A sample SAP WM Blueprint (Actual Customer)

Florian GmbH

 

Business Blueprint
Warehouse Management System

 

SCMOPEX.com

 

FLORIAN GMBH SCMOPEX.COM
WM MODULE BUSINESS BLUE PRINT

 

All revisions made to this document are listed here in chronological order.

S.No Reason for Change Version No. Effective Date
1 Original 1.0

 

 

  FLORIAN GMBH SCMOPEX.COM
WM MODULE BUSINESS BLUE PRINT

 

Business Blue Print Preparation and Approval
FUNCTION DEPARTMENT DESIGNATION NAME SIGN & DATE
Prepared by
Reviewed & Approved by
Authorized by

 

 

  FLORIAN GMBH SCMOPEX.com
WM MODULE BUSINESS BLUE PRINT

 

Table of Contents

Contents

INTRODUCTION…………………………………………………………………………………… 9

Objective of this Report…………………………………………………………………………….. 9

Structure of the Report…………………………………………………………………………… 10

1.1            Organization Overview…………………………………………………………………. 10

1.1.1         About Florian GmbH  ……………………………………………………………………… 10

1.2            Warehouse Management (WM) at Florian GmbH……………………………………. 11

ORGANIZATION STRUCTURE……………………………………………………………….. 12

2.1            Organization Structure………………………………………………………………… 12

2.1.1         Company Code………………………………………………………………………………. 12

2.1.2         Plant………………………………………………………………………………………… 12

2.1.3         Storage Locations…………………………………………………………………………. 13

2.1.4         Warehouse………………………………………………………………………………….. 17

2.1.5         Organization structure of Warehouse Management…………………………………… 18

MASTER DATA……………………………………………………………………………………. 26

3.1            Master Data………………………………………………………………………………. 26

3.1.1         Material Master…………………………………………………………………………… 26

3.1.2         Views in the Material Master Record……………………………………………………. 27

3.1.3         Organization Levels in Warehouse management for Material master data

maintenance…………………………………………………………………………….. 27

3.1.4         Defining Warehouse Data in the Material Master……………………………………… 27

3.1.5         Integration………………………………………………………………………………… 27

WAREHOUSE STRUCTURE……………………………………………………………………. 28

  FLORIAN GMBH SCMOPEX.com
wm module business blue print

 

4.1              General Description……………………………………………………………………. 28

4.1.1           Warehouse Number……………………………………………………………………….. 28

4.1.2           Storage type………………………………………………………………………………. 28

4.1.3           Interim Storage Areas……………………………………………………………………. 37

4.1.4           Stock Placement Using Storage Unit Types…………………………………………….. 39

4.1.5           Storage Section:………………………………………………………………………….. 42

4.1.6           Storage Bin:………………………………………………………………………………. 42

4.1.7           Quant:……………………………………………………………………………………… 44

4.1.8           Shelf life expiration date (SLED)……………………………………………………….. 45

4.1.9           Number Ranges……………………………………………………………………………. 45

4.1.10        Types of Stocks:………………………………………………………………………….. 47

4.1.11        Stock Category……………………………………………………………………………. 48

4.1.12        Status of Stock in the Warehouse………………………………………………………. 48

4.2        Put away and Picking Strategies……………………………………………………… 49

4.2.1           Forms and reports required……………………………………………………………… 50

warehouse management process components………………………………………………….. 51

5.1              Transfer requirement (TR)……………………………………………………………. 51

5.1.1           Use…………………………………………………………………………………………. 51

5.1.2           The system updates the transfer requirement…………………………………………. 51

5.1.3           Structure of Transfer requirement…………………………………………………….. 52

5.1.4           Transfer requirements can be created:…………………………………………………. 52

5.1.5           Transfer requirement updates:………………………………………………………….. 53

5.1.6           Automatic creation of transfer requirements…………………………………………. 53

5.1.7           Manual creation of TR…………………………………………………………………… 53

5.2        Transfer order………………………………………………………………………….. 54

5.2.1           Structure of Transfer Order (TO):…………………………………………………….. 54

5.2.2           Creating Transfer Orders……………………………………………………………….. 55

5.2.3           Prerequisites……………………………………………………………………………… 56

5.2.4           Confirmation of Transfer Orders (TO’s)………………………………………………. 56

posting changes IN WM…………………………………………………………………………… 57

6.1.1           Purpose…………………………………………………………………………………….. 57

6.1.2           Reasons for Making Posting Changes…………………………………………………… 57

6.1.3           Integration……………………………………………………………………………….. 57

6.1.4           Processing Posting Changes…………………………………………………………….. 57

6.1.5           Process Flow……………………………………………………………………………… 58

6.1.6           Displaying Posting Change Notices……………………………………………………… 58

6.1.7           Processing Posting Changes Entirely Within WM…………………………………….. 59

6.1.8           Processing Inspection Stock…………………………………………………………….. 59

  FLORIAN GMBH SCMOPEX.com
wm module business blue PRINT

 

6.1.9         Updates in the System:…………………………………………………………………….. 59

6.1.10       Releasing Stock from Inspection…………………………………………………………. 60

6.1.11       Releases from More than One Storage Type…………………………………………….. 60

6.1.12       Procedure in WM………………………………………………………………………….. 60

6.1.13       Processing Blocked Stock (Expired Goods)…………………………………………….. 61

6.1.14       Converting Available Stock to Inspection Stock………………………………………. 61

6.1.15       Converting Available Stock to Inspection Stock for Retest…………………………… 61

6.1.16       Forms and reports required………………………………………………………………. 61

GOODS RECEIPT………………………………………………………………………………… 63

7.1            Goods movements in Warehouse Management……………………………………….. 63

7.1.1         The Goods Receipt Process……………………………………………………………….. 63

7.1.2         WM – QM Interface………………………………………………………………………… 64

7.1.3         Process flow……………………………………………………………………………….. 64

7.1.4         Goods Receipt for Quality Inspection…………………………………………………… 65

7.1.5         Process Flow………………………………………………………………………………. 66

7.1.6         Releasing Material from Inspection Stock……………………………………………… 66

7.1.7         Tasks in Inventory Management and Quality Management…………………………….. 67

7.1.8         Customer return material handling process……………………………………………. 67

7.2            Goods Receipt – For Purchase order / Process order /

Return sale order……………………………………………………………………… 68

7.2.1         SAP Scenarios……………………………………………………………………………… 68

7.3            Goods Receipt without Purchase order……………………………………………… 69

7.3.1         SAP Scenarios……………………………………………………………………………… 69

7.4            Goods Receipt of Bulk Storage………………………………………………………… 69

7.4.1         SAP Scenarios……………………………………………………………………………… 69

7.5            Online Rejection Material Documents……………………………………………….. 71

7.5.1         SAP Scenarios……………………………………………………………………………… 71

GooDs issuE ………………………………………………………………………………………. 72

8.1            Goods Issue in the Warehouse Management…………………………………………. 72

8.1.1         Purpose……………………………………………………………………………………… 72

8.1.2         Process Flow………………………………………………………………………………. 73

8.1.3         Integration………………………………………………………………………………… 73

8.1.4         Features…………………………………………………………………………………….. 74

8.1.5         Impact of delivery on Warehouse Management system…………………………………. 74

8.1.6         Creating a TO for a Cancelled Delivery…………………………………………………. 76

8.1.7         Goods Issue Based on an Inventory Management Posting……………………………… 77

8.1.8         Goods Issue to a Cost Center…………………………………………………………….. 77

8.1.9         Goods Issue for return delivery to vendor (Vendor Return)…………………………. 77

  FLORIAN GMBH SCMOPEX.com
wm module business blue print

 

8.1.10       Creating a Transfer Order for a Material Document………………………………….. 77

8.1.11       Goods Issue for Production Supply……………………………………………………… 78

8.2            Goods Issue – To Process order / Cost center / Reservation /

Purchase order / Return      Delivery to Vendor………………………………… 79

8.2.1         SAP Scenarios……………………………………………………………………………… 79

8.3            Goods Issue – To Control samples…………………………………………………….. 79

8.3.1         SAP Scenarios……………………………………………………………………………… 79

8.4            Goods Issue against Sales Order……………………………………………………… 80

8.4.1         SAP Scenario……………………………………………………………………………….. 80

8.4.2         Forms and reports required………………………………………………………………. 80

transfer postings…………………………………………………………………………………… 81

9.1            General Description…………………………………………………………………….. 81

9.1.1         Features…………………………………………………………………………………….. 81

9.1.2         Transfer Postings and Stock Transfers…………………………………………………. 81

9.1.3         Stock Transfer Procedures………………………………………………………………. 81

9.1.4         Stock Transfers and Replenishment……………………………………………………… 81

9.1.5         Warehouse to warehouse stock transfer belong to two different plants………….. 82

9.1.6         From Warehouse to Warehouse (in the same Plant)……………………………………. 83

9.1.7         Internal Stock Transfers: Bin to Bin transfer in the same Warehouse……………… 83

9.1.8         Transfer of Stock from Sales order stock to Sales order Stock…………………….. 84

9.2            Transfer of material from one warehouse to another warehouse

which belong to two different plants……………………………………………… 85

9.2.1         SAP Scenarios……………………………………………………………………………… 85

9.3            Transfer Posting – Warehouse to Warehouse (Within the Plant)………………. 85

9.3.1         SAP Scenarios……………………………………………………………………………… 85

9.4            T ransfer Posting-Bin to Bin transfer of Material with in the

Warehouse………………………………………………………………………………… 86

9.4.1         SAP Scenarios……………………………………………………………………………… 86

9.5            T ransfer Document – Created by other movements………………………………… 86

9.5.1         SAP Scenarios……………………………………………………………………………… 86

9.6            Material Document – Created by other movements…………………………………. 88

9.6.1         SAP Scenarios……………………………………………………………………………… 88

9.6.2         Forms and reports required………………………………………………………………. 88

physical inventory………………………………………………………………………………….. 89

10.1        Purpose…………………………………………………………………………………….. 89

10.1.1       Features…………………………………………………………………………………….. 89

10.1.2       Physical Inventory Procedures…………………………………………………………… 90

10.1.3       Process Flow………………………………………………………………………………. 91

 

  FLORIAN GMBH SCMOPEX.COM
WM MODULE BUSINESS BLUE PRINT
10.1.4 Procedure to be followed for Physical Inventory in Warehouse

 

 

Management……………………………………………………………………………… 92

10.1.5             SAP Scenarios……………………………………………………………………………… 92

10.1.6             Forms and reports required……………………………………………………………… 93

10.1.7             Integration with other modules……………………………………………………………………. 93

 

  FLORIAN GMBH SCMOPEX.COM
WM MODULE BUSINESS BLUE PRINT

 

 

Introduction

The aim of the blue print on Warehouse Management System (WMS) is to know the functions, processes & procedures to be followed for the business requirements, integration with other modules & processes, which is the main deliverable of Business Blueprint Phase, is to serve as conceptual master plan for Warehouse Management System (WMS) module for Florian GmbH

This Blueprint has been developed by documenting all input gathered from the core team by scheduling meetings and workshops. This document shows the business requirements in detail, and serves as the basis for organization, configuration and development activities.

Objective of this Report

During the course of this phase of the assignment, the SCM group headed by SCMOPEX.com held business process workshop for the Core team members (across businesses) to discuss and deliberate the business requirements for respective functional areas. The objective of the workshops was to discuss the following aspects of each business process and to define the requirements of Florian GmbH in detail.

■ Business Process ■ Expectations/ Improvements ■ Reporting/Information requirements

Based on the discussions during the Business Process Workshop, various business scenarios have been documented which need to be addressed by the system. The purpose of this report is to confirm the understanding of these business scenarios, which would form the basis for system specifications and to also list requirements which cannot be addressed by the system. This document forms the basis for all subsequent activities to be conducted during the project.

  FLORIAN GMBH SCMOPEX.COM
WM MODULE BUSINESS BLUE PRINT

 

Structure of the Report

The report initially gives an overview of the Warehouse Management Module purview. This would essentially help in defining the boundaries of the module and also in identifying the activities to be performed within Warehouse Management Module in SAP. Subsequently, the report discusses in detail, the proposed coverage of SAP at Florian GmbH., in terms of organizational entities and business processes. Each business process has been described with all the variations. The authorization requirements would be identified and configured during the configuration phase.

1.1   Organization Overview

About Florian GmbH

Florian GmbH is an integrated manufacturers and exporter of finished construction equipment and tools using a customer’s brand name. Florian’s is a significant global player in developing tools and equipment per customer brand requirements with quality standards that meet the most stringent regulated market standards. Florian Design is a small R&D unit that develops customer specific products.

Florian has 6 world-class plants in Germany offering its partners the advantage of multi-location product sourcing.

Florian has marketing presence in 34 countries. This broad network facilitates partnering with global organizations ranging from UNICEF, UNDP, Local Governments and Distributors.

Sales and distribution out of Germany is performed by Florian Logistics GmbH.

In addition, Florian also undertakes Contract Research & Manufacturing of Specialty tools.

Florian have about 1500 employees in total in different operations across various geographical locations. The annual revenues of the group are in the range of 250 million Euro.

Florian have implemented SAP as the backbone ERP system in 20010-11, which is being successfully used for the few years. However, keeping in view the future challenges and growth plans, Florian has decided to implement mySAP ERP R/3 4.7 Ver. Warehouse Management Module.

 

  FLORIAN GMBH SCMOPEX.COM
WM MODULE BUSINESS BLUE PRINT

 

1.2   Warehouse Management (WM) at Florian GmbH

The Warehouse Management system (WMS) is implemented in the following all plants for the management of warehouse.

