......................................................................................................... 552 Connection to Shipping .......................................................................................................... 553 10 April 2001

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Warehouse Management Guide Release 4 .6C H E L P . L E W M Warehouse Management Guide SAP AG Copyright © Copyright 2001 SAP AG. All rights reserved. No part of this publication may be reproduced or transmitted in any form or for any purpose without the express permission of SAP AG. The information contained herein may be changed without prior notice. Some software products marketed by SAP AG and its distributors contain proprietary software components of other software vendors. ® ® ® ® ® ® ® Microsoft , WINDOWS , NT , EXCEL , Word , PowerPoint and SQL Server are registered trademarks of Microsoft Corporation. ® ® ® ® ® ® ® ® ® IBM , DB2 , OS/2 , DB2/6000 , Parallel Sysplex , MVS/ESA , RS/6000 , AIX , S/390 , ® ® ® AS/400 , OS/390 , and OS/400 are registered trademarks of IBM Corporation. ® ORACLE is a registered trademark of ORACLE Corporation. TM ® ® INFORMIX -OnLine for SAP and Informix Dynamic Server are registered trademarks of Informix Software Incorporated. ® ® ® ® UNIX , X/Open , OSF/1 , and Motif are registered trademarks of the Open Group. ® HTML, DHTML, XML, XHTML are trademarks or registered trademarks of W3C , World Wide Web Consortium, Massachusetts Institute of Technology. ® JAVA is a registered trademark of Sun Microsystems, Inc. ® JAVASCRIPT is a registered trademark of Sun Microsystems, Inc., used under license for technology invented and implemented by Netscape. SAP, SAP Logo, R/2, RIVA, R/3, ABAP, SAP ArchiveLink, SAP Business Workflow, WebFlow, SAP EarlyWatch, BAPI, SAPPHIRE, Management Cockpit, mySAP.com Logo and mySAP.com are trademarks or registered trademarks of SAP AG in Germany and in several other countries all over the world. All other products mentioned are trademarks or registered trademarks of their respective companies. 2 April 2001 SAP AG Warehouse Management Guide Icons Icon Meaning Caution Example Note Recommendation Syntax April 2001 3 Warehouse Management Guide SAP AG Contents Warehouse Management Guide ......................................................................13 Warehouse Structure in the Warehouse Management System.............................................. 17 Warehouse Number .................................................................................................................... 22 Storage Type................................................................................................................................ 23 Storage Section ........................................................................................................................... 26 Picking Area................................................................................................................................. 28 Storage Bin .................................................................................................................................. 29 Creating Storage Bins .............................................................................................................. 31 Editing Storage Bins................................................................................................................. 34 Blocking and Unblocking Storage Bins .................................................................................... 36 Displaying the Bin Status Report ............................................................................................. 38 Displaying Warehouse Capacity .............................................................................................. 39 Quant ............................................................................................................................................ 40 Door .............................................................................................................................................. 41 Staging Area ................................................................................................................................ 43 Warehouse Management with Lean WM................................................................................... 44 Setting Up Lean WM................................................................................................................ 46 Basic Functions........................................................................................................................... 48 Number Ranges........................................................................................................................... 49 Foreground/Background Processing........................................................................................ 51 Bar Code Use............................................................................................................................... 52 Authorization Checks ................................................................................................................. 53 Displaying Authorization Groups and Table Views.................................................................. 55 Archiving and Reorganization ................................................................................................... 56 Warehouse Controlling............................................................................................................... 58 Displaying Material Movement Data ........................................................................................ 61 Function Modules and Customer Exits in WMS....................................................................... 62 WM in the SAP Retail System .................................................................................................... 66 Planning and Monitoring ............................................................................................................ 67 Rough Workload Estimate.......................................................................................................... 68 Wave Picks................................................................................................................................... 70 Wave Picks with Capacity Restrictions .................................................................................... 72 Creating Wave Picks - Delivery Time ...................................................................................... 74 Processing Wave Picks............................................................................................................ 77 Subsequent Functions for Wave Picks .................................................................................... 78 Warehouse Activity Monitor....................................................................................................... 81 Unconfirmed Transfer Orders .................................................................................................. 84 Open Transfer Requirements................................................................................................... 85 Open Posting Change Notices................................................................................................. 87 Open Deliveries........................................................................................................................ 88 Critical Stock ............................................................................................................................ 89 Critical TRs for Production Supply ........................................................................................... 91 Using the Warehouse Activity Monitor ..................................................................................... 92 Example: Displaying Unconfirmed Transfer Orders ........................................................... 95 4 April 2001 SAP AG Warehouse Management Guide Basic Stock Management ........................................................................................................... 97 Material Master Data ................................................................................................................... 98 Defining Warehouse Data in the Material Master .................................................................... 99 Displaying the Material Master Record .................................................................................. 101 The Quant and Stock Management in WM.............................................................................. 102 Changing Quant Data ............................................................................................................ 105 Displaying Quant Information................................................................................................. 