Overview Notes
Overview Notes
Overview Notes
Warehouse Management in SAP is specifically known as SAP EWM that is extended warehouse
management. The software solution designed to optimize and automate various logistical
processes within a warehouse environment. It provides functionalities to manage the
entire flow of goods, from the moment they arrive at the warehouse until they are
shipped out to customers.
Basic Warehouse Management (WM): This comes included with S/4HANA and
covers essential warehouse tasks like receiving goods, put-away (storing them),
picking orders, issuing goods, and stock counting. It's suitable for businesses with
basic warehousing needs.
Extended Warehouse Management (EWM): This requires an additional license
and offers more advanced features for complex warehouses. It includes
functionalities like multi-warehouse management, labor management, value-added
services, and enhanced picking strategies.
Organization Structure 2
Organization structure : The organization structure in SAP Warehouse
Management refers to the hierarchical framework that defines how your physical
warehouse and its operations are mapped within the system. It essentially creates a
digital representation of your warehouse layout and functionalities.
We have different organizational units like plant and storage location which relates to
material management but performs the process with warehouse management units in
the system.
Plant
A core organizational unit in SAP which represents a manufacturing or production unit
while its not complete MM unit it also supports WM as well.
A warehouse number can be assigned to one or more plants.
Storage Location
A organizational Unit which allows the differentiation of material in a plant. Which
stores the material received at storage location level.
One storage location is assigned to one plant where as plant can have more than one
storage locations assigned to it.
Warehouse Number
This is the highest level of organization in WM. Each physical warehouse or storage
area is assigned a unique warehouse number in SAP.
Storage type
A physical storage area inside the warehouse which holds the storage sections and
further bins. Storage type differs according to organizational criteria.
Storage Section
A sub-division with in a storage type, It groups storage bins with similar attributes for
optimized storage to put away the stocks and retrieve it whenever in need.
Storage Bin
The smallest available space in warehouse to store the products which identifies the
exact location of goods in a warehouse.
Storage Unit: This refers to the smallest physical unit of storage, such as a pallet,
carton, or individual item. Storage units are managed and tracked within storage bins.
Storage Section Control: This defines rules and parameters for managing storage
sections, including storage capacities, picking strategies, and replenishment methods.
Storage Bin Control: It involves settings and configurations for individual storage bins,
including bin types, capacities, picking and put-away strategies, and hazardous material
handling.
Storage Unit Management: This component manages the movement and tracking of
individual storage units within the warehouse, including put-away, picking, and inventory
processes.
Warehouse Tasks: These are specific activities performed within the warehouse, such
as goods receipt, goods issue, internal movements, and physical inventory. Tasks are
created, assigned, and executed based on warehouse processes and priorities.
Warehouse Management Master Data: This includes material master data, storage
bin master data, warehouse product master data, and other relevant information needed
to manage warehouse operations effectively.
Now lets see how business is benefitted with this defined organization structure and
how smooth the process goes.
1.Goods receipt :
A crucial process where system marks the arrival and acceptance of goods into
warehouse
Verifies the delivery of goods against purchase orders and records the goods in
warehouse and stores into particular storage type/ bins based on material category.
3. Put-away:
Location assignment: Using the WMS, staff determines the optimal storage
location for the received goods based on factors like item size, weight, and
demand.
Product movement: Goods are transported to their designated storage
locations within the warehouse.
4. Storage:
Inventory Management: The WMS tracks the location and quantity of all stored
goods.
Stock control: Regular inventory checks ensure accuracy and prevent
stockouts.
5. Picking:
Order processing: When a customer order arrives, the WMS generates a pick
list detailing the items needed to fulfill the order.
Order picking: Warehouse staff use the pick list to locate and retrieve items
from storage. The WMS may guide them through optimized picking routes for
efficiency.
6. Packing:
Order consolidation: Picked items are brought together and verified for
accuracy.
Packing and labeling: The order is securely packed with appropriate protective
materials and labeled with customer and shipping information.
7. Goods Issue:
Order dispatch: The packed order is prepared for shipment by the chosen
carrier. Shipping documents are generated.
Inventory update: The WMS updates inventory records to reflect the reduction
in stock due to the fulfilled order.
Over all a well defined process flow of warehouse management helps businesses to
achieve a more automated, data-driven, and efficient warehouse operation, ultimately
contributing to a stronger overall supply chain performance.
Master Data
What is master data in SAP?
A core building block for business purposes where it holds essential information about
the products, objects, materials, entities in a system.
Long lasting of data with minimal changes when updates occurred, it serves as a
reference point in terms of transaction data for business processes.
Let's elaborate the concepts with deep diving in master data of warehouse
management.
1. Warehouse Structure:
Warehouse Number: This represents your entire warehouse facility, potentially
encompassing a single building or a complex with multiple storage areas.
Storage Types: Warehouses are further divided into storage types based on various
characteristics. This could include:
Function: Dedicated areas for raw materials, finished goods, hazardous
materials, or temperature-controlled storage.
Equipment: Areas designed for specific storage/retrieval systems like
automated storage and retrieval systems (AS/RS).
