Cartonization in Warehousing

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Title: CartonizationAbstract: How to set up Cartonization for Advanced Warehousing. Solution: 200783784 WDS-03-0019

Table of ContentsGeneral Setup Process of Cartonization Flowchart Sample R46472

General SetupCartons should be created from UDC table 46/EQ.

The initial Carton setup for WMS is the P46091 and this program does not use a dream writer version. The setup is off of menu G4641/8. The initial screen displays the list of cartons defined for the given B/P. Additional information is in the fold and needs to be verified. It should be noted that these are just carton codes, i.e. types of boxes. It is assumed that an infinite number of cartons are available in each carton code.

Two fields are of maximum importance. They are: Shipping Priority (PRSH): A number that identifies this shipping carton's place in the priority list that the system uses to make carton recommendations. When the system makes a carton recommendation, it uses shipping priority to determine which carton it should choose first, second, third, and so forth. If you want the system to look from large to small containers (downsizing), you should assign priority 1 to the largest container, priority 2 to the next largest, and so forth. Tolerance (CTPR and CTPM): CTPR is the minimum percentage of a shipping carton that must be filled before it can be shipped. If the content of the carton does not reach this percentage, the system recommends a smaller carton. The default minimum percentage is 85%. CTPM is the maximum percentage of a shipping carton that can be filled before the system recommends a larger carton. The default maximum percentage is 90%.

The important thing to remember is that the carton is considered full as soon as the minimum fill % is reached. A maximum fill% is defined to ensure enough space for packaging material. So, it is the users responsibility to define the minimum as high as possible and the maximum as close as possible to the minimum. Exactly how many of an item can fit into a carton is defined from option 15/G46311. Here, the user has to define the % of the carton occupied to 1 quantity of the item. The system calculates the total number of items that can fit into the carton. In the screen prints below, we are looking at items AG1 and AG2.

Further, the U/M Definition by Item should mention what method is to be used for cartonization. This can be accessed from option 24/G4641. Carton Recommendation Method ( CRMT ) is the code that indicates the method the system uses to recommend a carton for the specified item in this unit of measure.

Valid codes are: blank 1 Do not recommend cartons for the specified item in this unit of measure Recommend shipping cartons for the specified item in this unit of measure based on the volume of the item and the volume of the shipping carton Recommend shipping cartons for the specified item in this unit of measure based on the percentage of the shipping carton that the item and unit of measure occupy

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Also, the Location Profile Detail (15/G4641) for the location that is to be suggested should be enabled for cartonization. Carton Recommendation (CTNF) is the code that indicates whether the system recommends shipping cartons when it picks from this location.

Valid codes are: Yes, recommend cartons when picking from this location. Y The system recommends a carton only if you have set up the Carton Recommendation Method for the item. No, do not make carton recommendations when picking N from this location.

Enter a Sales Order to create requests. The order of requests are same as that of the Sales Order.

Create a version for P46471 (Create Picking Tasks) with the processing option set to perform cartonization.

Use that version of P46471 in the processing options behind P46171 (Process Pick Requests).

Process the requests to create suggestions. Back to top

Process of CartonizationAfter suggestions are created, P46471 calls X46450 to recommend cartonization. X46450 uses the following logic to assign cartons to suggestions: Take the carton code with highest Ship priority. In our case, it will be AGC11. Consider all suggestions in alpha-numeric order of item number. So 100 AG1 will be first. 1 quantity of item AG1 occupies 1.24% of carton AGC11. So the entire carton can hold only 80 quantities. So the suggestion is split into 80 and 20. 80 AG1 is assigned to a box (first) of type AGC11. (First task-first trip) Remaining 20 is written as a new suggestion, First box is full. Downsize flag is OFF 20 AG1 (new suggestion) is considered next.