The SAP Warehouse Management module allows:

□      Definition and mapping of the physical warehousing structures in the system

□      Processing goods movements like – receipts, issues and stock transfers

□      Maintain up to date stock inventories in the Warehousing complex at storage bin level

The Warehouse management is integrated with Material Management (MM), Sales & Distribution (SD), Quality Management (QM) modules. The base document for the material movement will be generated either in the MM or SD or Qm modules.

For all the Goods receipt (GR) from the vendors and other plants, the base document will be generated in MM module. For Goods Issue (GI) for either to production or to other plants the base document will be generated in MM module.

As quality management is active in the organization, all the materials will pass through the quality inspection process during the GR and GI and posting change document (change in the stock type of the material stock i.e. either from quality inspection stock to unrestricted etc) will be generated in quality management for the placement or removal of material in warehouse.

During the GR quality inspection process and online inspection process during production, the base document to return the material to the vendor will be generated in QM module.

For the delivery of goods against sales order, the delivery document will be generated in SD module for the removal of the material from the warehouse.

For handling the customer return materials, the base document will be generated either in SD module.

The inventory will be managed both in storage location level in Inventory management (IM) level in MM module and at bin level in Warehouse Management.

WM module also has RFID & Bar code reading functionality. These can be explored & implemented in future as separate project.

 

  FLORIAN GMBH SCMOPEX.COM
WM MODULE BUSINESS BLUE PRINT

 

Organization Structure

2.1    Organization Structure

In SAP, a company is made up of a variety of operational groups. These groups or organizational units can include sales, purchasing, accounting, distribution, and so forth. SAP R/3 System is designed to support each of these groups. Different software applications in the R/3 System can be linked to these organization units to create a completely integrated company structure.

Flexible organizational units in the R/3 System let user represent user’s organization with a comprehensive company structure. The combination and integration of organizational units form the legal and structural basis of a company. For example, organizational units can interface with materials management, sales and distribution, and financial accounting. Different application areas in the R/3 System can be linked through organizational units to create a completely integrated company structure.

Company Code

A Company code represents the XXX client Group legal entity and accounting unit where balance sheet and profit and loss statements are created.

There will be XX Company Codes representing XXX client Group.

1000
2000
3000

 

Plant

A plant is an organizational unit within the company, against which materials are purchased and stored. Only the above company codes are considered for the WM implementation.

Tool Company Code: 1000 –

1050 Tool Products Division
1060 Electronics Division
1070 Equipment Casings
1080 Specification Development
1090 Tool Facilities Formulation
1100 Global Distribution

 

Company Code: 2000 – FLORIAN DESIGN  

Florian Design

Company Code: 3000 – FLORIAN LOGISTICS GMBH

Florian Logistics GmbH.

Storage Locations

A storage location is a unit that allows the differentiation of material stocks within a plant. Inventory management on a quantity basis is carried out at storage location level. Physical inventory is also carried out at storage location level. Each plant may have multiple storage locations.

Plant Code Storage location
1050 CR01
1050 CSLF
1050 FG01
1050 NMFG
1050 PM01
1050 CSLP
1050 SMP1
1050 RM01
1050 CSLR
1050 FD01
1050 PS01
1050 SMR1
1050 RR01
1050 MI01

 

  FLORIAN GMBH SCMOPEX.COM
WM MODULE BUSINESS BLUE PRINT

 

Plant Code Storage location
1060 CR01
1060 CSLF
1060 FG01
1060 NMFG
1060 PM01
1060 CSLP
1060 SMP1
1060 RM01
1060 CSLR
1060 FD01
1060 PS01
1060 SMR1
1060 RR01
1060 MI01

 

Plant Code Storage location
1070 CR01
1070 CSLF
1070 FG01
1070 NMFG
1070 PM01
1070 CSLP
1070 SMP1
1070 RM01
1070 CSLR
1070 FD01
1070 PS01
1070 SMR1
1070 RR01
1070 CL01

 

  FLORIAN GMBH SCMOPEX.COM
WM MODULE BUSINESS BLUE PRINT

 

Plant Code Storage location
1080 CR01
1080 CSLF
1080 FG01
1080 NMFG
1080 PM01
1080 CSLP
1080 SMP1
1080 RM01
1080 CSLR
1080 FD01
1080 PS01
1080 SMR1
1080 RR01
1080 MI01

 

Plant Code Storage location
1090 CR01
1090 CSLF
1090 FG01
1090 NMFG
1090 PM01
1090 CSLP
1090 SMP1
1090 RM01
1090 CSLR
1090 FD01
1090 PS01
1090 SMR1
1090 RR01
1090 MI01

 

  FLORIAN GMBH SCMOPEX.COM
WM MODULE BUSINESS BLUE PRINT

 

Plant Code Storage location
1100 CR01
1100 CSLF
1100 FG01
1100 NMFG
1100 PM01
1100 CSLP
1100 SMP1
1100 RM01
1100 CSLR
1100 FD01
1100 PS01
1100 SMR1
1100 RR01
1100 MI01

 

Plant Code Storage location
2010 CR01
2010 CSLF
2010 FG01
2010 NMFG
2010 PM01
2010 CSLP
2010 SMP1
2010 RM01
2010 CSLR
2010 FD01
2010 PS01
2010 SMR1
2010 RR01
2010 MI01

 

  FLORIAN GMBH SCMOPEX.COM
WM MODULE BUSINESS BLUE PRINT

 

Plant Code Storage location
3010 CR01
3010 CSLF
3010 FG01
3010 NMFG
3010 PM01
3010 CSLP
3010 SMP1
3010 RM01
3010 CSLR
3010 FD01
3010 PS01
3010 SMR1
3010 RR01
3010 MI01

 

Above Same Storage Location will be activated for Warehouse management modules.

Warehouse

The Warehouse Management (WM) application provides flexible, automated support to assist in processing all goods movements and in maintaining current stock inventories in warehousing complex.

WM supports warehousing processes like:

>     Define and manage complex warehousing structures

>     Optimize material flow using advanced put away and picking techniques

>     Process goods receipts, goods issues and stock transfers quickly and easily

The Warehouse Management application is fully integrated into the SAP R/3 system.

Transactions that are initiated in other SAP components result in corresponding tasks in WM which activate the actual physical transfers within the warehouse.

A few of these activities include:

>     Material movements and changes in material status, such as releasing goods from inspection

>     Material staging to production supply areas

>     Picking and shipping goods for sales orders

  FLORIAN GMBH SCMOPEX.COM
WM MODULE BUSINESS BLUE PRINT
Organization structure of Warehouse Management

 

 

Company Code Plant

Code

Storage

location

Name Warehouse

Code

1000 – FLORIAN GMBH 1050 FG01 Finished Goods 105
CR01 Customer returns 105
CSLF Cus supp FERT 105
NMFG Non Moving FG 105
PM01 Packing Material 105
CSLP Cus supp Pack 105
SMP1 Slow-mvng PM 105
RM01 Raw materials 105
CSLR Cus supply ROH 105
FD01 Raw materials / Packing Mat. 105
PS01 Pre purchase sam 105
SMR1 Slow-mvng RM 105
RR01 Rejections 105
MI01 Miscellaneous 105
1000 – FLORIAN GMBH 1060 FG01 Finished Goods 106
CR01 Customer returns 106
CSLF Cus supp FERT 106
NMFG Non Moving FG 106
PM01 Packing Material 106
CSLP Cus supp Pack 106
SMP1 Slow-mvng PM 106
RM01 Raw materials 106
CSLR Cus supply ROH 106
FD01 Raw materials / Packing Mat. 106
PS01 Pre purchase sam 106
SMR1 Slow-mvng RM 106
RR01 Rejections 106
MI01 Miscellaneous 106

 

 

  FLORIAN GMBH SCMOPEX.COM
WM MODULE BUSINESS BLUE PRINT

 

1000 – FLORIAN GMBH 1070 FG01 Finished Goods 107
CR01 Customer returns 107
CSLF Cus supp FERT 107
NMFG Non Moving FG 107
PM01 Packing Material 107
CSLP Cus supp Pack 107
SMP1 Slow-mvng PM 107
RM01 Raw materials 107
CSLR Cus supply ROH 107
FD01 Raw materials / Packing Mat. 107
PS01 Pre purchase sam 107
SMR1 Slow-mvng RM 107
RR01 Rejections 107
MI01 Miscellaneous 107
CL01 Caryl stock 107

 

1000 – FLORIAN GMBH 1080 FG01 Finished Goods 108
CR01 Customer returns 108
CSLF Cus supp FERT 108
NMFG Non Moving FG 108
PM01 Packing Material 108
CSLP Cus supp Pack 108
SMP1 Slow-mvng PM 108
RM01 Raw materials 108
CSLR Cus supply ROH 108
FD01 Raw materials / Packing Mat. 108
PS01 Pre purchase sam 108
SMR1 Slow-mvng RM 108
RR01 Rejections 108
MI01 Miscellaneous 108

 

1000 – FLORIAN GMBH 1090 FG01 Finished Goods 109
CR01 Customer returns 109

 

 

  FLORIAN GMBH SCMOPEX.COM
     
WM MODULE BUSINESS BLUE PRINT

 

CSLF Cus supp FERT 109
NMFG Non Moving FG 109
PM01 Packing Material 109
CSLP Cus supp Pack 109
SMP1 Slow-mvng PM 109
RM01 Raw materials 109
CSLR Cus supply ROH 109
FD01 Raw materials / Packing Mat. 109
PS01 Pre purchase sam 109
SMR1 Slow-mvng RM 109
RR01 Rejections 109
MI01 Miscellaneous 109

 

1000 – FLORIAN GMBH 1100 FG01 Finished Goods 110
CR01 Customer returns 110
CSLF Cus supp FERT 110
NMFG Non Moving FG 110
PM01 Packing Material 110
CSLP Cus supp Pack 110
SMP1 Slow-mvng PM 110
RM01 Raw materials 110
CSLR Cus supply ROH 110
FD01 Raw materials / Packing Mat. 110
PS01 Pre purchase sam 110
SMR1 Slow-mvng RM 110
RR01 Rejections 110
MI01 Miscellaneous 110

 

2000 – FLORIAN DESIGN 2010 FG01 Finished Goods 201
CR01 Customer returns 201

 

 

 

  FLORIAN GMBH SCMOPEX.COM
WM MODULE BUSINESS BLUE PRINT

 

CSLF Cus supp FERT 201
NMFG Non Moving FG 201
PM01 Packing Material 201
CSLP Cus supp Pack 201
SMP1 Slow-mvng PM 201
RM01 Raw materials 201
CSLR Cus supply ROH 201
FD01 Raw materials / Packing Mat. 201
PS01 Pre purchase sam 201
SMR1 Slow-mvng RM 201
RR01 Rejections 201
MI01 Miscellaneous 201

 

3000 – FLORIAN LOGISTICS GMBH 3010 FG01 Finished Goods 301
CR01 Customer returns 301
CSLF Cus supp FERT 301
NMFG Non Moving FG 301
PM01 Packing Material 301
CSLP Cus supp Pack 301
SMP1 Slow-mvng PM 301
RM01 Raw materials 301
CSLR Cus supply ROH 301
FD01 Raw materials / Packing Mat. 301
PS01 Pre purchase sam 301
SMR1 Slow-mvng RM 301
RR01 Rejections 301
MI01 Miscellaneous 301

 

 

  FLORIAN GMBH SCMOPEX.COM
WM MODULE BUSINESS BLUE PRINT

 

Logistics Organization Structure of 3 Company Codes

Warehouse Organization structure for Plants

1050 (SPD)                          1060(BLD)

 

 

 

 

 

Master Data

3.1    Master Data

Master data is defined as data records, which remain unchanged over an extended period of time and contain information that is used in the same manner for similar objects. Consistency and correctness of format and input is essential to ensure full and proper use of the system.

Material Master

The material master record is the source of material specific data, which is used throughout the SAP R/3 system. The data contained in the material master record is required for many functions within the logistics system such as purchasing data for ordering, inventory management for posting goods movements, accounting data for valuation upon goods movements or invoice verification and materials planning data and for the storing the materials in warehouse / storage location.

Material data is held at different organizational levels:

Data on client level: Material group, base unit of measure, material descriptions, general technical data and conversion factors for alternative units of measure.

Data at plant level: All plant and related storage location specific data.

Data at storage level: All storage location specific data.

Data at Warehouse level: All warehouse specific data such as picking and placement strategies.

Data at storage type level: Storage specific data such as bin location specific to the storage area.

M aterial M aster: O rganizational Levels

Data that is valid for the whole company:

For exam ple, m aterial no., m aterial short text, m aterial group, base and alternative units of m easure, …

Data that is valid within one plant:

For exam ple, purchasing data, M R P data, forecasting data, work scheduling data, …

Data that is valid for one storage location:

For exam ple, storage bin description, picking area,

  FLORIAN GMBH SCMOPEX.COM
WM MODULE BUSINESS BLUE PRINT

 

 

Views in the Material Master Record

Data can be maintained and displayed in material master records using views. Just as data in the material master record is maintained for specific departments, such as quality assurance, sales or product planning, some of the data is used specifically by the Warehouse Management (WM) application.

For example, when user maintain material data from the viewpoint of warehouse management, the system displays only the data that is relevant for the storage of the material in the warehouse. General data that is relevant for more than one view (for example, the material’s description, its weight, and its volume) appears in several views.

