Replenishment even though no inventory

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Posted on by Guy Terry

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Is it valid for a Min/Max replenishment to succeed (and create a Put line for the full required quantity) if there is not enough inventory of the item anywhere in the warehouse?

In my scenario, there are 15 x BAG118 in the Warehouse. The item has one Fixed location, which I am attempting to fill using Min/Max replenishment. The fixed location is empty. The Max on the replenishment template is set to 100. The location directive allows split, and is set to look at Bulk locations in order of lowest physical inventory first.

I run the Replenishments periodic job. It creates several picks from the bulk locations, and then a Pick with no location for the remaining 85. It also creates a Put for the full 100. Where does it imagine I'll get the 85 from?!

AX 2012 R3 CU8

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Weaveriski 23,620 Moderator on at

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Logically the answer is yes, the system must replenish as per the rule and replenish back to the 100, this is the demand point. It would expect that your downstream configuration would replenish enough into bulk to cover the need to replenish back to the 100, which would ultimately go further downstream to MRP.

Why is it 100, can you use the replenishment type if you dont want to hold inventory to cover the 100 refill point?

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Guy Terry 28,924 Moderator on at

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Hi Steven. I do want to hold inventory in bulk to cover the 100, but if you do a Min/Max replen, say, once per day over all pick locations, you're bound to get something which has run low.

I don't actually mind what it does, but I'd prefer it to be consistent....

If I un-tick 'Allow spilt' (and change nothing else) I might expect a replen from one bulk location to be created. In my example above, from the first location with the qty 1. And then and then another pick line from blank location for the remaining qty.

What actually happened is that the replen fails. And I've just had an epiphany. Of course it fails; it's not allowed to create two picks. Therefore it can't create a put for the full quantity.

Ok - I get it. There's no bug. I can work with that. Thanks Steven!

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Guy Terry 28,924 Moderator on at

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For anyone who stumbles across this post later.. related to my original question about a 'Pick' which could not be picked...

It is possible to use a Location directive failure to ensure work does not get created in this scenario. If I run the scenario from the screenshot at the top of the page, and a Location directive failure exists for replenishments, I get the following result:

i.e. the Pick for 85 is not created, and the Put becomes only the quantity that can be replenished.

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I have a situation where only want to release work to warehouse if the qty is in the picking locations. AND not to allow any partial releases. This includes if I have a multiple line SO. If one line can't be picked the entire SO goes on a temp hold for replenishment.

We do this because of small parcel boxes and don't want to have workers shipping partial shipments. Since we use a lot of warehouse automation with Print and Apply we need to ensure no partial release unless directed by user to over-ride or remove line item.

So in your example above of a sales order having 100. If we have 15 in picking and 85 in bulk we don't want to release. How do we accomplish this?

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Guy Terry 28,924 Moderator on at

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Hi Kevin,

I would think about using two different functions. You have 'Fulfilment rate', which you can use to ensure that an order will only be released to the warehouse if all order lines are reserved in full. This means you can be sure that orders that are released can be picked in full.

technet.microsoft.com/.../dn887220.aspx

Using fulfilment rate, your example order of 100 could be released to the warehouse. To ensure that the inventory in bulk will get to the picking location, I would use Wave demand replenishments.

technet.microsoft.com/.../dn750873.aspx

Sales picking work that is dependent on a replenishment cannot be picked until the replenishment is completed, so it would not naturally be possible to short ship an order that was waiting for a replenishment.

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Thanks. The fulfillment rate is great. A follow up question on the replenishment.

If we have a batch replenishment based on demand, and another batch running to release to warehouse, how do we skip the SO's that don't have the inventory in the picking location until the warehouse has completed work from the replenishment. We typically do thousands of orders per day, so to manually review would be impossible. Appreciate the feedback.

Kevin

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Guy Terry 28,924 Moderator on at

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Hi Kevin,

If you are doing replenishment based on demand (rather than Min/Max replenishment), you don't need a batch job to create the replenishment work. The act of processing the Wave creates the replenishment work automatically.

So in the scenario that you want to use the 'Auto release of sales orders' batch job, you would set the fulfilment rate. This will ensure that orders which are released can be fulfilled in full by stock that is somewhere in the warehouse.

Releasing the order will create a Shipment, which is added to a Wave. Processing the Wave will create replenishment and picking work. The work is then released to the handhelds. (Note - all of these steps can be automated by the Wave template, so that Releasing an Order can appear to directly create released work). It is not possible to action Sales work on the handheld if it is blocked by replenishment work.

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babarnat 50 on at

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Thanks Guy,

I had the same issue and your suggestion saved my process. The question is why is trying to pick something even if there is no on hand availability. did you create a case in microsoft for this? Thanks again

Michele

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Guy Terry 28,924 Moderator on at

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No, I did not, and I do not consider it a bug. Really it means that the Location directive cannot find enough inventory in the locations in which you have allowed it to look. It could be that the Location directive is not configured to look in all locations.

In any case, you control the behaviour through the use of Location directive failures.

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babarnat 50 on at

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I'm checking only in my bulk locations and I'm fine with that. Anyway, I activated the location directive faiuere and it works, thanks.

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