Security Requirements: High-value items or sensitive materials might
require designated secure storage areas.
Storage Sections: Each storage type can be further subdivided into sections for better
organization within a specific area. These sections might be based on:
Product Category: Grouping similar items together for easier access and
picking.
Item Size: Storing bulky items in designated sections separate from
smaller items.
Retrieval Frequency: Frequently picked items might be placed in more
accessible sections.
Storage Bins: The most granular level represents individual storage compartments
within a section. Each bin has a unique identifier and capacity to reflect its storage
limitations.
2. Item Master Data:
Material Master Data: This core data, often integrated from the Material Management
(MM) module in SAP, provides essential details about each item stored in the
warehouse:
Material Number: Unique identifier for each item.
Description: Basic information about the item.
Weight and Dimensions: Important for storage space allocation and
weight restrictions.
Picking Unit: The unit in which the item is typically picked (e.g., box,
piece).
Special Handling Instructions: Specific requirements for storage or
handling (e.g., fragile, flammable).
Comprehensive and well-maintained warehouse management master data forms
the backbone of efficient warehouse operations. By providing the WMS with
essential details about your warehouse structure, items, resources, and
processes, you can enable better organization, streamlined workflows, and
ultimately, a more efficient and accurate warehouse environment.
Inbound Receiving
The inbound process in SAP Warehouse Management refers to all the activities
involved in receiving goods from suppliers and storing them within the warehouse. It's a
crucial stage in the overall supply chain, ensuring a smooth flow of goods and
maintaining accurate inventory levels.
1. Pre-Inbound Activities :
Purchase Order Creation (MM): The inbound process typically begins with the
creation of a purchase order in the Materials Management module. This document
specifies the items being ordered, quantities, and the expected delivery date from
the supplier.
Inbound Delivery Notification (WM): Based on the purchase order, an inbound
delivery notification is automatically generated in WM. This notification informs the
warehouse about the upcoming delivery, allowing for preliminary planning activities
like allocating resources or reserving storage space.
2. Goods Receipt:
Delivery Arrival: When the goods arrive at the warehouse, a worker verifies the
delivery against the shipping documents or purchase order details. This might
involve checking for quantity, damages, or missing items.
Goods Receipt Document Creation: Once the delivery is verified, a goods
receipt document is created in WM. This document captures details like the
received quantity, batch information and any issues noted during verification.
3. Quality Control :
Inspection Lots: For certain items or depending on company policies, quality
control checks might be required before accepting the goods into the warehouse.
WM allows for creating inspection lots, which group specific quantities of received
goods for quality checks. Integration with separate quality control systems might be
possible.
4. Put-away:
Storage Location Determination: The system identifies the optimal storage
location for the received goods based on predefined storage strategies. These
strategies might consider factors like item characteristics at activity level or special
storage requirements
Put-away Tasks: WM generates put-away tasks or instructions, which specify
the items, quantities, and designated storage locations for the received goods.
Warehouse personnel might utilize mobile devices or barcode scanners to confirm
put-away activities and update the system.
5. Inventory Update:
Stock Posting: Upon completing the put-away process, a stock posting is
triggered in WM. This updates the inventory record for the specific items, reflecting
the increased quantity in the designated storage location.
Benefits of an Efficient Inbound Process in warehouse management :
Improved Inventory Accuracy: Accurate goods receipt and putaway processes
ensure a clear picture of on-hand inventory, minimizing stock discrepancies.
Enhanced Receiving Efficiency: Streamlined procedures for verifying,
inspecting, and storing goods lead to faster processing times and reduced
congestion in the receiving area.
Optimized Warehouse Space Utilization: Effective putaway strategies based
on item characteristics allow for better space allocation within the warehouse.
Faster Order Fulfillment: Timely receiving and storing of goods ensures they
are readily available to meet customer order fulfillment requirements.
Over all to conclude inbound process businesses can achieve efficient goods receipt,
maintain accurate inventory data, and ultimately contribute to a smoother and more
responsive supply chain.
Receive Goods : The process of accepting, checking, and storing incoming shipments.
It's essentially the first step in making those goods available to be shipped out to
customers or used in production.
Put away : As discussed in the above slides Put away is the warehouse task where
products received are stored in the assigned storage bin which is the final storage of
goods in warehouse.
Stocking : Refers to the entire process of overseeing the flow of goods within a
warehouse. It encompasses everything from strategically planning inventory levels to
the physical storage and organization of items.
Picking : Picking refers to the process of selecting the exact items and quantities
required to fulfill a customer order, delivery order, transfer request, or production need.
It is the mandatory step within the outbound delivery process and involves ensuring
accuracy and efficiency.
Packing : Packing refers to the process of preparing picked items for shipment. It
involves grouping, securing, and labeling the items according to specific requirements to
ensure safe and efficient transportation to the customer.
Shipping : Shipping refers to the final stage of the outbound process where goods are
prepared and sent to customers. It involves a series of activities that ensure the safe
and timely delivery of orders.
Record usage of stock : The process of capturing and documenting the inventory
stock due to various warehouse activities to be performed in next steps.