Organization Levels in Warehouse management for Material master data maintenance

There are two organizational levels that can be defined for WM. In the WM view of the material master record, all the indicators and fields that are used for the entire warehouse number are entered at the warehouse number level. There is also a storage type level with all the indicators that apply to a single storage type but do not for the entire warehouse. If user enter a storage type for a material on the initial screen for the WM view, the system displays an additional section in which user can enter, for example, a fixed storage bin or a control quantity. These fields only apply to the storage type and not to the entire warehouse.

Defining Warehouse Data in the Material Master

The material master data for warehouse management system can be maintained separately or along with the other views. The procedure to be followed for the mater data maintenance is given below. If user want to create the material master data for a material for more than one storage area (storage type) for a warehouse, user have to create the data for each storage type – warehouse combination in creation mode of material master.

To define warehousing data in the material master:

  1. 1. Choose Logistics _ Logistics   Execution   _ Master    Data  _  Material _   Material   _  Create  _

immediately from the SAP menu. Transaction code is MM01.

  1. To change data in the material master, choose Logistics _ Logistics Execution _Master Data_ Material _ Material _ Create _ immediately. Transaction code is MM02. The steps for changing data are basically the same as those described below. Using this function, user can overtype existing data in the material master record. Transaction code is MM02 and MM03 to display the material master.

Integration

The WM has integration with Material management (MM), Sales & Distribution (SD), Quality management (QM) and Production Planning (PP).

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Warehouse Structure

4.1       General Description

The Warehouse Management (WM) application provides flexible, automated support to assist in processing all goods movements and in maintaining current stock inventories in warehousing complex.

WM supports warehousing processes like:

>     Define and manage complex warehousing structures

>     Optimize material flow using advanced put away and picking techniques

>     Process goods receipts, goods issues and stock transfers quickly and easily

The Warehouse Management application is fully integrated into the SAP R/3 system.

Transactions that are initiated in other SAP components result in corresponding tasks in WM which activate the actual physical transfers within the warehouse.

A few of these activities include:

>     Goods receipt from the vendors.

>     Inter plant stock transfers.

>     Material movements and changes in material status, such as releasing goods from inspection

>     Material staging to production supply areas

>     Picking and shipping goods for sales orders

Warehouse Number

In Warehouse Management (WM), a complete physical warehouse is defined under a single warehouse number. Using the warehouse number, user can manage several individual warehouse buildings that, together, form a complete warehouse complex. The warehouse number encompasses the organizational and physical aspects of a warehousing complex as a single concept.

Storage type

It is a storage area in warehouse facility, or a warehouse zone that is defined in Warehouse Management (WM) for a warehouse number. This is 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. A storage bin consists of one or several storage bins.

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Broadly Storage Types can be defined as:

>     Goods receipt area

>     Goods Issue area.

>     Bulk storage

>     Open Storage

>     High rack storage

>     Picking area

>     Shelf storage

We will define the important control indicators at the storage type level that determine the material flow (put away and picking activities) and the way inventory is handled in each storage type. These include the control indicators for:

❖    Put away strategy

❖    Picking strategy

For SPD (1050) plant the following storage types (areas) are finalized:

Ambient Temperature Area

A01 UQ PM Gr.Flr
A02 Open Area UQ PM Gr.Flr
A03 App PM Gr.Flr
A04 Open Area App PM Gr.Flr
A05 UQ PM Printed materials Gr.Flr
A06 Open Area UQ PM Printed materials Gr.Flr
A07 App PM Printed materials Gr.Flr
A08 Open Area App PM Printed materials Gr.Flr
A09 Rej RM/PM Gr.Flr
A10 Open area Rej RM/PM Gr.Flr
A11 UQ PM Ist.Flr
A12 Open Area UQ PM Ist.Flr
A13 App PM Ist.Flr
A14 Open Area App PM Ist.Flr
A15 Rej PM Ist.Flr
A16 Open area Rej PM Ist.Flr
A17 Open area PM cellar (App/UQ)
A18 Open Area Solvents\Liquids

 

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Cool Temperature Area

C01 UQ RM Room
C02 Open Area UQ RM Room
C03 UQ RM Controlled Substance
C04 UQ RM Hazardus chemicals
C05 App RM Room
C06 Open Area App RM Room
C07 App RM Controlled Substance
C08 App RM Hazardus chemicals
C09 UQ PM for Labels
C10 App PM for Labels
C11 App & UQ FG Gr. Flr
C12 Open Area App & UQ FG Gr. Flr
C13 Rejected FG Gr. Flr

 

Cold Temperature Area

D01 App/UQ/Rej for RM
D02 App/UQ/Rej for FG

 

For BLD (1060) plant the following storage types (areas) are finalized:

Ambient Temperature Area

A01 UQ PM Room 1
A02 Open Area UQ PM Room1
A03 Rej PM Room1
A04 Open area Rej PM Room1
A05 App PM Room 1
A06 Open Area App PM Room1
A07 UQ PM Printed materials
A08 Open Area UQ PM Printed materials
A09 App PM Printed materials

 

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A10 Open Area App PM Printed materials
A11 App PM Room 2
A12 Open Area App PM Room2

 

Cool Temperature Area

C01 Open Area UQ PM (PVDC/FOIL)
C02 App PM (PVDC/FOIL)
C03 Open Area App PM (PVDC/FOIL)
C04 UQ PM for Labels
C05 App PM for Labels
C06 Open Area FG ( App & UQ)
C07 Open Area FG ( Rejected)
C08 UQ RM room 1
C09 Open Area UQ RM room1
C10 Rej RM Room1
C11 Open Area Rej RM Room1
C12 App RM Room1
C13 Open Area APP RM Room 1
C14 App RM Room2
C15 Open Area APP RM Room 2
Cold Temperature Area
D01 Open Area RM (App/UQ/Rej)
For ODF (1070) plant the following storage types (areas)
Ambient Temperature Area
A01 UQ RM Room 1
A02 Open Area UQ RM room1
A03 Rej RM Room1
A04 UQ RM Controlled Room 1

 

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A05 UQ RM Room 2
A06 Open Area UQ RM room2
A07 App RM Controlled Room 1
A08 App RM Room1
A09 Open Area APP RM Room 1
A10 UQ RM Room 3
A11 Open Area UQ RM Room 3
A12 App RM Room2
A13 Open Area App RM Room 2
A14 Op Area Solvents(App & Uq)
A15 App & UQ PM
A16 Op Area App & UQ PM
A17 Rejected area PM
A18 App & UQ PM printed
A19 UQ Misc
A20 App Misc
A21 Open area App Misc
A22 Open Area Rej RM
A23 Open Area Rej PM

 

Cool Temperature Area

C01 UQ RM room 1
C02 Open Area UQ RM room1
C03 Rej RM Room1
C04 App RM Room1
C05 Open Area APP RM Room 1
C06 App RM Room2
C07 Open Area APP RM Room 2
C08 UQ RM Room 2
C09 Open Area UQ RM room2

 

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C10 App RM Room3
C11 Open Area APP RM Room 3
C12 App RM Room4
C13 Open Area APP RM Room 4
C14 Bulk storage tanks (both App & UQ)
C15 open area Bulk storage cellar (both App & UQ)
C16 EHG capsule storage(both App & UQ)
C17 Op Area EHG caps storage(both App & UQ)
C18 App & UQ PM (PVC/ PVDC)
C19 Open Area App & UQ PM (PVC/ PVDC)
C20 App & UQ PM (Foil & Label)
C21 Open Area App & UQ PM (Foil & Label)
C22 Rejected area PM
C23 App & UQ FG Gr. Flr
C24 Open Area App & UQ FG Gr. Flr
C25 Rejected FG Gr. Flr
C26 App & UQ FG Ist. Flr
C27 Open Area App & UQ FG Ist. Flr
C28 Misc Mat. FG Gr. Flr
C29 Open Area Rej RM
C30 Open Area Rej PM

 

Cold Temperature Area

D01 UQ RM
D02 APP RM
D03 Rej RM
D04 Op Area UQ RM
D05 Op Area App RM

 

 

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For Star (1080) plant the following storage types (areas) are finalized:

Ambient Temperature Area Cool Temperature Area

C01 UQ RM Gr. Flr
C02 Open Area UQ RM Gr. Flr
C03 Rej RM Gr. Flr
C04 App RM Gr. Flr
C05 Open Area APP RM Gr. Flr
C06 UQ RM Ist. Flr
C07 Open Area UQ RM Ist. Flr
C08 App RM Ist. Flr
C09 Open Area APP RM Ist. Flr
C10 UQ PM Gr.Flr
C11 Open Area UQ PM Gr.Flr
C12 App PM Gr.Flr
C13 Open Area App PM Gr.Flr
C14 Rej PM Gr.Flr
C15 Open area RM controlled Substance (App/UQ/Rej)
Cold Temperature Area

 

 

For SPD 2 (1090) plant the following storage types (areas) are finalized:

Ambient Temperature Area

A01 UQ PM Room 1
A02 Open Area UQ PM Room1
A03 Rej PM Room1
A04 App PM Room 1
A05 Open Area App PM room1

 

Cold Temperature Area

Open Area RM (App/UQ/Rej)

For GRL (1100) plant the following storage types (areas) are finalized:

Ambient Temperature Area

A01 UQ RM Gr. Flr
A02 Open Area UQ RM Gr. Flr
A03 Open Area UQ RM Gr. Flr Room2
A04 App RM Gr. Flr
A05 Open Area App RM Gr. Flr
A06 Open Area App RM Gr. Flr Room 2
A07 Open area Rejected RM Gr. Flr
A08 UQ/App Printed PM Gr. Flr
A09 Open Area UQ/App Printed PM Gr. Flr
A10 UQ/App Printed Labels Gr. Flr
A11 UQ/App PM Gr. Flr
A12 Open Area UQ/App PM Gr. Flr
A13 Open area Rej PM Gr. Flr
A14 Open Area App/UQ/Rej FG Gr. Flr

 

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Cool Temperature Area
C01 UQ RM Gr. Flr
C02 Open Area UQ RM Gr. Flr
C03 App RM Gr. Flr
C04 Open Area App RM Gr. Flr
C05 Open area Rejected RM Gr. Flr
C06 UQ/App PM Gr. Flr
C07 Open Area UQ/App PM Gr. Flr
Cold Temperature Area

 

 

For QLS (3010) plant the following storage types (areas) are finalized:

Ambient Temperature Area

A01 UQ PM Gr.Flr
A02 Open Area UQ PM Gr.Flr
A03 App PM Gr.Flr
A04 Open Area App PM Gr.Flr
A05 UQ PM Printed materials Gr.Flr
A06 Open Area UQ PM Printed materials Gr.Flr
A07 App PM Printed materials Gr.Flr
A08 Open Area App PM Printed materials Gr.Flr
A09 Rej PM Gr.Flr
A10 Open area Rej PM Gr.Flr

 

Cool Temperature Area

C01 App & UQ FG Gr. Flr
C02 Open Area App & UQ FG Gr. Flr
C03 Rejected FG Gr. Flr
C04 Open area Rejected FG Gr. Flr

 

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C05 UQ RM Gr. Flr
C06 Open Area UQ RM Gr. Flr
C07 App RM Gr. Flr
C08 Open Area App RM Gr. Flr
C09 Rejected RM Gr. Flr
C10 Open area Rejected RM Gr. Flr
C11 UQ PM for Labels
C12 App PM for Labels
C13 App RM Ist. Flr

 

Cold Temperature Area

The business requirement of SPD, BLD, QLS, ODF, SFF and GRL blocked storage area or rejected storage area, materials in this area should not be available for sales invoice i.e. for goods issue for either sales order or Process order. Customer return materials will go through the quality inspection and only quality rejected materials will be coming to customer return materials storage area. The materials in this area are not available for issue. The status of the materials in this area should be “blocked”.

Interim Storage Areas

Storage types that are commonly used by Inventory management and warehouse management are called Interim Storage Areas. 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.

Interim storage areas are:

>     Goods receipt area

>     Goods issue area

>     Interim storage area for differences

>     Posting change zone

SAP has predefined intermediate Storage types starting the number with ‘9’ series.

Code Description
901 GR Area for Production
902 GR Area External Rcpts
904 Returns
910 GI Area General
911 GI Area for Cost Center

 

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912 GI Area Customer Order
913 GI Area – Fixed Assets
914 GI Area Production Orders
915 Fixed Bin Picking Area
916 Shipping Area Deliveries
917 Quality Assurance
918 Goods Issue Area Contain.
920 Stock Transfers (plant)
921 Stock Transfers (StLoc)
922 Posting Change Area
923 Packaging Area
980 R/3 –> R/2 Cumulative
998 Init. Entry of Inv. Data
999 Differences

 

 

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Stock Placement Using Storage Unit Types

The Warehouse Management (WM) system allows user to use a number of different storage unit types when user transfer and store materials in the warehouse. For example, user can transfer materials on pallets of various sizes, such as European pallets or industrial pallets. Crates or pallets of materials that must be stored in different locations because of height or weight limits can be stored without unnecessary loss of space.

Usage of Storage Unit Types:

In order to use storage unit types user can

  1. Define storage unit types in the material master record
  2. Enter a storage unit type on the initial screen to create a transfer order without an originating document
  3. Enter a storage unit type on the preparation screen for a transfer order

When creating transfer orders, if user enters the storage unit type either on the initial screen or the preparation screen, the system uses the value user enter instead of the storage unit type in the material master record, if one is available. If user do not enter a storage type on the initial screen and user go to the preparation screen, the system uses the storage unit type defined in the material master record. If users do not enter a storage type on the initial screen and user goes to the item screen, the system does not propose a storage unit type, even if one has been defined in the material master. User must enter the storage unit type and then choose ENTER before the system will propose a storage type and bin.

