QAD 2017 Enterprise Edition > User Guides > Warehousing > Wave Planning > Replenishing a Wave > Replenishment Examples
  
Replenishment Examples
The following example shows how item replenishment occurs. In the example, you replenish for a single wave A with two orders for item B.
The following conversion factors are set:
 
Program
UM
Alternate
UM
UM
Conversion
Storage Location Maintenance (4.3.1)
PL (Pallet)
EA
100
Storage Location Maintenance (4.3.1)
BX (Box)
EA
20
For Wave A, item B, two order lines exist:
 
Order Line 1
=
182 EA
Order Line 2
=
173 EA
Total:
 
355 EA
The total requirement is for 355 EA.
Setup and Results for No Box Picking from Reserve Area
Replenishment Setup for No Box Picking from Reserve Area shows which fields to set in Wave Planning Control for replenishment for no box picking from the reserve area.
See here.

Replenishment Setup for No Box Picking from Reserve Area
 
Field to Set
Set To
Results
Pick Boxes in Pallet Area
No
Step 2 of the replenishment does not take place.
Pallet UM
blank
The system considers the setting of the Pick Multi Of field in Storage Location Maintenance (4.3.1) for step 1 (full pallet picking).
In the SLGs, the alternate UM is PL and staff need to pick by multiples of PL.
Note: For step 1 of wave replenishment—full pallet picking—the following picking properties are hard-coded and, therefore, not impacted by setup:
• Split allow is No.
• Overpicking is No.
Replenishment Overpick
Yes
Staff bring full pallets only to the detail picking area.
Allow Split Replen
No
Staff can only move full pallets to the detail area, even if the quantity required is less than the pallet quantity. This is because Replenishment Overpick is set to Yes.
Replen Pick UM
PL
This determines the pick by multiples of setup for step 3 of wave replenishment, which is picking for replenishment once full boxes and pallets are complete. Staff pick by PL multiples from the reserve area.
Note: This field can be blank. If blank, the system considers the Pick Multi Of field setting in Storage Location Maintenance (4.3.1) and the alternate UM of the inventory record it is processing.
The system does not consider other parameters such as overpicking, multiple transactions, and split pallets from the SLG for step 3 of wave replenishment. The settings always come from Wave Planning Control.
Replen Mult Trans
No
This setup creates multiple tasks if, for example, staff pick by box from the pallet area and you want staff to move one task per box as opposed to one task for all the boxes. This setup is not relevant for picking by multiples of pallets.
Using the setup illustrated in Replenishment Setup for No Box Picking from Reserve Area generates the following results for the three steps of wave replenishment:
Step 1: During full-pallet picking, the system considers each order line at a time. For order line 1, 182 EA were required. In the SLG for picking, there are pallets with a PL UM. The SLG picking details dictate the following:
• PL is a non-splittable unit of measure.
• Overpicking is not allowed.
• Staff pick by PL with no multiple transactions created.
Based on this standard setup, staff can pick one full pallet of 100 EA for order line 1 and one full pallet of 100 EA for order line 2.
Of the 355 EA required, staff have already picked two pallets of 100 EA. At this stage, the missing quantity is 155 EA for Item B.
Step 2: The system skips this step because of control settings.
Step 3: This is the actual replenishment. This step is a bulk replenishment by item. The system considers each item, but the requirements are the sum of all orders for the item in the entire wave. The system removes the item requirement for items staff already picked in step 1 or 2. Based on this, the remaining requirement of 155 EA for item B remains for step 3.
Finally, the system considers the quantity already available in the detail picking area for this item:
• Available in picking area: 11 EA
• Replenishment quantity needed: 144 EA (155 EA – 11 EA)
When the replenishment starts, the system considers the picking default properties from Wave Planning Control. This is different from traditional setup, when the system considers picking defaults coming from the SLG. In this example, staff pick by non-splittable pallets and cannot overpick.
Picking results also depend on the type of algorithm the system uses. Typically you specify a pick-by-level type algorithm. Using this type algorithm, the system sets up two replenishment tasks to move two pallets from the reserve area to picking area. Each task is for a pallet of 100 EA; therefore, in this example you replenish more than the required quantity.
Setup and Results for Use Box Picking from Pallet Area
Replenishment Setup for Use Box Picking from Pallet Area lists the Wave Planning Control setup when you use boxes from the pallet area. The UM for box picking is set to bx (box).

Replenishment Setup for Use Box Picking from Pallet Area
 
Field to Set
Set To
Results
 
For results of these settings, see Setup and Results for No Box Picking from Reserve Area on here.
Pick Boxes in Pallet Area
Yes
Step 2 of the replenishment will take place after the full pallet picking step.
Using the setup illustrated in Replenishment Setup for Use Box Picking from Pallet Area generates the following results for the three steps of wave replenishment:
Step 1: The same as setup for box picking from reserve area.
Step 2: Picking by boxes in the pallet area is set to Yes so the system processes step 2. For this step, the following picking properties are hardcoded and cannot be changed by any setup:
• Allow split is set to No.
• Overpicking is set to No.
The Pick by Multiple UM value is from the Box Pick UM field in Wave Planning Control or if not found, from the Pick Multi Of field setting in Storage Location Maintenance (4.3.1). Based on the picking algorithm, staff pick as many boxes as possible from the pallet area but without picking more than what is required (overpicking is No). This works per order line as per step 1.
For order line 1, the requirement is 82 EA (182 – 100). This means if staff pick by multiples of box without overpicking and one box contains 20 items EA, staff pick four boxes of 20, or 80 EA.
For order line 2, the requirement is 73 EA. (173 – 100). This means staff pick three boxes and move them directly to the consolidation or staging/dock area.
Step 3: This is the actual replenishment. This step is a bulk replenishment by item. The system considers each item, but the requirements are the sum of all orders for the item in the entire wave. The system also considers the quantity already picked in step 1 or 2 and removes those requirements. There is a remaining requirement of 15 EA for item B. The 15 includes 2 EA remaining for order line 1 and 13 EA for order line 2. Finally, the system considers the quantity already available in the detail picking area for this item:
• Available in picking area: 11 EA
• Replenishment quantity needed: 4 EA (15 EA – 11 EA)