I would like to present an example of Planned Replenishment in SAP EWM.
The purpose of my blog post is to understand a basic replenishment process, with an actual test case, in EWM environment.
It is useful to relate the theory concepts with a practical example.
Scenario Overview & Details:
We have 2 options at storage type – to activate it at bin level (Replenishment level is Blank)or at storage type level (Replenishment level is 1).
PRPL is the Storage type to be replenished from REAR storage type.
Current Stock position is as below:
Fixed bins maintained for material SUGAR in PRPL as below:
Quantity levels maintained in product master at storage type as below:
Case 1) We replenish PRPL storage type at bin level
As we see the results above, max qty. per bin is 50 KG and replenishment qty. is 5 KG,
so the system will calculate in multiples of 5 till it does not cross 50 KG, in both bins:
Bin PICK_REPL – 2 KG + (5KG)*9 = 47 KG
Bin PICK_REPL03 – 3 KG + (5KG)*9 = 48 KG
EWM will thus create 2 warehouse tasks, one to replenish bin PICK_REPL and other to replenish bin PICK_REPL01, from REAR storage type.
Case 2) We replenish PRPL storage at storage type level (put 1 in repl. level, the first screenshot in this post)
Note: We will amend product master data at storage type to increase min. qty. to 6 KG, as the storage type already has 5 KG (PICK_REPL – 3KG, PICK_REPL03 – 2KG):
Below are the replenishment results:
As expected, EWM system will replenish the storage type stock to 100 KG (product master max. qty).
- EWM system checks the product master data for min. qty, max. qty. to replenish when at storage type level. Bin level replenishment is useful for scenarios where products are storage in specific type of bin, for example glue, cold storage materials, etc.
- EWM system checks the fixed bin master data for min. qty, max. qty. to replenish when at storage bin level. Storage type level replenishment is used for products that can occupy any random bins in a storage type, for example: screws, nut bolts, etc. can be kept in any pick-box near the production line.
- The replenishment qty. is always maintained in product master ONLY, so extending product master at storage type (to be replenished) is mandatory
- The system uses the ROUND DOWN approach when calculation of the replenishment qty. In order related replenishment, the system uses the ROUND UP approach, as mandatory to fulfil customer demand.