Following Storage Unit Types will me configured for Florian

105 U1 Pallet
105 U2 Common Unit

 

106 U1 Pallet
106 U2 Common Unit

 

107 U1 Pallet
107 U2 Common Unit

 

108 U1 Pallet
108 U2 Common Unit

 

109 U1 Pallet
109 U2 Common Unit

 

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110 U1 Pallet
110 U2 Common Unit

 

301 U1 Pallet
301 U2 Common Unit

 

Following Storage Bin type will be configured for the entire Warehouse.

105 B1 Racks
105 B2 Cup Board
105 B3 Compactor
105 B4 Bulk Tank

 

106 B1 Racks
106 B2 Cup Board
106 B3 Compactor
106 B4 Bulk Tank

 

107 B1 Racks
107 B2 Cup Board
107 B3 Compactor
107 B4 Bulk Tank

 

108 B1 Racks
108 B2 Cup Board
108 B3 Compactor
108 B4 Bulk Tank

 

109 B1 Racks
109 B2 Cup Board

 

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109 B3 Compactor
109 B4 Bulk Tank

 

110 B1 Racks
110 B2 Cup Board
110 B3 Compactor
110 B4 Bulk Tank

 

301 B1 Racks
301 B2 Cup Board
301 B3 Compactor
301 B4 Bulk Tank

 

 

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Storage Section:

In Warehouse Management (WM), a storage section is an organizational subdivision of storage type that group’s together storage bins with similar features for the purpose of putting away stock.

The criteria for grouping bins can be defined on a user-individual basis, for example, heavy parts, bulky materials, fast-moving items, slow-moving items.

Following Storage Section will be created for High Racks as per the current Rack Levels are available.

L1 Level 1
L2 Level 2
L3 Level 3
L4 Level 4
L5 Level 5
L6 Level 6
L7 Level 7
L8 Level 8
L9 Level 9

 

Storage Bin:

The storage bin is the smallest available unit of space in a warehouse. The storage bin therefore describes the position in the warehouse where the goods are or can be stored. Since the address of storage bin is frequently derived from a coordinate system, a storage bin is often referred to as a coordinate. The coordinate 01-02-03 for example, can refer to a storage bin in row 1, stack 2, and level 3.

User assigns each storage bin to a specific warehouse number and storage type according to its location. User must also assign each storage bin to a storage section. User can also define the following additional characteristics of a storage bin:

❖    Maximum weight

❖    Total capacity

❖    Fire containment section

 

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Storing Materials in storage bins:

 

 

The WM system manages both homogeneous and mixed storage in storage bins.

  1. Homogeneous Storage

Homogeneous storage is the storage of only one material number in a storage bin. User can define a storage type so that only one material can be stored in each available storage bin. Bulk storage areas are set up so that one line or block contains only one material number. For example, materials such as cases filled with beverages, bottled gas and pallets of cement blocks and other construction materials are stored homogeneously in bulk storage areas. This method is preferable when large quantities of the same material are stored in a warehouse.

  1. Mixed Storage

When user define mixed storage for a storage type in your warehousing complex, it is possible to store two or more materials (quants) in each storage bin. There is no standard strategy in WM that automatically would place material together with another material that is already stored in a storage bin. User will manually place the different stock with physical bin partition. Mixed storage is particularly useful when user have smaller quantities of several material numbers that need to be stored in the same storage area. Often, slower moving items are stored in mixed storage areas. Homogeneous storage would not be useful here, because that would mean that only a few boxes might be stored in each storage bin.

Activities:

Creating a single storage bin

From the SAP Menu, choose Logistics _ Logistics Execution _ Master Data _Warehouse _Storage Bin _ Create________ Manually.

Transaction code is LS01.

Creating several storage bins simultaneously

To create a group of storage bins with similar characteristics, user defines a template with the coordinate structure as follows:

From the SAP menu choose Logistics_ Logistics Execution _ Master Data _ Warehouse _Storage Bin _ Create _ automatically.

Transaction code is LS10

Blocking and Unblocking Storage Bins

In WMS will give flexibility of blocking storage bins for put away as well as for picking. User must block any storage bins that are no longer accessible, that have been damaged or are to be renovated, or when put away or picks are not possible. User can block or unblock storage bins

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❖    Selectively

❖    On the basis of rows

❖    In bulk storage with a time limit for put away

❖    For the whole storage type

Quant:

Quant is the stock of any material with the same features in one storage bin. The system manages different batches of a material as different quant. The quantity of a quant can be increased by an addition to existing stock. Quant can be created or deleted solely through goods movements.

The quant serves to manage stocks at storage bin level. When goods are stored in empty storage bin in WM, the system automatically creates a quant in this bin. The system automatically assigns a quant number. The quant is automatically deleted by the system when the material quantity is picked.

In the quant record, the system manages the data of the materials grouped in the quant. This data includes:

>     Quant identification

>     Plant

>     Material number

>     Batch number

>     Stock category

>     Special stock indicator and number

The different types of stock (categories) and special stock are passed to WM from IM and serve as stock separation characteristics in the quant. WM has neither stock categories nor any special stock types of its own. Since it is possible to manage stocks from different plants within one warehouse complex number, the plant must also exist as a stock separation characteristic in the quant.

Since the system automatically assigns a quant number to each separate quant in WM, the system can optimize material flow and manage stock in the warehouse more efficiently.

 

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Shelf life expiration date (SLED)

The SLED field only exists in the quant when shelf life management is active in Materials Management (MM). This happens when the material master is maintained accordingly. During a stock placement in MM user can enter either the production date or the shelf life expiration date. This depends upon whether the field Remaining shelf life has been maintained in the material master record. For example, if 10 days have been entered into this field, the system assumes that when goods are received, the production date was entered and calculates the shelf life automatically. If user leaves this field empty in the material master, the system makes it possible for user to directly enter the shelf life expiration date.

This date that is entered or calculated during the goods receipt is then noted in the quant that is created in the storage bin. If user adds stock to an existing quant in a storage bin, the shelf life expiration date of the new quantity that is added is lost.

Enter the shelf life data into the storage view of the material master record. This data includes:

❖    Maximum time a material can be stored

❖    Minimum shelf life a material must have available to be accepted by the system

❖    Percentage of the total shelf life that must still be available if the goods are to be sent to another distribution point

❖    Time unit used for the shelf life data (days, weeks or years)

❖    Total number of days that the goods can be kept – from production to the shelf life expiration date

Number Ranges

Warehouse Management (WM) numbers many objects in the warehouse on a continual basis. The assignment of number ranges provides an orderly sequencing system for several functions within WM.

Assigning Number Ranges

Number ranges for the following objects in the Warehouse Management can be defined as:

❖    Transfer requirements

❖    Transfer orders

❖    Posting change notices

❖    Physical Inventory

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Following Number Ranges are defined for the above documents for the identification of documents.

Plant

code

Plant Description WH

No

Doc No. For TR Doc No. For TO
From To From To
1050 Tool Products Division 105 6500000000 6599999999 7500000000 7599999999
1060 Beta Lactam Division 106 6600000000 6699999999 7600000000 7699999999
1070 Equipment Casings 107 6700000000 6799999999 7700000000 7799999999
1080 Specification Development 108 6800000000 6899999999 7800000000 7899999999
1090 Tool Facilities

Formulation

109 6900000000 6999999999 7900000000 7999999999
1100 Global Distribution 110 6100000000 6199999999 7100000000 7199999999
3010 Quantum Life Sciences 301 6300000000 6399999999 7300000000 7399999999

 

Plant

code

Plant Description WH

No

Doc No. For PCN Doc No. For Quant
From To From To
1050 Tool Products Division 105 8500000000 8599999999 1 9999999999
1060 Beta Lactam Division 106 8600000000 8699999999 1 9999999999
1070 Equipment Casings 107 8700000000 8799999999 1 9999999999
1080 Specification Development 108 8800000000 8899999999 1 9999999999
1090 Tool Facilities

Formulation

109 8900000000 8999999999 1 9999999999
1100 Global Distribution 110 8100000000 8199999999 1 9999999999
3010 Quantum Life Sciences 301 8300000000 8399999999 1 9999999999

 

Plant

code

Plant Description WH

No

Doc No. For Phy.Inv Doc No. For Phy.Inv-TO
From To From To
1050 Tool Products Division 105 1500000000 1599999999 2500000000 2599999999
1060 Beta Lactam Division 106 1600000000 1699999999 2600000000 2699999999
1070 Equipment Casings 107 1700000000 1799999999 2700000000 2799999999
1080 Specification Development 108 1800000000 1899999999 2800000000 2899999999
1090 Tool Facilities

Formulation

109 1900000000 1999999999 2900000000 2999999999
1100 Global Distribution 110 1100000000 1199999999 2100000000 2199999999
3010 Quantum Life Sciences 301 1300000000 1399999999 2300000000 2399999999

 

 

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Types of Stocks:

Special Stock:

Special stock is managed separately in the Warehouse Management (WM) application for reasons of ownership or for various factors reflecting the location in which they are kept. Each type of special stock is assigned a special stock indicator to aid in managing it in the system. Special stock characteristics assigned during goods movements transactions in the IM component are displayed on WM screens and taken into consideration when processing stock in WM.

Types of special stock using WMS:

  1. Individual Customer (Sales Order) Stock (E)

Individual customer (make-to-order) stock is managed in WM using a special stock number and the special stock indicator E.

  1. Consignment Stock (K)

Stock of materials made available by the vendor and stored on the premises of the ordering party. This stock remains in the ownership of the vendor until it is removed from the warehouse and used for production purposes or taken over into the company’s own valuated stock. Consignment stock is managed in WM using a special stock number and the special stock indicator K. The special stock number for consignment stock is the same as the supplier (vendor) number.

  1. Project Stock (Q)

Material which is held in the warehouse for the completion of a project. For project stock, the system checks to see whether a corresponding master record exists.

 

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Stock Category

In WM, it is important to know what quantity of a stock is in a particular storage bin, but also its status and whether or not it is available. Stock in the warehouse is categorized in WM as follows:

  1. Available Stock

Unrestricted-use stock that is physically located in the warehouse, valuated, and not subject to any kind of usage restrictions. User can carry out all stock movements for this stock to include stock transfers, put away and picking.

  1. Inspection Stock

This stock carries the stock category “Q” to indicate that it is in quality inspection. Stock in quality inspection has been valuated but does not count as unrestricted-use stock. The Quality Management inspection data in the QM view of the material master determines whether a percentage of stock is to be designated as inspection stock when it is received in the warehouse. Once this stock has been inspected and a usage decision has been made, User carry out a transfer posting in the Inventory Management component and subsequent Posting Change in WM to remove the category Q, thus converting it to available stock.

  1. Blocked Stock

In IM it is possible to designate goods as blocked stock. These materials are a company’s own stock that should not be used. Stock can be blocked, for example, because it has been damaged and for various other reasons. This stock is displayed in WM with a stock category of “S”. This stock is processed in exactly the same manner as inspection stock.

  1. Blocked Stock Returns

When delivered goods are returned by a customer, they are first posted in the system to blocked stock returns” with a stock category of “R”. This stock is neither valuated nor is it considered to be unrestricted-use stock. It is possible store this stock in the warehouse. User must carry out a posting change to return it to available stock.

Status of Stock in the Warehouse

When goods arrive in the warehouse, they are usually received in the Goods Receipt Area (GR Area) near the receiving dock. Later, they are transferred using a transfer order to Under Quarantine within the warehouse. In some cases, goods can moved directly to fixed bins.

During the period of time when move orders have been created for the movement of goods between the various storage types that have not been fully processed, two availability statuses exist for this stock which has not yet been moved. When warehouse evaluation lists are displayed for this material, these goods appear on the display lists under the following three headers:

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  1. Quantity or Total Stock

This designator usually appears at the top of many stock display lists. This is the total quantity of material quants stored in the warehouse that does not include quantities for planned put away and picks. For the display of materials in a bin, the total quantity in each storage bin is also displayed.

  1. Stock Placement

This column designator appears in some stock lists. The system has created a transfer order for this stock to move it from one storage bin to another. It has been marked for put away (storage) in the warehouse.

  1. Stock Removal

This is also a column designator that appears in some stock lists. A transfer order has been created to pick this stock from a storage bin in the warehouse. In most cases, this stock will be transferred to a storage bin in the goods issue area.

4.2    Put away and Picking Strategies

Put away and picking strategies are used in Warehouse Management system to optimize the storage / removal of goods in the warehouse.

For inbound movements, in conjunction with controls entered in the material master record, the put away strategies assist the WM system to utilize the available warehouse capacity, automatically assigning optimum locations for goods received in the warehouse. For outbound movements, the system uses similar user-defined controls to execute the appropriate picking strategy to assign the best picking location. If user decides to manually process certain stock movements, user can change source and destination storage bins that are automatically proposed by the system.

When the system creates transfer orders to move goods into or out of the warehouse, user does not have to intervene when it comes to finding storage bins. This guarantees that stock movements are processed quickly and consistently.