106 Types of Stock........................................................................................................................... 107 Stock Category .......................................................................................................................... 109 Displaying Stock in the Warehouse ....................................................................................... 111 Blocking Stock in the Warehouse .......................................................................................... 112 Units of Measure ....................................................................................................................... 113 Batch Management ................................................................................................................... 116 Shelf Life Expiration Date......................................................................................................... 118 Displaying Materials with a Shelf Life Expiration Date (SLED).............................................. 119 Storing Materials in the Warehouse ........................................................................................ 120 WM Interface to Inventory Management (IM).......................................................................... 121 Interim Storage Bins............................................................................................................... 123 Creating Interim Bins with Predefined Coordinates.......................................................... 125 Order of Postings in Integrated WM....................................................................................... 126 Posting First in IM ............................................................................................................. 127 Posting First in WM........................................................................................................... 128 Comparing Stock Quantities in WM and IM...................................................................... 129 Hazardous Materials Management .......................................................................................... 130 Hazardous Material Records.................................................................................................... 132 Creating and Using Hazardous Material Records.................................................................. 133 Hazardous Material Evaluation Reports ................................................................................. 135 Displaying the Fire Department Inventory List ....................................................................... 136 Checking for Proper Storage of Hazardous Material ............................................................. 137 Displaying Stock with Hazardous Substances....................................................................... 138 Warehouse Movements ............................................................................................................ 139 Basics for Goods Movements.................................................................................................. 143 Movement Types in WM............................................................................................................ 144 Using Special Movement Indicators....................................................................................... 147 Transfer Requirement ............................................................................................................... 150 Creating Transfer Requirements............................................................................................ 152 Creating Transfer Requirements ...................................................................................... 154 Processing Transfer Requirements .................................................................................. 156 Transfer Order ........................................................................................................................... 159 Creating Transfer Orders ....................................................................................................... 161 Automatic Creation of TOs for Transfer Requirement ...................................................... 163 Using a Transfer Order as a Pick Order in Lean WM....................................................... 164 Displaying Transfer Orders .................................................................................................... 165 Print Transfer Orders and Labels........................................................................................... 166 Printing Transfer Orders and Labels................................................................................. 170 Evaluating Transfer Orders .................................................................................................... 172 Confirming Transfer Orders ................................................................................................... 173 Confirming Transfer Orders .............................................................................................. 175 April 2001 5 Warehouse Management Guide SAP AG Packaging Notification to Shipping ................................................................................... 177 Cancelling Transfer Orders .................................................................................................... 178 Transfer Order Split................................................................................................................ 179 Performance Data .................................................................................................................. 181 Planned Data .................................................................................................................... 182 Entering of Actual Data ..................................................................................................... 183 Handling Differences ................................................................................................................ 185 Clearing Differences............................................................................................................... 187 Storage of Pre-Picked Handling Units .................................................................................... 188 Putting Away, Picking, and Transferring Pre-Packed HUs .................................................... 191 Goods Receipt ........................................................................................................................... 193 Creating Transfer Orders Immediately at the IM Posting...................................................... 195 Manual Creation of Transfer Orders for Putaway .................................................................. 197 Posting a Goods Receipt Based on a Purchase Order ......................................................... 200 Posting Returns for Deliveries................................................................................................. 201 Goods Receipt for Inspection .................................................................................................. 202 Releasing Material from Inspection Stock.............................................................................. 204 Releasing Stock in IM from Inspection................................................................................... 205 Goods Receipt Without a Previous Posting in IM.................................................................. 206 Example: Sample ABAP to Follow-up Postings in IM............................................................ 208 Creating a TO in WM without a Previous Posting in IM......................................................... 209 Negative Stock Check............................................................................................................... 211 Stock Placement Using Storage Unit Types........................................................................... 212 Example: Using Storage Unit Types ...................................................................................... 213 Cross-Docking........................................................................................................................... 214 Stock Placement with Active Bypass ..................................................................................... 215 Setting up Active Bypass for Putaway ................................................................................... 216 Adding Goods to Existing Stock ............................................................................................. 217 Goods Issue............................................................................................................................... 