Outbound Process Using Wave, Pick-HU, Packing, Staging, and Loading SAP Extended Warehouse Management (SAP EWM) Rapid-Deployment Solution V2

Outbound Process Using Wave, Pick-HU, Packing, Staging, and Loading

SAP Extended Warehouse Management (SAP EWM) Rapid-Deployment Solution V2

© 2011 SAP AG. All rights reserved. 2

Physical Activity System Activity

Step 3Create a TU (SAP EWM)

Step 1 Assign the outbound deliveryorders to routes (SAP EWM)

Step 2 Create waves (SAP EWM)

Step 5 Pick the goods (SAP EWM)

Step 6Pack the goods (SAP EWM)

Outbound Process Using Wave, Pick-HU, Packing, Staging, and Loading – Part 1

The system assigns outbound delivery orders to routes

The system builds picking waves

The shipping office clerk orders transportation capacity

A warehouse worker logs on as a resource

The system proposes the next WO in the queue to be processed

The shipper confirms the transportation capacity and

communicates an external identifier

The shipping office clerk creates a TU with the external identifier and the

route

Step 4 Release the waves (SAP EWM)

The system releases the waves, creates WOs , and assigns them to

queues

The warehouse worker puts a pick-HU onto the resource

The warehouse worker creates the pick-HU

The warehouse worker picks the goods into the pick-HU and moves the pick HU to the packing station

The warehouse worker confirms the WO

A packer logs on as a resource

The packer scans the pick-HU

The packer prepares a shipping HU

The packer creates the shipping HU

The system prints HU labels

The packer labels the shipping HU and repacks the goods from the pick-

HU into the shipping HU

The packer confirms the repacking

The packer weighs and closes the shipping HU

The system prints the shipping HU labels and creates a WO to the

staging areaThe packer labels the shipping HU


Physical Activity System Activity

Step 7Stage the goods (SAP EWM)

Outbound Process Using Wave, Pick-HU, Packing, Staging, and Loading – Part 2

The warehouse worker confirms the WO

The warehouse worker moves the shipping HU to the staging area

The system determines the open WO for the shipping HU


The warehouse worker scans the shipping HU

Step 8 A truck arrives at the checkpoint and drives to the door (SAP EWM)

A truck arrives

The checkpoint clerk determines the door and confirms the arrival of the

truck

The checkpoint clerk communicates the door to the truck driver

The truck drives to the door

Step 9Load the truck (SAP EWM)

The warehouse worker confirms the loading of the shipping HU

The warehouse worker moves the shipping HU to the truck

The system determines the door for loading


The warehouse worker scans the shipping HU

Step 10 Post the goods issue andprint the delivery notes andloading lists (SAP EWM)

The shipping office clerk posts the goods issue

The shipping office clerk hands over the delivery papers to the truck driver

The system prints the delivery papers

Step 11 Truck Departure from the Warehouse (SAP EWM)

The truck leaves

The shipping office clerk confirms the departure of the truck


Purpose

Upon outbound delivery order creation, the system automatically assigns the outbound delivery orders to routes depending on scheduled dates. After the route assignment, the outbound delivery orders are assigned to picking waves automatically. The shipping office clerk orders transportation capacity from the shipper for each route. After the confirmation of the shipper, the shipping office clerk creates the transportation units (TU), and assigns them to the route and a door. With the automatic release of the waves, the warehouse activities begin. Warehouse workers pick the goods from different areas in the warehouse using mobile devices and bring them to a packing station where they are consolidated and packed onto shipping HUs such as euro pallets. The packer attaches shipping labels to the shipping HUs. Then the shipping HUs are moved to the staging area. When the truck arrives, it is checked in and directed to a door. The goods are loaded from the staging area into the truck. Upon loading completion, the shipping office clerk posts the goods issue, prints the delivery note(s) and loading list(s), and hands them over to the truck driver. The truck leaves the door and is checked out.


Prerequisites

•You have integrated SAP EWM with SAP ERP

•You have configured the warehouse structure and master data

•You have configured your systems for this process

•Customer orders and outbound deliveries exist in SAP ERP


Process step 1:Assign the outbound delivery orders to routes (SAP EWM)

This step is done automatically upon creation of the outbound delivery orders. The system assigns the outbound delivery orders to routes. The routes are determined based on the delivery dates and the route schedules.

If the system cannot find a route for an outbound delivery order (see Monitoring), it is necessary that a warehouse clerk determines the cause of the failure, for example, missing master data due to a new route or a new ship-to-party. Once the data is corrected by the warehouse clerk, the warehouse clerk, triggers a route redetermination.


Process step 2: Create waves (SAP EWM)

Upon outbound delivery order creation, the system automatically assigns the outbound delivery orders to waves. The wave assignment is done based on the route and the activity area.

If the system cannot determine a wave for an outbound delivery (see Monitoring), the shipping office clerk has to check the log for the wave assignment, and to maintain the necessary settings . Afterwards, the shipping office clerk re-triggers the wave assignment.