For SPD, BLD, QLS, ODF, SFF and GRL plants the following strategies are finalized:

  1. Put away strategy: The Addition to existing stock (I) strategy will be followed for placing the materials in the warehouse. The default location for a material will be identified in each storage area for the materials. As the warehouse is divided into many storage areas as explained above, a default location will be identified and same will be maintained in material master for the combination of material – storage area in each warehouse. With this strategy, during the Transfer order (TO) against goods receipt (GR) the default location will be captured which is maintained in material master during the first TO transaction. Materials can be placed other than the default location. If user change the material location other than default location, for the subsequent TO creation system will pick the material bin based on the last placement / TO.
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  1. Picking strategy: FEFO for Raw materials and FIFO principle for packing materials will be followed for the removal of material from the storage bins.

Forms and reports required

All report requirements is fulfilled by standard SAP reports, Layouts has to be finalized by Florian at Realization phase.

Standard reports in SAP:

Transaction Code
Creating the storage bin LS01N
Change / display storage bin LS02N / LS03N
Empty Bins LS04
List of Empty Storage Bins LX01
List of Fixed Storage Bins LX29
Capacity load utilization LX04
Stock per Material LS24
Bin stock per material LS25
Total Stock per Material LS26
Stock per storage unit LS27
WM stock for all materials Lx02
SLED Control List LX27
Display Quant LS23

 

 

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Warehouse Management Process Components

5.1      Transfer requirement (TR)

Transfer requirements are used to plan and initiate stock movements. They represent an existing requirement that goods in the warehouse need to be moved.

By differentiating between the planning and execution of a goods movement, user can recognize immediately whether a goods movement needs to be still executed (transfer requirement is open), is currently being executed (transfer order is created), or is completed (transfer order is confirmed).

Use

On the one hand, transfer requirements are used to pass on information on goods movements that are posted in Inventory Management (MM-IM) to the Warehouse Management System (WMS). User can, however, also use transfer requirements for the following purposes:

❖    To initiate goods movements in WMS

❖    To initiate material replenishment for production storage bins in the production supply areas using the Production Planning (PP) component

❖    To call up transfer requirement reports in order to get an overview of all pending goods Movements.

On the basis of existing transfer requirements, the Warehouse Management System creates transfer orders, which, in turn, serve to execute the physical goods movements in the warehouse.

The system updates the transfer requirement

❖    When user create, confirm or cancel a transfer order

❖    When user cancel a goods receipt or goods issue posting in Inventory Management (MM-IM) before the respective transfer order was generated in the Warehouse Management System (WMS).

In this case, the system automatically reduces the transfer requirement quantity by the quantity to be canceled, or it deletes the transfer requirement altogether if the entire requirement quantity is to be canceled.

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Structure of Transfer requirement

A transfer requirement consists of a transfer requirement header with general information and one or several transfer requirement items with material information.

The transfer requirement contains all the necessary information on a planned goods movement.

❖    What should be moved?

❖    Which quantity should be moved?

❖    When should it be moved?

❖    The planning date is important for further automatic processing.

❖    Which transfer type is the basis of the goods movement?

Each goods movement in the warehouse is classified by a transfer type indicator. This key differentiates between:

❖    A stock put away

❖    A stock pick

❖    A stock transfer

❖    Why is it to be moved?

❖    Was the transfer order created as a result of a purchase order or a Process order, or was it created manually?

Transfer requirements can be created:

1)    Automatically by posting a goods movement in Inventory Management

2)    Automatically by requesting materials using the Production Planning system

3)    Manually using WM

Transfer requirements can be created:

With reference:

❖    to a material document to move stock into or out of the warehouse

❖    to a Process order to supply required materials to a production supply area

Without reference:

❖    to move stock from one bin to another in the warehouse

❖    to request crate parts and release order parts to replenish

❖    their assigned storage bins in production supply areas

❖    to initiate the replenishment of fixed bins in WM

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Transfer requirement updates:

A transfer requirement is updated by the system

1)    During the creation, confirmation or cancellation of transfer order: Once user confirmed the corresponding transfer order, the system updates the field for the open transfer order items in the transfer requirement. When the entire quantity of a transfer requirement has been processed by a transfer order, that is, all items have been processed; the system sets the Header status to E, meaning that the transfer requirement is completed.

2)    When user cancels a goods receipt posting or a goods issue posting in Inventory Management. Sometimes when a goods receipt or goods issue posting is canceled in IM, an open transfer requirement exists for the quantity being canceled. This can happen if the goods have not yet been transferred in WM, that is, a transfer order has not been created. In this case, the system automatically determines if a corresponding transfer requirement exists. If it finds one, the system reduces the quantity in the transfer requirement by the quantity being canceled or deletes the transfer requirement if the entire quantity is to be canceled.

Automatic creation of transfer requirements

Depending on the type of movement, transfer requirements are normally created automatically as a result of a transaction in another SAP component. The IM posting (for goods receipts, goods issues and stock transfers) generates most transfer requirements automatically. For material staging to production through the production planning (PP) interface, user can create transfer requirements by simply releasing the Process order. User can also create transfer requirements manually using a transaction that was developed for that purpose.

When a goods receipt for a purchase order is posted in IM, the system automatically generates a transfer requirement for the put away. In this case, the goods are to be moved from the goods receipt area into the warehouse.

For a goods issue to a cost center or Process order, the transfer requirement contains an indicator for stock removal. In this case, the goods are to be moved from the warehouse into the goods issue area.

Transfer requirements can be created with or without reference to other system documents.

Manual creation of TR

For goods movements such as internal movements, user can also create transfer requirements within WM manually. The following cases, for example, allow for manual creation of transfer requirements:

1)    Goods issue for a cost center

2)    Manual supplies to production supply areas for pick parts

3)    Replenishment for fixed bins in WM

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5.1       Transfer order

The transfer order (TO) is the “trigger” for the actual physical put away, pick or stock transfer in the Warehouse. Transfer orders used in WM are “move orders” that contain all the information needed to carry out the physical movement of goods in the warehouse.

Use

Transfer order (TO) can be created with reference to a source document from WMS or other SAP application components. A source document can be a:

1)    Material document

2)    Delivery document

3)    Transfer requirement

4)    Posting change notice

The transfer order contains all the required information order to execute the physical transfer of materials into the warehouse, out of the warehouse, or from one storage bin to another storage bin within the warehouse. In addition, it is also used for executing logical stock transfers. Logical transfers of stock occur, for example, when goods are released from inspection and made available for general use. These logical transfers are called posting changes in WM.

When user confirm a transfer order, user inform the system that it has been processed and that the goods have arrived at the intended destination. If the planned quantity (target quantity) differs from the actual quantity of stock that is moved, a difference quantity exists. If user confirm a transfer order with a difference, the difference quantity is automatically posted to an interim storage type for differences.

Once they have been carried out, transfer orders also have a control and monitoring function since they document movements in the warehouse

Structure of Transfer Order (TO):

A transfer order contains all the necessary information on a planned goods movement.

❖    What should be moved?

❖    Which quantity should be moved?

❖    From where (source storage bin) should the bin be moved, and whereto (destination storage bin)?

The transfer order consists of a transfer order header with general information and one or several transfer order items with material information.

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Transfer Order Header

The transfer order header contains the transfer order number and the date that it was created and confirmed. It also identifies the transfer requirement or delivery on which it is based as well as the movement type.

Transfer Order Item

A transfer order can have one or several items. The number of items contained in a transfer order depends on how many storage bins the system accesses in order to reach the total quantity of goods needed for the picking requirement or how many bins are needed to store the goods (put away).

A transfer order item contains subsections that specify the direction of the goods movement for each item.

Source storage bin

This subsection contains the source storage bin and the quantity of material that is being transferred. It indicates the storage bin from which goods are to be picked (goods issue) or an interim storage type (such as the goods receipt area) from which goods are taken to be put away in the warehouse.

Destination storage bin

This subsection contains the quantity of material that is being transferred and the storage bin into which the goods are to be put away. For example, it may contain a storage bin in a Approved RM storage area that has been selected for a stock put away, or an interim storage type (the goods issue area) for a stock pick.

Return storage bin

If, for example, user has the complete stock requirement set and user pick more stock than required from a storage bin, the system creates a subsection for the return storage bin. This can be the case, for example, when a complete pallet is removed from the shelf, but only a portion of the materials on the pallet is picked. In this case, the remaining quantity can either be returned to its original storage bin or transferred to another one.

Creating Transfer Orders Use

To execute goods movements in the warehouse, transfer orders are created in the Warehouse Management System (WMS).

1) Create a transfer order for an outbound delivery if user wants to supply a delivery to a sales order for which user have previously created an outbound delivery in the system.

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2) Create a transfer order for the transfer requirement whenever the transfer requirement has been created as a source document. This is the case, for example, if user post a goods receipt in Inventory Management (IM) or if a transfer requirement is created through the PP interface for production supply.

Prerequisites

One of the following source documents exists for a transfer order:

❖    Outbound delivery

❖    Transfer requirement

❖    Posting change notice

❖    Material document

When transfer order (TO) is created, the system determines all the bins in the warehouse that are affected by the goods movement (source storage bin, destination storage bin, and possibly also the return storage bin), and it automatically updates the storage bin data. The system also updates the respective fields in the document that was used to create the transfer order in the first place.

Confirmation of Transfer Orders (TO’s)

Use

When user confirm a transfer order or a transfer order item, user are verifying that the required quantity of material has actually been transferred from one location to another and that the processing of the transfer order or item has been completed. If confirmation is required, the quantity of material transferred into or out of the warehouse is not available for use until the transfer order or item has been confirmed.

 

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Posting Changes in WM

Purpose

A posting change generally refers to a bookkeeping change – a change in information – about a particular material. For most posting changes, such as changing a batch number or releasing blocked stock, the goods themselves remain in the same physical location.

Reasons for Making Posting Changes

Posting changes are made for several reasons. These include:

❖            Releasing stock from inspection into available stock

❖            Converting blocked stock to inspection stock

❖            Designating available material as inspection stock

❖            Splitting available materials into two or more batches

❖            Converting special stock, such as consignment stock or returned stock, into the company’s own stock

❖            Changing ownership of stock in the same warehouse from one plant to another

Integration

Although some material status changes can be initiated within the Warehouse Management (WM) component, posting changes are generally initiated in the IM application component as transfer postings and then subsequently processed in WM. When user initiate a transfer posting in IM, the system creates a posting change notice in WM. Posting change notices are only relevant for materials tracked within WM that have undergone a change in status. To finalize the process, user creates and confirms a transfer order for the posting change notice in WM.

Processing Posting Changes

Purpose

The process of posting changes is used in Inventory management (IM) and WM to change the status of a material in the warehouse.

 

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Process Flow

  1. Initiation for a posting change will be in the Inventory Management component by carrying out a transfer posting. User can also start this process from within Warehouse Management (WM) for some posting changes (see below).
  2. The system creates a posting change notice in WM. Additionally, the system creates two quants of equal negative and positive amounts in the posting change interim storage area – a negative quant for the material to be removed and a positive quant for the material to be added.
  3. In WM, user can view the posting changes that were initiated in IM by displaying the posting change notice list in WM. When user retrieves this list, user can display all posting change notices that are still open and/or those that are partially or fully cleared.
  4. In WM, user process the posting change from the posting change notice list to create a transfer order. The transfer order contains 2 items for each item in the posting change notice — one to move the material quant into the interim posting change area and one to move it back out again with the status change. This is a logical step used for tracking data that takes place in the system without any physical movement of stock. In most cases, the material stays in the original storage bin. However, in some instances, user has the option to transfer the material to another bin within the warehouse during this step.
  5. To complete the change in material status, user confirms the transfer order. This clears the posting change area.

Displaying Posting Change Notices

To display posting change notices from the Posting Change Notice List:

  1. Logistics _ Logistics Execution _ Internal Ware house Processes _ Post Change _ Via Inventory Management _ Posting Change Notice _ Display _ Single Document (Transaction code is LU03). or Logistics _ Logistics Execution _ Information System _ Warehouse _ Posting Change Notice _ Document Overview (Transaction code is LU04) from the SAP menu.
  2. As a minimum user must enter user’s warehouse number. When user display the Posting Change List, all other fields on the initial screen can be used to limit the number of items user will retrieve in the list. For example, to display a list of open posting change notices for materials in inspection, mark the Status open field and enter Q in the Stock category field on the initial screen.
  3. To display the list of posting change notices, choose ENTER. From the list of posting change notices, user can create transfer orders or display further information about the posting change notices.

 

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Processing Posting Changes Entirely Within WM

Purpose

Some posting changes can be processes for quants entirely within the Warehouse Management component. The system then carries out all necessary processes in the Inventory Management (MM-IM) component.

This processing method is possible for material status changes in both directions between:

❖           Quality inspection, blocked stock and unrestricted-use stock

❖           Consignment stock and own restricted stock

❖           Individual customer stock and own stock

Common situations used to carry out posting changes directly as a one-step process the WM include such activities as:

Changing available stock to blocked stock.

Converting consignment stock to one’s own stock for use in production.

Processing Inspection Stock

The most common type of posting change involves goods received in the warehouse that are posted for inspection. When goods are received into the warehouse, they are frequently held for inspection before they are released as stock available for issue. User use the IM component to assign the stock category Q (quality inspection) to inspection stock. The stock category is not removed until the goods have been inspected and released from quality inspection. Once the release of material from inspection is authorized, user can release all or part of the material for use. The process is as follows:

  1. Release the stock from inspection in WM or IM. QM-managed stock can only be released in QM (usually through a usage decision). (See also Releasing Stock from Inspection in IM.
  2. Process the resulting posting change notice in WM by creating a transfer order. For this procedure, see Releasing Stock from Inspection.