20 quantities of AG1 occupies only 24.8% of the carton. 20 AG1 is assigned to a box (second) of AGC11. (Second Task-First trip) This is less than the minimum fill% of AGC11. Second box is not full. Downsize flag is ON Ordered by item number, 50 AG1 is considered next. 50 AG1 occupies 62% of the carton. In total, 86.8% of the carton is full. 50 AG1 is assigned to a box (second) of AGC11. (Second Task-second trip) This is still less than the minimum fill%. Second box is still not full. Downsize flag is ON 60 AG2 is considered next. No rules are found for AG2 and AGC11. 40 AG2 is considered next. No rules are found for AG2 and AGC11. No more suggestions found. As downsize flag is ON, program tries to downsize the last box. Carton code AGC12 is considered. 1 AG1 occupies 1.41% of AGC12. 20 AG1 (Second task, first trip) occupies 28.2% 50 AG1 (second task, second trip) occupies 70.5% Totally, the suggestions occupy 98.7% of the carton of type AGC12. Since this is between the min and max fill%, the box is considered full Carton type for Second task-first trip and second task-second trip is changed to AGC12 Carton code AGC12 is considered next, based on ship priority. 60 AG2 is considered first. No rules are found for AG2 and AGC12. 40 AG2 is considered next. No rules are found for AG2 and AGC12. No more suggestions found. Carton code AGC21 is considered, based on ship priority. 60 AG2 is considered first. 1 AG2 occupies 1.95% of AGC21. So 60 AG2 occupies 117%, which is more than max fill% Only 51 AG2 can fit in one box; suggestion split into 51 and 9

51 AG2 is assigned to a box (first) of AGC21 (Third task-first trip) First box is full. Downsize flag is OFF 9 AG2 is considered next. 1 AG2 occupies 1.95% of AGC21. So 9 AG2 occupies 17.55%, which is less than min fill% 9 AG2 is assigned to a box (second) of AGC21 (Fourth task-first trip) Second box is not full. Downsize flag is ON 40 AG2 is considered next. So 40 AG2 occupies 78%, making the total 95.5, which is between min and max fill% 40 AG2 is assigned to a box (second) of AGC21 (Fourth task-second trip) Second box is full. Downsize flag is OFF No more suggestions found. Downsize flag is OFF, so downsizing not attempted. The results can be verified from the report R46472. Suggestions are shown in the same order as requests. Note that the first and second requests have 2 suggestions each.

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Technical Flow of the Cartonization ProcessMain flow of X46450

S003 - Assign carton to suggestions

S007 - Downsizing

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Sample R46472 ReportDate 10/07/03 JDEdwards and Company

Time

-

11:07:39

Pick Slip and Tags

Page Number

-

1

Branch/Plant -

AGWH

Ship-To: Supplier Name Ship-To 00336680 2000 S Union #15 Wave Number Denver CO Task Number -

9841

9257

23456 United States Container: AGC11 Aravind's

Carton 11 Trip Order FROM Location Item Number/

TO Location

Number Lot / Storage Unit # Unit # Number Ty Suf

Description

Quantity

UM Lot / Storage

------- -------------------- ------------------------- --------------- --------------------- -------- -- --1.000 1 74 SO 000 .1 .1 AG1 80 PK

Aravind's 1.5 Lot Grade. . . . 80 Container: Weight ---------------------------------------------------------------------------------------------------------------------------56.80 LB Pounds PK Lot Potency. . .

Date

-

10/07/03

JDEdwards and Company

Time

-

11:07:39

Pick Slip and Tags

Page Number

-

1

Branch/Plant -

AGWH

Ship-To: Supplier Name Ship-To 00336680 2000 S Union #15 Wave Number -

9841

Denver CO Task Number 23456

9258

United States Container: AGC12 Aravind's

Carton 12 Trip Order FROM Location Item Number/

TO Location

Number Lot / Storage Unit # Unit # Number Ty Suf

Description

Quantity

UM Lot / Storage

------- -------------------- ------------------------- --------------- --------------------- -------- -- --1.000 1 74 SO 000 .1 .1 AG1 20 PK

Aravind's 1.5 Lot Grade. . . . 20 Container: 2.000 1 74 SO 000 .1 .1 AG1 50 PK PK Lot Potency. . .

Aravind's 1.5 Lot Grade. . . . 50 Container: Weight ---------------------------------------------------------------------------------------------------------------------------49.70 LB Pounds PK Lot Potency. . .

JDEdwards and Company Date 10/07/03 Pick Slip and Tags Time 11:07:39

Page Number

-

1

Branch/Plant -

AGWH

Ship-To: Supplier Name Ship-To 00336680 2000 S Union #15 Wave Number Denver CO Task Number 23456 United States Container: Carton 21 Trip Order FROM Location Item Number/ TO Location AGC21 Aravind's

9841

9259

Number Lot / Storage Unit # Unit # Number Ty Suf

Description

Quantity

UM Lot / Storage

------- -------------------- ------------------------- --------------- --------------------- -------- -- --1.000 2 74 SO 000 .2 .2 AG2 51 PK

Aravind's 15 Lot Grade. . . . 51 Container: Weight ------------------------------------