Microsoft Dynamics AX (Archived)

Strategy "Round up to full LP" does not work together with location limit if LP qty is less than standard pallet qty for item

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Posted on by Lauri Looga

I have problem to find a solution for this problem already for days. So all help is much appreciated :)

My warehouse has picking locations (no LP traced, no multi SKU allowed) and bulk locations (LP tracing).

I have item with following data:

- base unit is ea

- unit conversion has setup 100 ea = 1 PLL

- unit sequence group is "EA PLL"

- fixed location is not set for item, it can be picked from any location with profile "picking location". I'd like to use "dynamic" locations for picking, because I have less picking locations than items. So only in case of demand pallets should be moved from bulk area to picking area

- item has currently on-hand inventory at three bulk locations, 99 pieces at each location (not full pallets because of returns)

I also have following setup for directives:

- sales pick: split lines is allowed, one action line, picking location profile is set on query

- sales put: fixed location "BAYDOOR" is set

- replenishment pick: split lines is allowed, bulk location profile is set on query, line has strategy "Round up to full LP"

- replenishment put: split lines is allowed, picking location profile is set on query

On work templates I have grouping by Replenish location Id and Location Id on Replenishment work template

On replenishment template I have set up demand based template, with "Allow wave demand to use unreserved quantities" checked. Item replenishment unit is set to "ea"

On location limits I have setup, where limit 1 pallet is set for all picking locations.

Now about my problem. If i have one sales order with qty 140 ea, I really hoped for following result: 2 full pallet (2x99) replenishment are done into 2 separate picking locations and one sales picking work is created, where first pick line is from first replenished location for qty 99 and second line is from another location fro qty 41.

Instead of that i got 3 replenishments 2 sales works. First 2 replenishments were full pallets to same location (2X99) and it was reserved for first sales work (from total 140 qty 100 was split for first picking work) and third replenishment was to second picking location and qty 40 was reserved against it.

If I remove location limit, then it works like a charm ( 2 full pallet replenishments 1 sales work), problem is that both replenishments and picking are done to same location and it is not possible in real life.

It also works OK, if I have also only correct pallets (100 pcs-s on pallet) or only one not full pallet on bulk or demand is from multiple sales orders and every sales line qty is smaller than smallest LP qty on stock. So far my only solution to this problem is to store not full pallets in picking area but that is not a solution I am looking for.

Has anyone some idea how to solve this? Maybe I am missing some setup.

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Sagar Suman 6,550 Super User 2025 Season 2 on at

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Hi Lauri Looga,

First of all I would say a great post by you as you have explained almost everything you are doing.

What I have seen from you post and I tried in my system as well the behavior you are getting is consistent with mine and for obvious reasons. Let me explain

I have done all the setups as mentioned by you and here are the finding

Instead of that i got 3 replenishment 2 sales works. First 2 replenishment were full pallets to same location (2X99) and it was reserved for first sales work (from total 140 qty 100 was split for first picking work) and third replenishment was to second picking location and qty 40 was reserved against it.

This is correct as you have put a stocking limit of 1 pallet which is fine but the pallet you are moving from bulk is not a full pallet and is one pcs short of making it a full pallet.

Now as Dynamics want to make sure all picking locations should have max one pallet (Your stocking limit setup) it moves two full pallets to same location. (This happened as you have setup Round up to full LP"). So Dynamics has moved two full pallets as you dont want individual parts picking from pallets which is correct as the second pallet is moved just to fill that missing one item.

Also remember the second pallet is obviously more than what that location can hold and system acknowledges the same and expect your worker to fill the one pcs on the picking location and move it back to bulk locations manually. Thats why third pallet was not moved to the same location.

Third work is for another full pallet but this time to a new location as the old location is full (Second pallet contributing just one pcs as you did round to full LP system moved pallet else it would have been a piece)

If I remove location limit, then it works like a charm ( 2 full pallet replenishments 1 sales work), problem is that both replenishments and picking are done to same location and it is not possible in real life.

This is now obvious as there is no limits Dynamics will dump both full pallets to same location.

Your wish is to move each pallet to a new location and for that stocking limit is not a good choice to limit stock in locations.

For this your warehouse should be setup for location volumes and item volumes.

Volumetric setup is much more advance and real than stocking limits.