Updates in the System:

When a transfer order is created and confirmed for a posting change notice in WM, the system removes the stock category of Q as follows:

The system

  1. a) Posts a negative quantity with a stock category of Q to the warehouse.
  2. b) Posts two quantities to the posting change area:
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❖          a positive quantity with a stock category of Q

❖          a negative quantity with a blank stock category

  1. c) Posts a positive quantity with a blank stock category to the warehouse. With these postings, although the stock remains in the same physical location, the system “moves” the unavailable inspection material into the “logical” posting change area and then back into the warehouse as available material.

To see what happens in the system, display a transfer order that was created for a posting change notice.

No physical area needs to exist for this posting change area. This is a logical storage type and is known as an interim storage area in WM.

When materials are released from inspection, although they remain in the same “physical” location, the materials are moved “logically” to the posting change interim storage area with the stock category of Q. When the posting change is carried out in WM and confirms the newly created transfer order, the material is moved back into the same storage bin without the stock category of Q.

Releasing Stock from Inspection

In order to release stock from inspection, initiate this action in WM or in IM. For QM active components, start this function in Inventory Management. Follow the same process of releasing the stock from quality inspection to un-restricted stock type in QM module.

Releases from More than One Storage Type

When part of the material in a goods receipt for a purchase order is held in the goods receipt area for inspection while the remainder is placed into another storage type within the warehouse, part or all of the stock in the purchase order may be released after it has been inspected. When inspection stock is received in the goods receipt area (storage type 902 in the standard system), a stock category of Q is assigned and an open transfer requirement appears in WM. Because of the stock category, none of the materials in either location can be released as available stock until the inspection has been completed.

There are two options of releasing stock from inspection in the Inventory Management component or from within WM. For QM active components, start this function in IM.

Procedure in WM

Once the stock has been released from inspection in IM, use the same steps to complete the posting change in WM as those described in Releasing Stock from Inspection. The only difference is that when user select quantities in the Quant List, user cannot deselect the Post in same bin column for quants that are still in the goods receipt area. This is because an open transfer requirement exists for these quants and they must be left in the same bin. When user process the posting change, the system updates the corresponding transfer requirement items for the amount in the transfer order. In addition, the system creates a new item in the transfer requirement to place the remaining materials released from inspection into available stock.

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Processing Blocked Stock (Expired Goods)

Stock designated in IM as blocked stock is displayed in WM with a stock category of “S”. For posting changes, process this stock in WM in the same manner as inspection stock. There are two options of initiating posting changes to change the status of blocked stock in the Inventory Management component or from within WM.

Converting Available Stock to Inspection Stock

If warehouse stock has been damaged, it can be reassigned as inspection stock. There are two options of initiating posting changes to convert the status of available stock to inspection stock in the Inventory Management component or from within WM. If the material is QM-managed, user must change the stock to inspection stock using functions in IM and QM.

Converting Available Stock to Inspection Stock for Retest

If warehouse stock can be Re-test, it can be reassigned as inspection stock. The system will automatically Transfer the stock from Un-restricted use stock to Quality inspection stock. This transfer of stock will post posting change notice in WM. The Quality Stock in WM will display with stock category of ‘Q’.

Forms and reports required

All report requirements is fulfilled by standard SAP reports.

Standard reports in SAP:

Transaction Code
Display Transfer order (TO) – Single document LT21
TO – List LT23
TO per storage type LT22
TO per material LT24
TO per storage bin LT26
Cancel TO – Single document LT15
Cancel TO for storage unit LT16
Return Transfer for Outbound Delivery LT0G
Transfer requirements with processed quantity as %ges LX09
Evolution of movement per storage type for TO LX10
TO – Reference document with tracking dates LX11
TO detailed over view LX12
TO with differences LX13

 

 

CLIENT LOGO
ODnANT7ATTON> n TENT NAME

 

 

 

 

Evaluation of material movements per storage type LX14
List of posting change notices LU04

 

 

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Goods Receipt

7.1       Goods movements in Warehouse Management

Goods receipts are inbound movements of stock that has been received as the result of a purchase order, without purchase order by 503 mvt type, process order and for other reasons. All goods receipts result in an increase in the total stock in IM and WM. The IM posting increases the total stock in IM and WM at the same time. In this case, WM has a “distribution” function to move the stock that was posted in IM from the goods receipt area to storage bins in the warehouse. For this purpose, a transfer order is created to determine the most appropriate storage bins. After the stock has been moved, the transfer order is confirmed.

For the goods movements, two postings are normally required to complete the process – one in Inventory management (IM) and one in Warehouse Management (WM).

The following kinds of goods receipts are considered in the SAP System:

  1. Goods receipt with reference to a purchase order
  2. Goods receipt with reference to a process order
  3. Goods receipt with reference to a delivery
  4. Other goods receipts (without reference)

The Goods Receipt Process

When goods are received in the warehouse, the processes that take place in the Warehouse Management (WM) system are generally automatic and transparent to the user.

  1. To initiate the receipt of goods into WM, user post a goods receipt in IM.
  2. With the IM posting, the system assigns a quantity of material to a storage bin in an interim storage area for goods receipts and creates a transfer requirement in WM.
  3. Subsequently a transfer order is created based on the information in the transfer requirement.
  4. Using a predetermined search strategy, the system determines where in the warehouse the goods should be placed and palletizes the goods.
  5. The transfer order is used to transfer the goods from the interim storage bin in the receiving zone to one or several storage bins in the warehouse.
  6. The warehouse worker confirms the transfer order that the goods have been transferred to the destination storage bin.
  7. Any discrepancies between the quantity requested and the quantity transferred into the warehouse are recorded in WM. These differences must be cleared later in the IM component. At this point, the goods receipt process is completed.

 

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WM – QM Interface

The Warehouse Management (WM) application interface to the Quality Management (QM) component allows warehouse administrators to manage and track inspection lots that are stored in the warehouse.

The primary processes in the interface between WM and QM function as follows:

  1. Based on the inspection data in the QM view of the material master, the system can create an inspection lot when user post a goods receipt in the Inventory Management (IM) component. The QM inspection data also determines whether an inspection lot is to be inspected with an inspection plan and determines the quantity of the material that is to be selected as an inspection sample.
  2. In WM, the normal process takes place for the goods receipt posting in IM — the system creates a quant in the interim storage area and, depending upon the system definition, a transfer requirement in WM. An inspection lot number is noted in the quant in the interim storage area and in the transfer requirement. The system stores the interim storage bin coordinates in the inspection lot itself.
  3. If a usage decision has not yet been made for the inspection lot, the system displays a dialog box to inform user that a sample quantity exists when user process the transfer requirement for the goods receipt in WM.
  4. In QM, a usage decision is made after the inspection has been completed. The resulting postings are passed on via the IM component to WM and there they initiate stock removals or posting changes.

For detailed processes about Quality inspection procedure to be followed pl refer the Quality Management (QM) Business blue print.

Process flow

  1. Posting changes:

For posting changes i.e. for bringing the material status from quality inspection to unrestricted- use stock, a posting change notice and 2 interim storage quants are created in WM. When user creates a transfer order for this posting change notice, WM automatically selects all quants for this inspection lot no matter where the material is located in the warehouse. If a transfer requirement still exists for this inspection lot, the material data in this transfer requirement is changed in accordance with the posting change notice (in this case the stock category is changed from “Q” to “available”). If user decided to retain the inspection sample in the goods receipt area, this transfer requirement remains open and must still be processed.

  1. Picking:

In WM there is no stock placement before the usage decision, that is, the complete goods receipt quantity remains in the GR Area (interim storage area for goods receipts) and the stock placement transfer requirement is completely open. The usage decision triggers off the process “Return to vendor”.

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If the goods receipt quantity is already placed into stock and if it has to be removed again on the basis of the usage decision, the system will only select those quants that belong to the respective inspection lot when the stock removal transfer requirement is being converted into a transfer order

Identifying the inspection lot in warehouse:

To find all materials belonging to an inspection lot in the warehouse inspection lot number should be known. The system enters this number into the WM quant. User can view quant information from any stock display list in WM.

  1. Note down the inspection lot number.
  2. Choose Logistics _ Logistics Execution _ Internal Whse Processes _ Bins and Stock _Dispiay _ Bin Stock per Material from the SAP menu.
  3. Transaction Code : LS22
  4. On the initial screen, enter the warehouse number, material, plant and inspection lot number in the Inspection lot field and choose ENTER.

When processing transfer orders for stock removal, materials are displayed automatically for the corresponding inspection lot in the stock overview.

Goods Receipt for Quality Inspection

Purpose

Goods that are delivered from an external supplier or from the company’s own production department can be posted first into stock that is scheduled for inspection. Goods that are first posted into inspection stock are not available for use.

Prerequisites

The goods receipt for an inspection is identical to a goods receipt based on a purchase order, with one difference. On the IM item overview screen, user must make sure that the inspection indicator for the stock type (the T column) is set. When the indicator is set, the quant that is posted to the interim storage area and the transfer requirement that is created both have the value Q in the Stock Category field.

To ensure that the inspection indicator is always set on the item screen, set the inspection indicator

❖    in the material master record

❖    when user create a purchase order

 

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Process Flow

Receiving Material into Inspection Stock

  1. Process inspection stock initially in the Inventory Management component by creating a goods receipt for a purchase order.
  2. Create a goods receipt (GR) against PO for receiving the materials from the vendor. Based on the quality parameters set for the material the material will be received into quality inspection stock (stock category Q).
  3. In the standard system, with movement type 101 the goods are moved to the interim storage type 902 (GR Area).
  4. In addition to posting the stock to the goods receipt area, the system generates a transfer requirement.
  5. The system sets the stock category for the quant and the transfer requirement to Q (Quality Inspection).
  6. In WM, user uses the transfer requirement to create a transfer order to place the goods into the warehouse.

Although the material is in the warehouse, it cannot be removed from stock for a goods issue. Because the material has a stock category of Q, it does not belong to the available stock.

Releasing Material from Inspection Stock

Purpose

After a material in the warehouse has been inspected, it should be released from inspection stock and made available for general use.

There are two different scenarios.

  1. Scenario 1: The material has been moved from the interim storage area for goods receipts into the warehouse, that is, a transfer order has been created to transfer the quant to a storage bin.

For example, 100 pieces of material have been moved from the interim storage area for goods receipts to storage bin in high rack storage. The quant, which can be identified by a goods receipt number, has the stock category of Q.

  1. Scenario 2: Some of the material has been moved from the interim storage area into the warehouse, that is, a transfer order has been created to transfer the quant to a storage bin. The rest of the material stays in the goods receipt interim storage area.

For example, 50 pieces of material have been moved from the interim storage area for goods receipt to storage bin in high rack storage. The remaining 50 pieces stay on the interim storage area. Both quants, which can be identified by a goods receipt number, have the stock category.

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Tasks in Inventory Management and Quality Management

Releasing Stock from Inspection in IM and quality management.

Tasks in WM

Once stock has been released from inspection in Inventory Management, user creates a transfer order in WM using a posting change notice as the basis for the transfer order. (For stock in which no QM components are active, it is also possible to release stock from inspection entirely within WM).

Process in the system:

When user post the release of the material in IM, the system takes the following actions:

  1. A posting change notice is created in WM.
  2. Two quant’s are posted to the interim storage area for posting changes:

❖    a negative quant with a stock category of Q

❖    a positive quant with a unrestricted stock category

Customer return / Recalled material handling process

The material which is returned by the customer will be handled by the following procedure:

When the customer returns or recalled the material, it is received into the system against the return sales order no. After the receipt the material goes to the quality inspection procedure. The usage decision will be taken in quality management and the material is received into either unrestricted or blocked stock or customer return material storage area based on the usage decision.

 

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7.2   Goods Receipt – For Purchase order /Process order /Return sale order.

SAP Scenarios

  1. Goods receipt against Purchase order for Approved Manufacturer.
  2. Goods receipt against Purchase order from Non-approved Manufacturer.
  3. Goods Receipt for Import and Domestic Purchase order.
  4. Goods receipt against Process order.
  5. Goods receipt against Customer returns or recalls.
  6. Good receipt against Stock Transport order.
  7. Goods Receipt from Sub-contractor.

For all the above process we will be following the WM process from step 1 to step 5 as listed below.

STEP Procedures TCODE Input Output
1 Creation of Goods receipt in Inventory management for PO or against process order and return sales order for customer return materials MIGO PO document / Process order or Return sales order Material

document /

return delivery document

2 If the quality management is active the material will be in quality inspection stock and usage decision to be taken in QM module both for GR against external PO or for customer return material against return sales order QA11 Material

document

Material

document

3 Creation of Transfer order (TO) LT06 / LT03 Material

document

Transfer order

no

4 Confirmation of Transfer order LT12 Transfer order

no

Transfer order

no

5 Change in stock type in Inventory management Posting change notice Transfer order

no

 

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7.3    Goods Receipt without Purchase order

SAP Scenarios

  1. Goods receipt without Purchase order by 503 mvt type.
  2. Goods receipt without PO for Non-valuated materials for Loan Licenses, example Sandoz or BLD plant material in QLS plant.

For all the above process we will be following the WM process from step 1 to step 5 as listed below.