218 Goods Issues Based Upon a Delivery..................................................................................... 220 Random Picking Using Transfer Orders ................................................................................ 222 Pick-and-Pack During Picking........................................................................................... 224 Picking from a Fixed Bin without a Transfer Order ................................................................ 226 Picking Quantities Based on Size .......................................................................................... 227 Goods Issue for a Delivery..................................................................................................... 228 Creating a Delivery ........................................................................................................... 229 Automatic Creation of Transfer Orders for Outbound Delivery......................................... 230 Confirming a Transfer Order for a Delivery....................................................................... 232 Processing Differences for a Delivery............................................................................... 233 Partial Picking ................................................................................................................... 234 Creating a TO for a Cancelled Delivery ............................................................................ 235 Goods Issue Based on an IM Posting ..................................................................................... 236 Goods Issue to a Cost Center................................................................................................ 238 Posting a Goods Issue to a Cost Center .......................................................................... 239 Creating a Transfer Order for a Material Document ......................................................... 240 Manual Creation of Transfer Orders for Picking.................................................................... 241 Goods Issue for Production Supply........................................................................................ 242 6 April 2001 SAP AG Warehouse Management Guide Pick Part ................................................................................................................................. 245 Crate Part ............................................................................................................................... 246 Release Order Part ................................................................................................................ 247 Setting up the Interface between PP and WM....................................................................... 248 Production Supply Areas .................................................................................................. 249 Creating a Control Cycle................................................................................................... 250 Production Storage Bins ................................................................................................... 251 The Material Staging Process................................................................................................ 252 Creating a Production Order ............................................................................................. 253 Displaying a Production Order .......................................................................................... 254 Releasing a Production Order........................................................................................... 255 Automatic Staging for WM ................................................................................................ 256 Displaying TRs for Material Staging ................................................................................. 258 Creating TRs for Material Staging Manually ..................................................................... 259 Processing TRs for Material Staging ................................................................................ 261 Posting a Goods Issue for Material Usage ....................................................................... 263 Kanban Replenishment.......................................................................................................... 264 Handling Cancelled Kanbans............................................................................................ 267 Material Staging for Repetitive Manufacturing ....................................................................... 269 Staging Release Order Parts for Repetitive Manufacturing.............................................. 272 Multiple Processing .................................................................................................................. 273 Selecting TRs for Multiple Processing ................................................................................... 275 Selecting Deliveries for Multiple Processing .......................................................................... 277 Sample Report: Multiple Processing Selection................................................................. 278 Creating Transfer Orders for a Group.................................................................................... 279 Releasing Groups .................................................................................................................. 280 Confirming TOs for a Group................................................................................................... 281 Partial Processing of TRs and Deliveries............................................................................... 282 Analysis of Groups ................................................................................................................. 283 2-Step Picking............................................................................................................................ 285 2-Step Picking Process .......................................................................................................... 287 Work Method 1: Delivery to Goods................................................................................... 288 Work Method 2: Goods to Delivery................................................................................... 292 How to Carry Out 2-Step Picking ........................................................................................... 294 Using the Analysis Tool for 2-Step Picking ............................................................................ 297 Bestandsfindung ....................................................................................................................... 298 WM Interface to Quality Management ..................................................................................... 300 How the QM Interface Process Works .................................................................................... 301 Making Stock Placements Using the QM Interface ............................................................... 302 Examples: Making a Usage Decision .................................................................................... 305 Finding an Inspection Lot in the Warehouse ......................................................................... 308 Examples for the Putaway of Inspection Stock ..................................................................... 309 After Usage Decision: Sample Stored ................................................................................... 310 After Usage Decision: Stock Returned to Vendor.................................................................. 311 After Usage Decision: Sample Destroyed.............................................................................. 312 Before Usage Decision: Sample Stored ................................................................................ 313 Before Usage Decision: Stock Returned to Vendor............................................................... 314 Before Usage Decision: Sample Destroyed........................................................................... 315 Stock Transfers and Replenishment....................................................................................... 316 April 2001 7 Warehouse Management Guide SAP AG Plant/Storage Location to Plant/Storage Location ................................................................ 317 Internal Stock Transfers ........................................................................................................... 319 Moving Stock from One Storage Bin to Another .................................................................... 320 Replenishing Fixed Bins in the Warehouse ........................................................................... 