The biggest difference is that as your picking location is set for 100 pcs limit and first pallet moved was for 99 pcs leaving space for 1 pcs in the location. To compensate the same system moved another full pallet just to fill that one item. (your setup to round full LP)

If this was volumetric setup the location usable volume is 110 m3 and volume of 1 pl is 105 system will never suggest to put another pallet to fill the remaining 5 m3 of volume and will select a new location for second pallet.

I have used volume based setup and it works to the perfection. The only thing is the hard work to maintain master data once for the location and item volumes.

Before I did volumetirc setup same result as yours as I got three replenishment work and two sales work

For the same setup I did voumetric setup and and it worked as it should considering two full pallets cant be stored at one location and Dynamics moved both pallets to individual locations.

The key point is remaining quantity in a location as per stocking limit will be filled by another full pallets but remaining partial volume will not be filled by a full pallet if its not enough to accommodate it fully and a new location will be suggested.

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Lauri Looga 70 on at

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Hi Sagar Suman,

thank you for your response. I tried your suggested setup but I did not get the same result as you did. For me it worked as it worked before. Maybe I am missing some setup here.

What I did:

1. First I removed current location limit (1 PLL limit for certain type of location profile)

2. Second I set up item volume (1 ea = 1 volume unit):

3. Next I set up volumetric limit for location profile (max volume is 100 volume units):

So with this setup I expected now, that second LP is not replenished to same location.

Then I released again my sales order and got again 3 replenishments and 2 sales orders, where first 2 replenishments were into same location as before :(

Is there any other setup somewhere I should check for volumetric limit?

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Sagar Suman 6,550 Super User 2025 Season 2 on at

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Hi Lauri Looga,

You need to setup item volume on the physical dimension group ID in the released products.

Do setup here and try again. Make sure one pallet volume is less than one location volume and one location volume cannot accommodate two pallets.

Dynamics will select another location for put as first location run out of volume.

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Lauri Looga 70 on at

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Hi Sagar Suman,

I tried this also but it did not work.

I have 3 pallets in bulk area, each contain 99 pcs (volume = 99).

I have empty locations I hope to replenish some of those pallets (no other items on location).

I have item Physical dimension group EA, where volume for 1 EA is 1.

I have location profile, where max volume = 100.

And i still got 2x99 replenish to one location and 1x99 to another location.

Clearly there is something I am missing. Or we have different test data. Are your replenishment locations actually empty and there are not any other items at these locations? When there is even small qty already at location it affects how demand is split and result may be different.

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Lauri Looga 70 on at

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Just in case I provide also version info:

Installed product version : Microsoft Dynamics 365 for Finance and Operations (8.0)

Installed platform version : Update15 (7.0.4841.35234)

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Sagar Suman 6,550 Super User 2025 Season 2 on at

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Hi Lauri Looga,

After creating some scenarios it seems that the location volume is working no differently to location stocking limits.

I could succeed in making sure one partial pallet was moved to unique location as the volume of the one item (1331cm3) was more than the remaining volume in the location 110 cm3 as a result in my case Dynamics did not moved another pallet to the same location as it does in your case.

As I took a physical example from the business it seemed that Dynamics is moving the next full pallet to next location but that is not the case sadly.

Logic is that if there is enough volume remaining for one item than Dynamics will more one full pallet to fill that one item( as we have done round up to full LP) and it seems there is nothing we can do to stop it for now sadly. (Seems logical also but on other hand but I also get your business requirement which is also justified)

Location stocking limits only work to perfection for full pallets and anything less than a full pallet will cause the above scenario.

So your findings and setups are fine as I also get same results if one item volume is more than or equal to remaining space in location Dynamics will move a full pallet and same hold true for stocking limit.

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Lauri Looga 70 on at

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Hi Sagar Suman,

Thank you for confirming, that I am not missing something: I hope Microsoft will address this issue, because in may reasons, there can be not standard pallets in warehouse.

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Sagar Suman 6,550 Super User 2025 Season 2 on at

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Hi Lauri Looga,

Yes I agree and I believe the thought is that we are supposed to move one full pallet to fill remaining volume and then move it back to bulk locations once done.

The issue is that as soon as quantity goes below full pallet Dynamics does not consider it as a physical pallet anymore (Physically it is)

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