STEP Procedures TCODE Input Output
1 Creation of Goods receipt in Inventory management for PO by 503 mvt type MIGO Movement

Type: 503

Material

document

2 If the quality management is active the material will be in quality inspection stock and usage decision to be taken in QM module both for GR against external PO or for customer return material against return sales order QA11 Material

document

Material

document

3 Creation of Transfer order (TO) LT06 / LT03 Material

document

Transfer order

no

4 Confirmation of Transfer order LT12 Transfer order

no

Transfer order

no

 

7.4    Goods Receipt of Bulk Storage

SAP Scenarios

  1. Goods Receipt of Bulk storage materials like oils.

For the above process we will be following the WM process from step 1 to step 4 as listed below.

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STEP Procedures TCODE Input Output
1 Creation of Goods receipt in Inventory management for PO. MIGO Purchase order No. Material

document

2 If the quality management is active the material will be in quality inspection stock and usage decision to be taken in QM module both for GR against external PO or for customer return material against return sales order QA11 Material

document

Material

document

3 Creation of Transfer order (TO), if partial qty is stored in Tanks and remaining in barrels – Split the TO qty into different storage types. LT06 / LT03 Material

document

Transfer order

no

4 Confirmation of Transfer order LT12 Transfer order

no

Transfer order

no

 

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7.5    Online Rejection Material Documents

SAP Scenarios

  1. On line process rejection.
  2. Online process rejection of Foils.

For all the above process we will be following the WM process from step 1 to step 6 as listed below.

STEP Procedures TCODE Input Output
1 Creation of material document in Inventory management MB1A Movement

Type: 262

Material

document

2 Creation of Transfer order (TO) LT06 / LT03 Material

document

Transfer order

no

3 Confirmation of Transfer order LT12 Transfer order

no

Transfer order

no

Change in stock type in Inventory management from Unrestricted to Blocked
1 Creation of Transfer order (TO) LT06 / LT03 Posting change notice Transfer order

no

2 Confirmation of Transfer order LT12 Transfer order

no

Transfer order

no

 

 

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Goods issue

8.1       Goods Issue in the Warehouse Management

Purpose

A goods issue is defined in WM as a physical outbound movement of goods or materials from the warehouse. A goods issue is a goods movement that is used to post the internal use of material, the issuing of material and the shipment of goods to a customer. A goods issue results in a decrease of stock in the warehouse.

  1. Issues to a Process order or cost center.
  2. Delivery of goods to customer.
  3. Goods issue to subcontracting vendor
  4. Goods issue against STO
  5. Goods issue for vendor returns.
  6. Goods issue of control samples.
  7. Goods issue to scrap.

Purpose

Companies usually distinguish between various types of goods issues, each of which is handled in the System as follows:

  1. Stock Scheduled for Delivery

Withdrawal, picking, and shipping of goods to customers are carried out in the Sales & Distribution (SD) component and are dealt with in detail in the document SD Shipping Guide. They are not dealt with in this section.

  1. Material Withdrawals for Process orders

Inventory Management provides for the staging of components for production. User enters withdrawals for production as goods issues with reference to the Process orders for which the components are required.

  1. Other Types of Internal Staging of Material

Materials can be withdrawn not only for production but also for other purposes (for example, for cost center, CO order, maintenance order, or asset), Goods issue to subcontracting vendor, STO.

  1. Return Deliveries to Vendors

Return deliveries to vendors are entered with the function Material document Return delivery or with the function Goods receipt for purchase order.

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  1. Control samples

A partial quantity of material is issued from production to QC as control samples.

  1. Scrapping/Sampling

If a material is no longer usable, it must be scrapped. Scrapping of a material is entered in the System as a goods issue. The withdrawal of samples must also be entered as a goods issue.

Process Flow

Entering a Goods Issue with/Without Reference Document

Before entering a goods issue, user have to find out whether any reference document or data exists in the system.

When user enters a goods issue, user can reference:

>     Purchase order in case of STO or Subcontracting PO.

>     Process orders.

>     Delivery document against sales order.

Integration

As shown in the following table, various application components in the SAP System initiate the transfer of goods from the Warehouse Management system (WMS) by producing a document on which the goods movement is based. These systems also carry out the necessary checks to determine if the material is available in the warehouse.

SAP Application Component Relevant WM document
Inventory management Transfer requirement (TR)
Production Planning Transfer requirement (TR)
Sales & Distribution Delivery document

 

 

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Features

Goods issues in WMS can be based on

  1. Deliveries: In this case, user picks goods for deliveries that are created in Shipping.
  2. IM Postings: When user post a goods issue in IM, the system generates transfer requirements that are used as a basis for creating transfer orders.
  3. Two-step Picking: For 2-step picking, the picking process is divided into 2 separate steps. In the first step, user pick the entire quantity of materials need to fill requests (for example, several deliveries or transfer requirements). During the second step, user divide up the materials and allocate them to match the corresponding requirements.

Goods Issue for a Delivery:

The following describes picking using transfer orders. For this process description, the sales order already exists and the delivery based on the sales order must be processed. At the item level at the storage location, the system recognizes that items are relevant for Warehouse Management (WM). The following steps must be carried out for the goods issue:

  1. Create a delivery against sales order.
  2. Creating a Transfer Order for each delivery.
  3. Confirm Transfer Orders

Impact of delivery on Warehouse Management system

After the delivery has been saved, the following data has been set in the delivery document:

❖    The SD picking status is set to A, which means that the material must be picked.

❖    The WM activity status is set to A, which means that a transfer order is required for further processing.

Confirming a Transfer Order for a Delivery:

After the goods have been picked from the warehouse, user confirms the transfer order in WM. When user remove stock from the warehouse user typically confirm the entire transfer order at one time.

After the transfer order has been confirmed, the following data has been set in the delivery document:

❖    The SD picking status is still C, which means that the material has been picked.

❖    The WM activity status is set to C, which means that the transfer order has been confirmed.

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Processing Differences for a Delivery:

During the confirmation of a transfer order, a difference between the required quantity and the available quantity can occur.

Example: A transfer order for a delivery states that 50 pieces are to be picked from storage bin. However, the warehouse worker finds only 45 pieces in the storage bin and confirms the transfer order with a difference of 5 pieces.

After the difference in the transfer order item has been confirmed, the following data has been set in the delivery document:

  1. The system updates the quantity to be picked.
  2. The SD picking status is B, which means that the item has been partially picked.
  3. The WM activity status is set to C, which means that the transfer order has been confirmed. Now the decision has to be made whether another picking is to be carried out for the missing quantity or whether the customer receives a partial delivery.

Another Picking

If the remaining open quantity of 5 pieces in the above example is to be picked, create a second transfer order from the delivery document. In this case process the transfer order as described above in “Creating a Transfer Order.” Confirm the new transfer order for 5 pieces after they are picked. In this case the system sets the SD picking status in the delivery document to C after the remaining quantity of 5 pieces from the second transfer order has been picked and confirmed. Afterwards, user can post the goods issue.

Partial Picking:

Partial picking can occur in the following situation. When sales order or delivery is created, the system determines that the goods are available in the warehouse to fill the delivery. However, when transfer order is created based on the delivery, the system determines that the quantity in the warehouse is not sufficient to meet the quantity for the delivery. Normally, in this situation, the system would not continue with the transfer order creation. So create a transfer order only if the items can be fully satisfied. However, there is a way to allow partial picking so that a transfer order can be created in spite of reduced stock.

Procedure:

Sometimes, it is not possible to pick goods at a later date due to organizational or technical reasons. In this case, the customer can make a partial delivery. If the customer is to receive a partial delivery, quantity in the delivery document to be changed.

  1. Choose Delivery _ Change from the SD shipping menu bar.
  2. On the initial screen enter the required information and choose Overview _ Picking.
  3. On the overview screen for picking, change the value in the Delivery quantity field to match the value in the Pick quantity field manually or choose Edit _ Copy the picked qty from the menu bar.
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  1. To post the change choose Delivery _ Save.

The system sets the SD picking status in the delivery document to C. Once the SD picking status and the WM activity status are set to C, post the goods issue to IM using the task in SD, as described above in “Posting a Goods Issue.”

Creating a TO for a Cancelled Delivery

In case if a delivery has been picked incorrectly, return complete deliveries (delivery view) or individual transfer order items from a delivery (TO item view) to the warehouse.

Prerequisites

User can only return deliveries that are relevant to WM that have been fully picked (WM picking status = C). This means that transfer orders must have been created for the deliveries and they must have already been confirmed.

Procedure

  1. Choose Transfer Order _ Create _ Cancel picking from the WM menu bar.
  2. On the initial screen enter a warehouse number, a movement type and at least one delivery.

The system displays movement type 999 as a default.

  1. From the display screen, user can select the deliveries or TO items for materials that user wants to place back into the warehouse.

Possible three options:

1)    Return to stock: The system attempts to return the quants back to the bin from which they were picked.

2)    Put away in the foreground: The system displays a dialog box where user can specify where the quant is to be stored.

3)    Put away in the background: The system finds a storage bin based on the put away strategies defined in the system.

The system resets the picking status of the delivery accordingly.

 

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Goods Issue Based on an Inventory Management Posting

Use

When user post a goods issue in IM, the system generates transfer requirements that are used as a basis for creating transfer orders.

Features

When user uses the Inventory Management (IM) component to pick goods from the warehouse, the system posts a negative quantity to the goods issue interim storage type. For this task the system can automatically create a transfer requirement. Subsequently user creates a transfer order based on the information in the transfer requirement. Using a predetermined search strategy, the system searches for storage bins from which the material will be picked. The transfer order is printed and the warehouse worker transfers the goods from the storage bins in the warehouse to the goods issue area. The warehouse worker confirms that the goods have been transferred and records any discrepancies between the required amount and the delivered amount.

Goods Issue to a Cost Center

To issue material to a cost center, user carries out the following tasks in the IM and WM components:

Tasks in Inventory Management: Post a goods issue to a cost center. Tasks in Warehouse Management: Create a transfer order and Confirm the transfer order after it has been created.

Goods Issue for return delivery to vendor (Vendor Return).

To return material to vendor, user carries out the following tasks in the IM and WM components:

Tasks in Inventory Management: Post a goods issue to a vendor by return delivery document.

Tasks in Warehouse Management: Create a transfer order and Confirm the transfer order after it has been created.

Creating a Transfer Order for a Material Document

Transfer order can be created with reference to a number of different source documents. Immediately after posting a goods issue to a cost center in IM, user creates the transfer order with reference to the material document that was just created.

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Procedure

To create a transfer order based on a material document

  1. Choose Logistics _ Logistics Execution _ Inbound Process _ Goods Receipt for Purchase Order, Order, Other Transactions _ Put away _ Create Transfer Order _ By Material Document from the SAP menu. (Transaction Code : LT06 or LB10
  2. Enter the number and year of the material document. Choose ENTER.

The system displays the overview screen for the transfer requirement. Materials displayed on this screen will be removed from the storage bins and transferred to the goods issue interim storage area (910 in the standard system). The storage bin in the interim storage area is dynamically created from the cost center.

From this point on, the processing of the transfer order is basically the same as creating a transfer order for a transfer requirement for picking and Creating Transfer Orders for Picking Manually.

Goods Issue for Production Supply

Use

The Warehouse Management (WM) application component is interfaced to the Production Planning Shop Floor Control (PP-SFC) application component to assist in providing materials to supply areas in production. The significant advantage for customers using this WM-PP interface is that it provides pinpoint accuracy in timing the supply of materials to production supply areas.

The basic concept is for workers in production to be able to order needed materials themselves, which, in turn initiates the creation of transfer requirements in WM. Warehouse Management component, then, is responsible for supplying needed materials to the storage bins in production.

It does so by creating a transfer order for each respective transfer requirement. This is part of the standard WM procedure.

The subsequent goods issue posting reduces the stock quantity of materials that have been removed from “production” storage bins and no additional activities are required in WM.

 

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8.2   Goods Issue – to Process order / Cost center / Reservation / Purchase order / Return Delivery to Vendor

SAP Scenarios

STEP Procedures TCODE Input Output
1 Creation of Goods Issue in Inventory management MIGO / MB1A / MBRL GRN document Goods Issue

Document

2 Creation of Transfer order (TO) LT06 GI document no Transfer order no
3 Confirmation of Transfer order LT12 Transfer order no Transfer order no

 

 

8.3   Goods Issue – To Control samples

SAP Scenarios

STEP Procedures TCODE Input Output
1 Creation of Goods receipt in Inventory management by Production MB1A GRN document Goods Issue

Document

2 Creation of Transfer order (TO) by splitting the qty , partial for control samples and remaining for stores as FG goods. LT06 GI document no Transfer order no
3 Confirmation of Transfer order LT12 Transfer order no Transfer order no

 

 

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8.4    Goods Issue against Sales Order.

SAP Scenario

STEP Procedures TCODE Input Output
1 Goods Issue against sales order: Delivery document will be generated against sales order which will act as transfer requirement. VL01N Sales order Delivery document
2 Creation of Transfer order (TO) LT03 GI document no / delivery document Transfer order no
3 Confirmation of Transfer order LT12 Transfer order no Transfer order no

 

 

Forms and reports required

All report requirements is fulfilled by standard SAP reports.

Form: Picking slip format is awaited.

Standard reports in SAP:

Transaction Code
Analysis of stock placements and removals MCL1 / MCL9
Analysis of quantity flows MCL5 / MCLD
Analysis of movement types MCLH

 

 

 

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Transfer Postings

9.1      General Description

Transfer postings are used to remove materials from one storage location / warehouse / bin and place them in another storage location / warehouse / bin. Stock transfers can occur either within one plant or between two plants or company codes.

Features

A transfer posting usually refers to a change in a material’s stock (for example, release from quality inspection, accepting consignment material). In a transfer posting, the material can remain in its original storage bin or be transferred.