Each stock posting activity is associated with a specific movement type in WM.
Movement types categorize different goods movement scenarios within the warehouse.
Here are some common movement types related to warehouse stock postings:
1. Goods Receipt from an external supplier.
2. Goods Issue for fulfilling a sales order or internal transfer.
3. Inventory Transfer between storage locations within the warehouse.
4. Inventory Adjustment (positive or negative) due to factors like shrinkage or
damage.
5.
When a stock posting is triggered, the WM system performs the following steps
Identifies the Item: The system identifies the specific item affected by the
warehouse activity based on the material number or other relevant identifiers.
Updates Inventory Record: The stock level for the item in the designated
storage location (bin) is updated. This could be an increase or a decrease (e.g.,
picking).
Batch Management : If the item is batch-managed (meaning it has expiry dates
or production lot information), the system might update the stock level for a specific
batch within the storage location.
Accounting Integration: Depending on the configuration, the stock posting
might trigger updates in integrated accounting modules to reflect the change in
inventory value.
KANBAN Process in warehouse management
Kanban is a visual inventory replenishment system that relies on signaling mechanisms
to maintain optimal stock levels. While SAP WM doesn't have a dedicated Kanban
module, it offers functionalities to configure and manage Kanban-based replenishment
strategies for warehouse operations.
Production Integration
Production integration in warehouse management refers to the seamless flow of
information and materials between the warehouse and the production floor. This
integration ensures that the production process has the necessary materials available at
the right time, while also managing the finished goods produced.
Benefits of Production integration process
Improved efficiency.
Reduced inventory levels.
Enhanced order fulfillment.
Better production planning.
Production integration in SAP WM allows for a seamless flow of materials between the
warehouse and production processes. This integration ensures that:
Raw materials are readily available for production when needed.
Finished goods are efficiently received and stored after production.
There are two primary approaches to production integration in EWM:
1. Delivery-Based Production Integration:
This is the traditional approach and involves the following steps:
Production Planning & Control (PP): In the SAP Production Planning (PP)
module, a Production Order is created, specifying the items to be produced,
quantities, and required materials.
Bill of Materials (BOM): The BOM, also defined in PP, lists the components and
raw materials needed to produce the finished good.
Material Reservation: Based on the Production Order and BOM, EWM
automatically reserves the required materials in the warehouse. This ensures the
materials are available for picking when needed.
Picking for Production: A warehouse worker picks the reserved materials
based on a picking list generated by EWM.
Goods Issue: Once picked, the materials are issued to production through a
goods issue process in EWM. This updates inventory records and reflects the
materials consumed in production.
Production Confirmation (PP): In the PP module, a confirmation is made upon
completion of production, specifying the quantity of finished goods produced.
Goods Receipt for Finished Goods: Based on the production confirmation,
EWM generates a goods receipt document for the finished goods. This document is
used to receive and store the finished products in the warehouse.
2. Advanced Production Integration (API):
This approach offers a more tightly integrated and automated process, particularly
suitable for repetitive manufacturing scenarios. Here's how it works:
Production Material Request (PMR): The PP module creates a PMR in EWM
when a Production Order is released. The PMR specifies the components and
quantities needed for production.
Staging: EWM generates staging tasks for the required materials. This instructs
warehouse personnel to move materials from storage locations to a designated pre-
production staging area.
Consumption: Production consumes the materials directly from the staging
area. Consumption can be confirmed electronically or manually through EWM.
Automatic Goods Receipt: Upon confirmation of production completion, EWM
automatically generates a goods receipt document for the finished goods,
eliminating the need for a separate process.
Why we use Production integration process what benefits we get from It let's see
Outbound Process GI
Sales Order Creation : The starting point typically lies in the Sales and
Distribution module, where a sales order is created. This document specifies:
Customer details
Ordered items
Requested quantities
Delivery date
Picking Execution: Pickers utilize mobile devices or paper pick lists to navigate
the warehouse and retrieve items from designated locations. They might scan
barcodes to confirm picking accuracy and update the system in real-time.
Pick Confirmation: Pickers confirm the completion of picking tasks in WM,
updating inventory records to reflect the reduced stock levels for the picked items.
Packing: Picked items are staged in a designated packing area. Packing
personnel might utilize functionalities like:
Packing List Generation: WM generates packing lists that detail the
items, quantities, and packaging instructions for each shipment.
Packaging Material Selection: The system might suggest appropriate
packaging materials based on item characteristics and shipping requirements.
Weight and Dimension Capturing: The weight and dimensions of the
packed goods might be captured for shipping cost calculation or compliance
purposes.
4. Goods Issue and Shipment Preparation:
Goods Issue Posting: Once the items are picked and packed, a goods issue is
posted in WM. This process:
Debits the inventory records for the shipped items.
Updates accounting records to reflect the cost of goods sold.
Delivery Creation: Based on the sales order and packing information, WM might
generate a delivery document. This document serves as a packing slip and shipping
instruction, containing details like:
Customer information
Ordered items
Shipped quantities
Weight and dimensions.
Thank you