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Materials ManagementWarehouse Management Overview
- Ramakrishna Mangena SAP CoE, Telecom TEG
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Agenda
• Overview of ERP / SAP & Modules of SAP • MM Overview • MM Organization Structure • Master data
• Purchasing• Inventory Management• Invoice Verification• Concepts of Warehouse Management
– Overview
– Warehouse Management structure
– Functionalities
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Logistics Execution Overview
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Logistics Execution
Logistic Execution provides all of the functions (for the most part cross-industry) required to map the execution of logistics processes.
Logistics Execution is the link between procurement and distribution in SAP R/3,regardless of whether the processes involved are internal or relate to third-parties (vendors, customers, or service providers).
Warehouse Management
Shipping
Transportation
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The SAP Warehouse Management system (WMS) provide flexible, automated support in processing all goods movements and in managing stocks at storage bin level in highly complex storage facilities.
Warehouse Management optimizes the use of all storage bins, mix pallets belonging to several owners in randomly slotted warehouses and know exactly where a particular material is located in the warehousing complex at all times.
Warehouse Management
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Warehouse Management in SAP R/3 contains the following five basic functions:
Inventory Management exact to storage bin level
Mapping and control of all goods movements
Monitoring of the processing of these goods movements
Connection to mobile data entry as part of the integrated Radio
frequency (RF) solution
Connection to specialist external systems using an interface
Warehouse Management
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Optimizing the storage space utilization
More number of materials and more inventory transactions
Special storage conditions for certain materials
Handling Hazardous materials
Always store in specified fixed bin (Paints, glue, gas, acids etc.)
Better visibility over stocks under quality inspection
Availability of warehouse stocks near production work centers
Flexible to different shipping requirements
Integration with other Logistics modules
What SAP WM offers
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Integration with Other Modules
Inventory Management
Quality Management
Production Planning
Sales & Distribution
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Advanced features of WM
Storage Unit Management
Wave picking
Cross docking
Handling Unit Management
RFID
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Warehouse structure
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Warehouse Number
Warehouse number encompasses the organizational and physical aspects of a warehouse complex as a single concept.
SAP recommends single warehouse number for group of storage areas or buildings that are in the same geographical area.
For a given Plant & Storage location combination, you can have only one Warehouse number assigned to it.
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Storage Type
A physical or logical subdivision of a warehouse complex that is characterized by its warehouse technique, the space used, its organizational form, or its function.
Storage type has the following features:
A storage type does not have an address, but a short description.
It is possible to maintain storage-type-specific material data.
With in a storage type, inventory is executed for each storage bin.
Strategies for Putaway and Picking are maintained at storage type level.
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Storage Types
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Storage section, Picking area & Storage Bin
Storage section is an organizational subdivision of a storage type that groups together storage bins with similar features for the purpose of putting away stock. The criteria for grouping bins for example, heavy parts, bulky materials, fast-moving items, slow-moving items.
Picking area is a section within a storage type in which all picking activities are carried out in the same way.
Storage bin is the smallest available unit of space in a warehouse. Storage bin type is used to subdivide into groups for example, large bins, small bins etc.
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Storage section & Storage Bins
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Storage Bin
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Automatic creation – Storage Bins
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Sort sequence for Putaway/Picking
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Quant
Quant is the stock of any material with the same features in one storage bin. Quants can be created or deleted solely through goods movements.
The following are the criteria for the quant splitting:
Material number
Plant & Storage location
Stock category
Special stock assignment
Batch number (if applicable)
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Assignment
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Assignment
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Assignment
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Interim Storage Type
The Inventory Management (IM) application component communicates with the Warehouse Management component through interim storage types. Goods receipts and issues posted in IM are automatically updated in WM in these interim storage types.
Standard SAP interim storage types:
901 GR area for Production
902 GR area for external receipts
910 GI area general
916 Shipping area deliveries
917 Quality assurance
999 Differences
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IM – WM Interface
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Reference Movement Type
Each Inventory Management movement type that is relevant for the WM system is allocated to a reference movement type, with which the system determines the corresponding movement in the WM system.
If you do not want to connect an IM movement type to WM movement type, then assign Reference movement type 999. For example goods receipt posting for account assigned purchase order.
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WM Movement Type
The warehouse management movement type provides the following information required for stock placements and stock removals:
Interim Storage type
Coordinate of the storage bin
Confirming and printing transfer orders
Indicator for Storage type search
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WM Documents
Transfer Requirement (TR) is a base planning document records interface movement. Information captured in the Transfer requirement is taken as base for the Transfer order creation.
Posting change notice (PCN) is similar to Transfer requirement in terms of subsequent process, created for a posting change in Inventory Management.
Transfer Order (TO) is the central document in warehouse management. Every material movement in the warehouse requires a transfer order, regardless of whether the movement is real or virtual.
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IM – WM Interface
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Goods movements in WM
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Search Sequence
Storage Type search
Storage section search (optional)
Storage bin search
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Putaway
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Fixed bin - Fixed bin assignment per material
Open storage - One storage bin per storage section
Addition to existing stock - Attempt to add material to existing
stock
Empty bin - Search for next empty storage bin in the storage
section
Bulk storage - Search for bin in the bulk storage area
Putaway Strategies
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Picking
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FIFO - The system proposes the oldest quant for the stock pick
LIFO - The system proposes the most recent quant for picking
Partial quantity - Removal from partial pallets first, then standard
pallets.
Large/small - Pick proposal based on quantity
Fixed bin – Picking from the fixed bin.
Picking Strategies
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Posting changes
Stock Transfer – Physical Vs Logical
Plant to Plant Transfer
Bin to Bin - Movements
Material to Material / Batch to Batch Transfer
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Physical Vs Logical movement
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Stock transfer & Posting change
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Bin to Bin movements
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Material to Material
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Interface with Quality Management
In case of materials subjected to quality checks, after goods receipt inspection lots are generated in Quality Management module. This inspection stock of the material can be handled using any of the following four options in Warehouse Management.
Move Inspection lot stock to Interim storage type relevant for Quality
assurance (917) and the remaining to destination bin
Retain Inspection lot stock at GR area interim storage type (902) and
the remaining to destination bin
Move entire quantity to the destination bin
Retain entire receipt stock at GR area interim storage type (902)
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Interface with Production Planning
Using WM – PP interface, materials required for the production are not moved to goods issue interim storage type, instead they are sent directly to Production Supply Area (PSA).
PSA groups together Work Centers for the purpose of Materials staging from the Warehouse.
Once the production process is complete, confirm production order. The consumed components are back flushed (goods issue is posted during the confirmation) from staging area.
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Physical inventory in WM
Block Storage type for Physical Inventory – LI06
Create Physical Inventory Document – LI01N
Enter Inventory count – LI11N
Check Inventory status – LX22
Clear differences in WM – LI20
Clear difference in IM – LI21
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Warehouse activity monitor
Warehouse activity monitor is an instrument for monitoring warehouse movements. It informs you processes that have failed to run completely or have run with errors, and offers you the opportunity to create or correct missing documents. The Warehouse activity monitor contains seven objects for monitoring.
01 – Unconfirmed Transfer orders
02 – Open Transfer requirements
03 – Open Posting change notices
04 – Open Deliveries
05 – Negative stocks
06 – Interim storage stocks
07 – Critical stocks for production supply
A document or stock item is only displayed in the Warehouse activity monitor if the defined processing periods (in customizing) are exceeded.
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Thank You