Stock transfers and transfer postings are used to represent organizational-relevant transfers within the company.

Transfer Postings and Stock Transfers

Levels for Stock Transfers

In a company, goods movements do not only occur in the form of goods receipts and goods issues. Depending on the organization of the company (for example, decentralized storage) and its sales policy, internal stock transfers might also be necessary.

Stock transfers can occur at three different levels:

>    Stock transfer from plant to plant

>    From storage location to storage location (in the plant)

>    Bin to bin transfer of material with in the warehouse

Stock Transfer Procedures

>    Stock transfer using stock transport order.

Stock Transfers and Replenishment

Purpose

Stock transfers in the Materials Management system include the physical movement of materials from:

  1. One plant/storage location / warehouse to another plant/storage location / warehouse
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  1. Warehouse to warehouse with in the same plant
  2. Storage bin to storage bin (internal transfers) with in the same warehouse

For stock transfers within the same warehouse complex (that is, within a warehouse number), user can create, manage, and display information about the movement of stock from the time it is received until it leaves the warehouse using the Warehouse Management system (WMS). For stock transfers from one storage location to another storage location, the process begins in the Inventory Management (IM) component and is completed in WMS.

Warehouse to warehouse stock transfer belong to two different plants

Usage

A stock transfer from plant to plant not only leads to a change in stock quantity in both plants; if both plants are assigned to different valuation areas, an accounting document is also created. This type of stock transfer can only be carried out from unrestricted-use stock of the issuing plant to unrestricted-use stock of the receiving plant. Stock transfers from plant to plant are relevant for Material Planning, since Materials Planning operates at plant level.

For stock transfer from plant to plant and storage location to storage location, three options available:

  1. Transfers from a WMS storage location to a non-WMS storage location. In WMS, this is processed the same as a goods issue (and subsequent pick).
  2. Transfers from a non-WMS storage location to a WMS storage location. In WMS, this is processed the same as a goods receipt (and subsequent put away).
  3. Transfers from a WMS storage location to another WMS storage location.

When two different warehouses, for example, are assigned to two separate WMS storage locations, this type of transfer is processed the same as a goods issue (and subsequent pick) in the issuing warehouse and as a goods receipt (and subsequent put away) in the receiving warehouse.

If materials are transferred within the same WMS warehouse which is assigned to two separate WMS storage locations, it is handled as a plant to plant posting change.

Carrying out the Transfer

Stock transfers that involve the movement of materials from one storage location to another storage location are first processed using the Inventory Management component. In IM, the transfer of stock from one storage location to another storage location is processed as a transfer posting. Unlike most such changes, however, no posting change notice appears in the WM system.

Only one storage location can be managed in one warehouse number at a time in WMS. It depends upon which storage location is being managed at the time as to whether a put away or a pick will take place.

To clear the stock transfer user must create and confirm a new transfer order based on the material document which was originated in IM.

There are two ways to process a stock transfer from one storage location to another storage location:

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❖    Create a transfer order by selecting from a list of open transfer requirements.

❖    Create a transfer order using the material document number (from the IM component) for the stock transfer.

Process stock transfers by selecting them from a list of transfer requirements, materials that are being transferred out to another storage location are listed as a pick (movement type 311 in the standard system) to the stock transfer interim storage area (storage type 921 in the standard system). When a transfer order has been created from a transfer requirement and confirmed, the negative quant in the stock transfer interim storage area is cleared from WMS.

From Warehouse to Warehouse (in the same Plant)

A stock transfer from warehouse to warehouse in the same plant simply causes an update of the stock quantities in both warehouses. The stock value remains unchanged, and the event is not relevant for accounting.

A stock transfer from warehouse to warehouse is possible for all stock types.

Internal Stock Transfers: Bin to Bin transfer in the same Warehouse

Usage

To transfer stock from one storage bin to another storage bin within the same warehouse, user manually creates and confirms a transfer order for the material to be moved. Since the total quantity of stock in the warehouse remains the same, stock movements that take place within the same plant and warehouse number do not require the use of the Inventory Management component. Consequently the transfer does not require Inventory Management postings and can be administered within WM.

Reasons for Making Internal Transfers

Possible reasons for transferring stock from one storage bin to another within the same warehouse include:

❖    Combining smaller quantities of the same material that are dispersed among several storage bins and moving them into a single bin

❖    Supplying stock from bulk or rack storage to a picking area

❖    Clearing bins for technical reasons, for example, to renovate a range of storage bins or for maintenance work

❖    Transferring stock as soon as a specified capacity has been reached

❖    During the transfer of material from one storage area to another storage area. EX: Transfer of material from main storage area to bulk storage area or from main storage area to damage material storage area.

❖    During the rearrangement of materials in the warehouse.

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During the rearrangement of warehouse i.e. during the changing the bin locations of the materials the following procedure to be followed:

❖    The issuing material – bin location combination should be identified.

❖    Destination bin location should be identified.

❖    Then transfer the material from bin to bin.

Procedure:

To manually create a transfer order

  1. Choose Logistics _ Logistics Execution _ Internal Whse Processes _ Bins and Stock _Block from the SAP menu.
  2. Enter the warehouse number and storage type. User can limit the entry to a storage bin or range of storage bins. The system displays a stock list.
  3. From the list displayed, select line items which are not blocked (a lock appears at the beginning of the line) that user want to move to another bin.
  4. To specify the destination storage bin, select “Stock transf. frgrnd” (stock transfer foreground).
  5. Once user has moved the stock to the new bin location, confirm the transfer order to complete the transaction.

Transfer of Stock from Sales order stock to Sales order Stock

A special sales order stock may transfer from one sales order to another sales order. Only Stock quantity gets affected with changes of sales order number in the quant. The stock value remains unchanged, and the event is not relevant for accounting.

 

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9.1    Transfer of material from one warehouse to another warehouse which belong to two different plants

SAP Scenarios

STEP Procedures TCODE Input Output
1 Create transfer posting in Inventory management. MIGO / MB1B GRN document Material document
2 Create a transfer order LT06 Material

document

Transfer order
3 Confirm the transfer order LT12 Transfer order Transfer order
 

 

9.2    Transfer Posting – Warehouse to Warehouse (Within the Plant)

SAP Scenarios

STEP Procedures TCODE Input Output
1 Create transfer posting in Inventory management. MIGO / MB1B GRN document Material document
2 Create a transfer order LT06 Material

document

Transfer order
3 Confirm the transfer order LT12 Transfer order Transfer order
 

 

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9.3    Transfer Posting-Bin to Bin transfer of Material with in the Warehouse

SAP Scenarios

STEP Procedures TCODE Input Output
1 Creation of the bin location for the combination of warehouse – storage area LS01 Enter Bin No. Manually Bin location
2 Assign or modify the bin location for material – storage area combination. MM02 Material Code Material

Code

3 Create transfer order for the bin to bin transfer. The movement type will be 999 and inputs will be source storage type and storage bin and destination storage type and storage bin. LT01 Source storage type and storage bin Transfer

Order

 

 

9.4    Transfer Document – Created by other movements.

SAP Scenarios

  1. Material to Material transfer.
  2. Excess Material received from subcontracting vendor.

For all the above process we will be following the WM process from step 1 to step 6 as listed below.

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STEP Procedures TCODE Input Output
1 Creation of Material document in Inventory management MB1B Movement Type:      309,

541

Material

document

2 Creation of Transfer order (TO) LT06 Material

document

Transfer order

no

3 Confirmation of Transfer order of issuing and Receiving materials LT12 Transfer order no Transfer order

no

Change in stock type in Inventory management
1 Creation of Transfer order (TO) LT06 Material

document

Transfer order

no

2 Confirmation of Transfer order LT12 Transfer order no Transfer order

no

 

 

  1. Storage location to storage location transfer.

For the above process we will be following the WM process from step 1 to step 6 as listed below.

STEP Procedures TCODE Input Output
1 Creation of Material document in Inventory management MB1B Movement Type: 311 Material

document

2 Creation of Transfer order (TO) LT06 / LT03 Material

document

Transfer order

no, TO to be

Confirmed

Automatically

 

 

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9.5    Material Document – Created by other movements.

SAP Scenarios

  1. Material posted to Quality from Unrestricted for Re test.
  2. Material posted to Blocked from Unrestricted for Expiry.

For all the above process we will be following the WM process from step 1 to step 3 as listed below.

STEP Procedures TCODE Input Output
Change in stock type in Inventory management
1 Creation of Transfer order (TO) LT06 / Material

document

Transfer order

no

2 Confirmation of Transfer order LT12 Transfer order

no

Transfer order

no

 

 

Forms and reports required

All report requirements is fulfilled by standard SAP reports.

Standard reports in SAP:

Transaction Code
Material document list MB51
Stocks for posting date MB5B
Stock Overview MMBE
Plant Stock availability MB53
 

 

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Physical Inventory

10.1 Purpose

This component allows user to carry out a physical inventory of user’s company’s warehouse stocks for balance sheet purposes.

Features

Physical inventory can be carried out both for a company’s own stock and for special stock. Inventory for a company’s stock and for special stocks (such as, consignment stock at customer, external consignment stock from vendor or returnable packaging) must be taken separately (in different physical inventory documents), however. Furthermore, the stock can be divided into stock types. In the standard system, a physical inventory can be carried out for the following stock types:

>     Unrestricted-use stock in the warehouse

>     Quality inspection stock

>     Blocked stock

>     Reserved stock

If batch status management is active, the first stock type covers both unrestricted use stock and restricted-use stock.

Inventory of all stock types mentioned can be taken in a single transaction. For the materials to be inventoried, one item is created in the physical inventory document for every stock type. Physical inventory takes place at storage location level. A separate physical inventory document is created for every storage location.

If a material does not exist in a storage location, this means that no goods movement has ever taken place for the material in the storage location. The material, therefore, has never had any stock in this storage location. The material does not exist at stock management level in the storage location. It is therefore not possible to carry out a physical inventory for the material in this storage location.

This is not to be confused with a material for which a goods movement has taken place and for which the stock balance is currently zero. A physical inventory must be carried out in this case, since storage location data is not deleted when the stock balance is zero.

 

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Physical Inventory Procedures

The System supports the following physical inventory procedures:

>     Periodic inventory

>     Continuous inventory

>     Cycle counting

>     Inventory sampling

  1. Periodic Inventory

In a periodic inventory, all stocks of the company are physically counted on the balance sheet key date. In this case, every material must be counted. During counting, the entire warehouse must be blocked for material movements.

  1. Continuous Inventory

In the continuous inventory procedure, stocks are counted continuously during the entire fiscal year. In this case, it is important to ensure that every material is physically counted at least once during the year.

  1. Cycle Counting

Cycle counting is a method of physical inventory where inventory is counted at regular intervals within a fiscal year. These intervals (or cycles) depend on the cycle counting indicator set for the materials.

The Cycle Counting Method of Physical Inventory allows fast-moving items to be counted more frequently than slow-moving items.

  1. Inventory Sampling

In MM Inventory sampling randomly selected stocks of the company are physically counted on the balance sheet key date. If the variances between the result of the count and the book inventory balance are small enough, it is presumed that the book inventory balances for the other stocks are correct.

Constraints

The posting of physical inventory differences is subject to certain time constraints:

The posting period is automatically set during counting. Therefore, the inventory difference must be posted to the same period or – if postings to the previous period are allowed – in the following period.

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The fiscal year is set by specifying a planned count date when creating a physical inventory document. All subsequent postings to this document must take place in this fiscal year and/or in the first period of the following fiscal year, if postings to the previous period are allowed.

Process Flow

Regardless of the physical inventory method, the process of physical inventory can be divided into three phases:

  1. 1. Physical Inventory Preparation

>     Create a physical inventory document.

>     Blocking Materials for Posting

>     Print and distribute the physical inventory document.

  1. Physical Inventory Count

>     Counting stocks

>     Entering the result of the count on the physical inventory document printout

  1. Physical Inventory Analysis

>     Entering the result of the count into the system

>     Initiating a recount, if necessary

>     Posting inventory differences

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Physical Inventory in Warehouse Management

SAP Scenarios

S. No Procedures TCODE Input Output
1 Create a Physical Inventory document LI01N Storage Type, Bin No. Inventory document
2 Activate Physical Inventory LX22 Inventory document Inventory document
3 Print count sheet LI04 Inventory document Inventory document
4 Inventory count LX26 Inventory document Inventory document
5 Entering count results LI11N Inventory document Inventory document
6 Change count results LI12N Inventory document Inventory document
7 Recount on need basis LI14 Inventory document Inventory document
8 Generate difference report LX17 Inventory document Inventory document
9 Differences clearing in WM LI20 Inventory document Inventory document
10 Differences posting             in

Inventory Management

LI21 Inventory document Inventory document
 

 

 

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Forms and reports required

All report requirements is fulfilled by standard SAP reports.

Standard reports in SAP:

Transaction Code
Physical Inventory list MI24
Physical Inventory Overview MIDO
ABC analysis for cycle counting MIBC
Physical Inventory data for material MI23
Physical Inventory documents for material MI22
Changes to Physical inventory document MI12
Difference list per storage type LX17
Statistics for inventory differences LX18
Inventory status LX25
Evaluation of quant inventory LI15
Stock comparison of inventory and warehouse management LX23
 

 

 

Integration with other modules

Integration with MM as the physical inventory process will be updating the base document / Reference document in MM. The physical inventory differences should be cleared both in WM and MM.