Process step 3: Create a TU (SAP EWM)

The shipping office clerk orders transportation capacity from the shipper for the routes. The shipper confirms the transportation capacity and the shipping office clerk receives an identifier (unique number) from the shipper (this is not done in the system) for the transport. For truck ordering, it may be useful to check the expected volume and weight per scheduled route (see Monitoring).

Once the transportation has been confirmed by the shipper, the shipping office clerk creates the TUs with the received identifier from the shipper, and assigns them to the route and a door in SAP EWM.

In exceptional cases, the shipping office clerk can manually unassign outbound delivery orders from waves to assign them to a different route and route schedule and to a different wave, for example, to process them earlier in case of a raise of priority communicated by the customer.


Process step 4: Release the waves (SAP EWM)

Upon the automatic wave release, the system creates warehouse tasks (WTs). The system joins the warehouse tasks together into warehouse orders (WOs) to optimize the working packages for the pickers. The WOs are used to pick the goods and move them to a packing station. The WOs are assigned to different queues according to specific criteria such as the activity area and the type of resource necessary to access the bins. Within one WO, the WTs are sorted according to specific criteria such as the pick path.

If for some of the wave items, no WTs can be created (see Monitoring), for example, due to insufficient stock, a warehouse clerk checks the log for the wave release and the stock for the given outbound order delivery item and triggers if necessary a pick denial or a replenishment. Once the stock is sufficient he re-releases the wave manually.


Process step 5 - Part 1: Pick the goods (SAP EWM)

In this step, the warehouse worker picks the goods and brings them to the packing station. This step is executed using a mobile device.

The warehouse worker goes to the starting point for picking, takes the equipment necessary for the picking (for example, vehicle, mobile device), and logs on as a resource. The worker puts always a wire basket as pick HU onto the vehicle (this has not been created in the system yet). A permanent HU number is attached as number and barcode on each pick-HU.

The warehouse worker receives the first WO of the queue he is assigned to on his mobile device. He is prompted to create the pick-HU for this WO. For this purpose he scans the barcode of the pick-HU.

Then he or she drives to the first source bin of the first WT displayed on his or her mobile device, picks the required quantity of the product and puts the product into the pick-HU proposed by the system. He or she scans data such as source bin, product, pick-HU for verification purposes, and enters the quantity. After all fields have been verified, the WT is confirmed and the worker proceeds with the execution of the next WT displayed on his or her mobile device.

After the last WT of the WO is confirmed, the warehouse worker is prompted to bring the pick-HU to the packing station. There he or she moves the pick-HU from the resource to the packing station and confirms this last step as well.

Then the worker returns to the starting point for picking to prepare the pick HU for the next warehouse order.


Process step 5- Part 2: Pick the goods (SAP EWM)

If the picker finds a quantity smaller than the requested quantity in the storage bin, he or she enters an exception code and records the quantity difference in the WT by entering the quantity he or she has actually picked. With the confirmation the system reduces the stock on the current bin by the difference quantity and automatically tries to create a new pick WT from another bin. If possible, the new WT is added to the current warehouse order of the picker. If not, the new WT is assigned to a new warehouse order, which is put an RF queue.

The exceptional situation, that a new WT cannot be created, for example, because there is no other stock of the product in the warehouse or only in a reserve storage type, can be seen in the monitor and requires manual interaction, for example, triggering a pick denial or a replenishment (see Monitoring).

Another possible procedure could be that the picker uses an exception to block the bin and triggers an inventory counting to correct the quantity on the bin as a whole.

When the last carton of a pallet is picked from the source bin, the empty pallet remains at the source bin and is removed during the putaway of a new pallet onto the bin.


Process step 6: Pack the goods (SAP EWM)

At the packing station, a warehouse worker packs the goods into shipping HUs (for example europallets) per consolidation group. A consolidation group is used to group the goods that should be packed and shipped together (for example for one specific customer and route). The packer can use the monitor to get the information when to start packing for a certain consolidation group and what kind of packaging material to be used (see Monitoring).

The packer takes a packaging material (for example europallet), and creates an HU. He or she prints an HU identification label. The packer transfers the goods from a pick HU to the shipping HU. He or she scans the pick-HU, the product to be repacked and the shipping HU. The system internally creates a WT from the pick HU to the shipping HU and confirms it immediately.

The pick HU is automatically deleted upon WT confirmation when it is empty. The wire baskets is returned later to the starting point.

Once a shipping HU has been completely packed (HU physically full or no more open WTs for the consolidation group), it is weighed and an additional label is printed. It contains HU information such as customer, route, weight and volume. The packer confirms the completion of the shipping HU in the system. This triggers the creation of an HU warehouse task to move the HU to the staging area.

If the packer finds a quantity smaller than the requested quantity in the picking HU, he enters an exception code and records the quantity difference in the warehouse task by entering the quantity he or she has actually packed. The system corrects the stock on the picking HU with the confirmation of the difference. This exceptional case can be seen in the monitor and requires manual interaction (see Monitoring).


Process step 7:Stage the goods (SAP EWM)

In this step, a warehouse worker moves the shipping HUs to multiple staging areas. This step is executed using a mobile device.