321 Executing Replenishment for Fixed Bins ............................................................................... 322 Choose Logistics ( Logistics Execution ( Internal Whse Processes ( Stock Transfer ( Planning of Replenishments ( Based Upon Outb. Deliveries to be Selected from the SAP menu. ................................................................................................................................ 323 Creating a Replenishment TO During TO Confirmation........................................................ 324 Posting Changes in WM ........................................................................................................... 326 Processing Posting Changes................................................................................................... 327 Displaying Posting Change Notices....................................................................................... 328 Automatic Creation of TOs for Posting Change Notices........................................................ 329 Processing Posting Changes Entirely Within WM................................................................. 330 Example: Changing the Status of Consignment Stock .......................................................... 332 Processing Inspection Stock ................................................................................................... 334 Releasing Stock from Inspection............................................................................................ 336 Releases from More than One Storage Type ........................................................................ 338 Releasing Consignment Stock from Inspection .................................................................... 339 Processing Blocked Stock ....................................................................................................... 340 Converting Available Stock to Inspection Stock ................................................................... 341 Changing a Material Number.................................................................................................... 342 Dividing Materials into Two or More Batches ........................................................................ 344 Changing Stock Ownership from Plant to Plant .................................................................... 345 Storage Locations in TRs, TOs and Posting Changes.......................................................... 346 Possible Scenarios Based on Storage Locations .................................................................. 348 Example: Stock Movement from GR Area........................................................................ 350 Example: Material Staging for Production ........................................................................ 352 Putaway and Picking Strategies .............................................................................................. 354 Putaway Strategies ................................................................................................................... 355 Manual Entry .......................................................................................................................... 359 Strategy F: Fixed Bin Storage................................................................................................ 360 Strategy C: Open Storage...................................................................................................... 362 Strategy I: Addition to Existing Stock ..................................................................................... 363 Strategy L: Next Empty Storage Bin ...................................................................................... 365 Strategy K: Putaway near Picking Bin ................................................................................... 366 Strategy P: Storage Unit Type ............................................................................................... 367 Example: Optional SUT Check When Creating a TO....................................................... 370 Strategy B: Bulk Storage........................................................................................................ 371 Combined Placement........................................................................................................ 374 Partial Quantities............................................................................................................... 375 Blocking Transfers into a Row .......................................................................................... 376 Defining Time Limits for Block .......................................................................................... 377 Total .................................................................................................................................. 378 Round Off.......................................................................................................................... 379 Strategy Q: Dynamic Quant Number ..................................................................................... 380 Additional Factors that Affect Search Strategies .................................................................. 381 Cross-Line Stock Putaway..................................................................................................... 382 8 April 2001 SAP AG Warehouse Management Guide Capacity Checking ................................................................................................................. 385 Capacity Checking Based on a Neutral Indicator ............................................................. 387 Picking Strategies ..................................................................................................................... 390 Strategy F: FIFO (First In, First Out) ...................................................................................... 392 Strategy: Stringent FIFO Across All Storage Types............................................................... 393 Strategy L: LIFO (Last In First Out)........................................................................................ 394 Strategy A: Partial Quantities First ......................................................................................... 395 Strategy M: According to Quantity ......................................................................................... 396 Example: Rounding Off Requested Quantities ................................................................. 398 Strategy H: Shelf Life Expiration Date ................................................................................... 399 Strategy P: Fixed Storage Bin................................................................................................ 400 Stock Return Methods .............................................................................................................. 401 Storage Unit Management ........................................................................................................ 403 Warehouse Management at the Storage Unit Level............................................................... 405 SU-Managed Storage Types..................................................................................................... 407 Putaway using Storage Unit Management.............................................................................. 409 Creating Storage Units........................................................................................................... 410 Creating Homogeneous Storage Units ............................................................................. 412 Creating Mixed Storage Units for a TR............................................................................. 413 Adding Materials to an Existing Storage Unit ................................................................... 414 Creating Storage Units Manually ...................................................................................... 415 Automatic Bin Search............................................................................................................. 417 Confirming Transfer Orders for Storage Units ....................................................................... 418 Displaying the Contents of a Storage Unit ............................................................................. 419 Identification Point.................................................................................................................. 420 Using an ID Point .............................................................................................................. 422 Example: Putaway Using an ID Point.......................................................................... 