Replenishment /Partial Bin to Bin Transfer if TO exists

[Former Member]

Hi ,

We designed FIFO picking strategy for an automobile assembly company and Near Picking bin strategy for Putaway.

Whenever Pick Parts TO is created, system checks material in both Pick & Recerve(Overflow) location and allocates automatically(enabled storage type search to consider overflow storge type)

Lets say

Material A in Bin at Pick Location = 24 Pcs

Overflow at level 4,5,6 contains = 24 Pcs each

So the total stock available = 96(24 in pick & 72 in overflow/reserve)

When 30 TOs are created, 24 qty in pick location is consumed and remaing 6 in overflow location.

Further 66 TOs are created and all the overflow stock is assigned to TOs.

As the material is in overflow location, picking is difficult (every time either the material to be brought down or picker needs to go up)

If we try to perform bin to bin transfer from overflow to pick locatin, system says that confirm the open TO( i.e. TOs for 6 Pcs)

Is there any workaround or user exit to handle this situtation?

Regards

Siva

[MANIS]

Concept of Pick location is to pick the less then pallet load from the pick face location but as per your thread(TO for 30 unit) system is picking the full quantity from the Pick location (24 unit) and rest from the Overflow location(6 unit),  in my opinion you need to look to change the business logic for picking (if it is allowed)

[Former Member]

Thanks Manish!

Is there any way to address, moving stock from overflow to pick location even if there is open TO.

Any user exit or custom development will help?

Regards

Siva

[MANIS]

We don't have any exit which help you to create TO even if there are open  Transfer order exist for the storage bin and functionally it is not advisable also to transfer the stock to another location if the source bin are having an open transfer order

[Former Member]

Hi Manish

We have 3 overflow bins(level 4,5 & 6), when TOs are created first the pick location stock are allocated and then start allocate stock in overflow(Level 4,5 & 6).

Business expects to perfrom replenishment or bin to bin transfer(From level 4,5 & 6 ) to Pick location which is level 1 or 2 even with open transfer order

Can we  handle this with current picking strategy(FIFO) with custom program so that it will address both picking operation(with out reach truck or picking at overflow) and replenishment

Please advise

Regards

Siva

[MANIS]

We have 3 overflow bins(level 4,5 & 6), when TOs are created first the pick location stock are allocated and then start allocate stock in overflow(Level 4,5 & 6). - As mentioned earlier in my mail instead of direct allocating the stock from the pickface you need to put a check if the requirement quantity is less then a pallet load then only pick from pick location else overflow location

Business expects to perform replenishment or bin to bin transfer(From level 4,5 & 6 ) to Pick location which is level 1 or 2 even with open transfer order - Not advisable if there are open transfer order for the bin exist also technically it is not possible to create the another transfer order from the same bin as the stock will be block against the first transfer order and LQUA_VERME(Available stock)  will be zero,

What is the basis for creating the transfer order if it is against the delivery then explore the possibility to use LP24 - Replenishment by delivery before start the picking which will help you to transfer the required quantity to Pick face and then you can start the picking process

[Former Member]

Hi Manish

Thanks for the support.

Please find the clarifications

1) We have 3 overflow bins(level 4,5 & 6), when TOs are created first the pick location stock are allocated and then start allocate stock in overflow(Level 4,5 & 6). - As mentioned earlier in my mail instead of direct allocating the stock from the pickface you need to put a check if the requirement quantity is less then a pallet load then only pick from pick location else overflow location

<<Siva>> : W/H is HU(SU) managed and the Pick Parts(Production Order based picking) TOs are created. Usually one HU contains 4,8,12 pcs of material and it will be required in terms of 1  or 2 pcs per TO. So when the TOs are created, materials in HU are getting allocated in terms of 1,1,1,1 pcs....etc.

Once pick location stock is completely allocated, for next set of TO creation system will start allocate from overflow level 4 and then 5 and finally 6. There are 700+ materials to be picked for one TO. Which are geographyically located in different aisle,sections

So the issue is not box picking rather pick parts from HU one by one. If the part is in overflow level which requires reach truck at every aisle(not practically possible to have reach truck). There are quite a number of parts in overflow

Otherwise picker moves in reach truck and bring the material down which potentially may cause picking wrong material or wrong qty

These are the key issues

2) Business expects to perform replenishment or bin to bin transfer(From level 4,5 & 6 ) to Pick location which is level 1 or 2 even with open transfer order - Not advisable if there are open transfer order for the bin exist also technically it is not possible to create the another transfer order from the same bin as the stock will be block against the first transfer order and LQUA_VERME(Available stock)  will be zero,

<<Siva>> : Business wants to keep creating TO, and picking should happen or they can keep some TOs open and replenishmnet to happen

Will 2 step picking help here? Here the scneario is Picking for Production order and not for delivery. There is no grouping enabled for this funtionality

3) What is the basis for creating the transfer order if it is against the delivery then explore the possibility to use LP24 - Replenishment by delivery before start the picking which will help you to transfer the required quantity to Pick face and then you can start the picking process

<<Siva>> :  From Production order, when WM staging is done, TRs generated and converted to TO

So picking is for production order related TO (No outbound delivery related)

We suggested to use LP21 for replenishent but min max data is not proper. Moreover this is HU managed, even if replenishment TRs are generated, WH admin needs to split the HU and transfer material from Overflow to Pick location.

There are 5000+ parts in the WH, doing this activity is quite time consuming

Putaway is Near Picking Bin and Picking is FIFO. Will fixed bin strategy for putaway help? As there are many bins untocuched(losing storage bin), but business has to live with pick and overflow. Any suggestion on putaway as well?

Please let us know is there any way to handle this technically

Thanks in advance

Regards

Siva