The warehouse worker takes the equipment necessary for the loading (for example, vehicle, mobile device) and logs on as a resource. The worker picks a shipping HU from the packing station and scans its ID. The system automatically finds the open HU warehouse task created upon completion of the shipping HU. The worker is prompted to bring the shipping HU to a staging area. There he or she drops the shipping HU and scans the staging bin, thus confirming the HU-WO. The worker drives back to the packing station to proceed with the next shipping HU


Process step 8: A truck arrives at the checkpoint and drives to the door (SAP EWM)

When the truck arrives, the checkpoint clerk selects the TU with the external identifier (unique number assigned to the TU during creation). If the door assigned to the truck is not free yet, the truck must wait. Once the door is free, the checkpoint clerk advises the truck driver to drive to the assigned door. Assuming a small to medium size yard, the checkpoint clerk confirms the arrival of the truck at the door. This step is necessary for the checkpoint clerk to see that the door is occupied.

For large yards, it would be possible to have the arrival at the door confirmed by the shipping office clerk in a separate step. In this case, the checkpoint clerk only confirms the arrival of the truck at the checkpoint.


Process step 9: Load the truck (SAP EWM)

A warehouse worker begins with the loading from the staging area. This step is executed using a mobile device.

The warehouse worker takes the equipment necessary for the loading (for example, vehicle, mobile device) and logs on as a resource. The warehouse worker picks a shipping HU from the staging area and scans its ID. He loads the shipping HU onto the truck and scans the door bin. The system automatically creates a WT for loading the TU assigned to this door and confirms it in the same step. The warehouse worker proceeds with the next shipping HU until the staging area is empty. Then he or she goes to the shipping office. The shipping office clerk checks that all delivery items have been loaded into the truck and confirms the completion of the loading.

If the warehouse worker loads an HU, which is intended for a different route than the route of the TU, he is notified by the system and can reverse the loading, if necessary.


Process step 10:Post the goods issue and print the delivery notes and loading lists (SAP EWM)

The shipping office clerk posts the goods issue for the TU. This triggers the printing of the delivery note and the loading list for each delivery.

The shipping office clerk hands over the delivery note(s) and loading list(s) to the truck driver.

The goods issue is communicated to SAP ERP, where the billing can begin and an advanced shipping notification (ASN) can be sent to the customer.


Process step 11: Truck Departure from warehouse (SAP EWM)

The truck leaves the door and the premises. The shipping office clerk confirms the departure of the truck from the checkpoint and with this implicitly from the door. This step is necessary for the checkpoint clerk to see that the door is free.

For large yards it would be possible to have the departure from the checkpoint confirmed separately by the checkpoint clerk.


Process Monitoring – Part 1

Process Step

Objects To Be Monitored

Activities

1 Outbound delivery orders without route

Extended Warehouse Management →Monitoring →Warehouse Management Monitor → Outbound → Documents → Outbound Delivery Order

Select outbound delivery orders by initial route

1 Aggregated outbound delivery order data per route

Extended Warehouse Management → Monitoring → Warehouse Management Monitor → Outbound → Documents → Route

Select by route and route departure date

2 Outbound delivery orders without wave

Extended Warehouse Management →Monitoring →Warehouse Management Monitor → Outbound → Documents → Outbound Delivery Order

Select outbound delivery orders by special route and initial wave

3 Aggregated outbound delivery order data per route

Extended Warehouse Management →Monitoring →Warehouse Management Monitor → Outbound → Documents → Route

Select by special route and route departure date

4 Wave items without picking WT

Extended Warehouse Management →Monitoring → Warehouse Management Monitor → Documents → Wave → Wave Item

Select wave items by special route and WT creation status initial (No WTs Created) or A (WTs Partially Created)

4 and 5 Outbound delivery orders without picking WT

Extended Warehouse Management → Monitoring → Warehouse Management Monitor → Outbound → Documents → Outbound Delivery Order

Select outbound delivery orders by special route, route departure date and planned picking status 1 (not started) and 2 (partially completed)


Process Monitoring – Part 2

Process Step Objects To Be Monitored

Activities

4, 5 and 6 Overdue outbound delivery orders without picking WT

Extended Warehouse Management →Alert →Overdue Outb. Delivery w/o WT

Select overdue outbound delivery orders by route

5 Picking workload per activity area, per route, per wave

Extended Warehouse Management → Processes → Picking → Picking Workload per Activity Area

Picking Workload per Route

Picking Workload per Wave

Select picking workload by route,

Select picking workload by activty area,

Select picking workload by wave

6 Packing workload per wave, per work center

Extended Warehouse Management → Processes → Packing → Packing Workload per Wave →

Select packing workload by wave, Select packing workload by work center

9 Loading workload per Route

Extended Warehouse Management →Monitoring →Warehouse Management Monitor → Processes →Loading

Select loading workload by route


More Information

For more information, see SAP Library for SAP Extended Warehouse Management on the SAP Help Portal at http://help.sap.com.


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