Wave Replenishment Steps
Wave replenishment typically includes the following three steps; however, depending on the setup, you may not use all steps:
• Step 1: Full-pallet picking
• Step 2: Box picking from the reserve area
• Step 3: Picking area replenishment
The following subsections describe each step in more detail. Setup information is provided in the subsections. The following warning message displays when at least one item is not set up correctly:
No Replenishment Definition
You can view a list of all items that are not set up correctly in Wave Unprocessed Orders Inquiry (4.15.4.6).
Step 1: Full-Pallet Picking
For larger quantities to pick, such as for distribution orders, staff can pick full pallets from the reserve area and move them either to the picking area or directly to the shipping lanes, bypassing the picking area. You can bypass the picking area only if the quantity on a single order line is bigger then the pallet quantity. The system uses picking algorithms and other replenishment options to split pallets, overpick, and so on, that you specify when you set up replenishment tasks for warehouse staff.
The system can create tasks associated with full-pallet picking with a priority of 0 (zero). Even though the system creates the tasks, warehouse staff cannot process the tasks on the RF device. When you release the wave, you activate full-pallet picking tasks along with detail picking tasks. This means that warehouse staff complete full-pallet picking tasks and detail picking tasks at the same time.
If you create full-pallet picking tasks with a non-zero priority when you replenish the wave, warehouse staff bring full pallets to the consolidation or staging area before they replenish items for the wave and before they pick items for the rest of the wave. Moving the full pallets directly to the staging area at this point means that staff use unnecessary space in the staging area. Also, since the system already created the task, it reserves the pallet for the task, even though you have not activated the task.
Step 1 creates a pre-shipper for sales orders or distribution orders. You must print the pre-shipper in Wave Replenishment (4.15.6) at the end of step 2.
Skipping Step 1
To skip the full-pallet picking step, set the
Pallet SLG Level From/To field in Wave Planning Control to SLG levels that do not correspond to the picking levels of the pallet SLG levels. The system avoids picking in the reserve area by skipping the SLG that has a picking level equal to or within the range of the values you specify in Pallet SLG Level From/To.
Example: The storage location groups in the pallet area have a picking level between 10 and 20. When you set Pallet SLG Level From/To from 30 to 40, picking does not occur in the pallet area.
Setting Up Step 1
Set up step 1 of the replenishment in the same way you set up traditional order picking. Set the following:
• Use Internal Routing Group Maint (4.2.1) to assign an internal routing group to the pallet area.
• Use Internal Routing Maintenance (4.2.5) to assign an internal routing from the pallet area to the dock/consolidation area for a transaction type that is based on the order you use in the wave; for example, transaction type PICK-SO for sales orders, transaction type PICK-FAS for sales orders for configured kits, or PICK-DO for distribution orders.
• Use Algorithm Assignment Maintenance (4.6.9) to assign a pick-by‑level algorithm to a PICK-SO or PICK-DO transaction type. Assign a pick-by-level algorithm such as pick-by-level-by-location to ensure that the first step consists of picking only in the pallet area.
Step 2: Box Picking from the Reserve Area
In step 2, staff can pick either:
• Full boxes from the reserve area
• Full or open boxes from the picking area
You can use this step to pick multiple boxes from the reserve area and move them directly to the consolidation or staging area.
The same rules apply when applying a zero or non-zero priority to the picking tasks as when using the full-pallet picking.
Skipping Step 2
You can skip this step by setting the same option in Wave Planning Control that you set to skip step 1. If you do, staff replenish the picking area and pick full boxes from the picking area; for example, through batch picking.
Setting Up Step 2
If you want to pick full boxes from the reserve area in this step, set the following:
When Yes, staff can perform box picking after the full-pallet picking. When No, the system sets the box picking completion percentage to 100% without processing any picking tasks.
• Set up other replenishment picking parameters in Wave Planning Control.
Step 3: Picking Area Replenishment
When full-pallet picking or box picking is complete for a wave, the system calculates the remaining missing quantities in the picking area to fulfill all order lines from the wave. The system creates the tasks to move items to the picking area from the reserve area.
The system calculates the requirement per item across the entire wave; that is, the remaining quantities needed are the sum of all order line quantities needed for a given item at a time. You can view the remaining quantity replenishment as bulk replenishment because staff replenish multiple orders at the same time.
For replenishment examples, see
here.
Also, depending on the setup, you can over-replenish (overpick) a location by creating one or multiple tasks for each box and moving entire pallets to the replenishment area.
When step 3 of replenishment finishes, the system creates a dynamic replenishment SLG definition for the given item and an SLG to replenish.
Setting Up Step 3
• Use Internal Routing Assignment Maint (4.2.9) to assign an internal routing group between the pallet area and the detail picking area.
Because these two areas are typically part of the same storage internal routing group, set up a one-step internal routing and assign it to the replenishment picking transaction type PICK-RE.
• Use Algorithm Assignment Maintenance (4.6.9) to assign a pick-by- level algorithm to transaction type PICK-RE. Assign a pick-by-level algorithm such as pick-by-level-by-location to ensure that staff do not pick in the pallet area for this step.
• Use Algorithm Assignment Maintenance to assign a put-away algorithm to the PICK-RE transaction type.
• Use Replenishment SLG Maintenance (4.16.9) to create an SLG replenishment definition.
• Set other default replenishment controls in Wave Planning Control.
Specifying Replenishment Options
Fields Considered During Replenishment explains which fields the system considers for picking parameters in the three steps of wave replenishment. You can also refer to
Replenishment Setup for No Box Picking from Reserve Area and
Replenishment Setup for Use Box Picking from Pallet Area, which list replenishment setup for explicit examples.
Fields Considered During Replenishment
|
Step
|
For Pallet
Splitting
|
For Over-Picking
|
For Picking by Multiples of
|
For Multiple Transactions
|
|
Step 1:
Full-pallet picking
|
Set Allow Split Replen to No.
|
Set Replenishment Overpick to No.
|
Set Pallet UM to pallets or blank.
If blank, set Pick Multi Of in Storage Location Maintenance (4.3.1) to pallets.
|
Set Replen Multi Trans to No.
|
|
Step 2:
Box picking
from reserve
|
Set Allow Split Replen to Yes.
|
Set Replenishment Overpick to No.
|
Set Box Pick UM to box.
|
Set Replen Multi Trans to No.
|
|
Step 3:
Replenish picking
from reserve
|
Set Allow Split Replen to Yes.
|
Set Replenishment Overpick to Yes.
|
Set Replen Pick UM to either pallets or boxes or leave blank.
If blank, set Pick Multi Of in Storage Location Maintenance (4.3.1) to pallets or boxes.
|
Set Replen Multi Trans to Yes.
|