423 Transferring a Storage Unit from the ID Point ............................................................. 424 Stock Picking Using Storage Unit Management .................................................................... 425 Partial Stock Removals .......................................................................................................... 428 Pick Point ............................................................................................................................... 429 Picking Using a Pick Point ................................................................................................ 431 Example: Returning Stock from a Pick Point............................................................... 432 SU-managed Bulk Storage ....................................................................................................... 435 System Controls..................................................................................................................... 437 Transfer Order Processing for Stock Removals .................................................................... 440 Confirming SU-Neutral Transfer Order Items ................................................................... 441 Partial Storage Unit Processing ............................................................................................. 443 Example: Optimization in Bulk Storage ............................................................................ 445 Storage Unit Documents .......................................................................................................... 446 Printing SU Documents Manually .......................................................................................... 448 Storage Unit Preplanning ......................................................................................................... 449 Preplanning Storage Units via an ID Point............................................................................. 451 Receiving Preplanned Storage Units ..................................................................................... 452 Handling Differences for Preplanned Storage Units .............................................................. 453 Blocking Storage Units............................................................................................................. 454 Multiple Processing for SU Management ............................................................................... 455 Inventory .................................................................................................................................... 456 April 2001 9 Warehouse Management Guide SAP AG Controlling the Inventory Process........................................................................................... 458 Take Continuous Inventory ...................................................................................................... 460 Selecting Storage Bins........................................................................................................... 462 Creating the System Physical Inventory Document............................................................... 463 Activating/Changing the Physical Inventory Document ......................................................... 464 Printing the Physical Inventory Document ............................................................................. 465 Closing the Inventory ............................................................................................................. 466 Processing Inventory Differences in WM............................................................................... 467 Entering the Inventory Results in WMS ................................................................................. 470 Using Batch Input for Inventory Count Results................................................................. 472 Take Annual Inventory.............................................................................................................. 473 Executing the Cycle Counting Inventory Method .................................................................. 475 Cycle Counting at Quant Level .............................................................................................. 477 Take Continuous Inventory Based on Putaway..................................................................... 479 Run a Zero Stock Check ........................................................................................................... 482 Example: Automatic Zero Stock Check ................................................................................. 485 Example: Manual Zero Stock Check...................................................................................... 486 Interfaces to External Systems................................................................................................ 487 Automated Warehousing Systems.......................................................................................... 488 Mobile Data Entry (MDE)........................................................................................................... 490 R/2-R/3 Link................................................................................................................................ 491 General Communication Process............................................................................................ 495 Link from Storage Location to R/3 Warehouse Number ........................................................ 496 Master Data............................................................................................................................ 498 When Does Communication Take Place? ............................................................................. 500 Communication Process R/2 -> R/3....................................................................................... 502 Communication Process R/3 -> R/2....................................................................................... 503 Technical Communication Process .................................................................................. 504 Terms that Apply to the Communication Process ............................................................ 506 Record Types.................................................................................................................... 507 Communication Technique ............................................................................................... 510 Error Prevention Mechanisms .......................................................................................... 511 R/2 -> R/3 Processes................................................................................................................. 512 Overview of R/2 -> R/3 Processes ........................................................................................... 513 Material Master Maintenance................................................................................................. 514 Creating the Material Master Record in R/2........................................................................... 516 Goods Receipt / Goods Issue ................................................................................................ 522 Posting Changes in R/3 ......................................................................................................... 528 Stock Transfers in R/3............................................................................................................ 530 Cancellation Posting .............................................................................................................. 532 R/3 -> R/2 Processes................................................................................................................. 534 Overview of R/3 -> R/2 Processes ........................................................................................... 535 Stock Transfers from R/3 to R/2............................................................................................. 537 Recording Differences............................................................................................................ 543 Cumulative Transmission of Differences R/3 -> R/2............................................................. 546 Set-up for Inventory Differences Storage Type 999 ......................................................... 549 Example: Set-up for Cumulative Postings ........................................................................ 551 Bi-directional Processes .......................................................................................................... 552 Connection to Shipping .......................................................................................................... 553 10 April 2001

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