Navigator Solutions

Replenishment

Replenishment is the process of ensuring that picking locations have enough stock to allow picking to take place without interruptions. Navigator supports two models for replenishment - basic and directed.

Each 'fixed' picking location is dynamically allocated a priority to ensure that replenishment tasks are performed in a sequence which maximises pick throughput.

Navigator maintains a minimum inventory level for each picking location.
Each time inventory levels are adjusted, Navigator checks to see if the quantity in the pick location is:
1. Lower than the total required to be picked (based on incomplete pickslips) (a high replenishment priority is set)
2. Lower than the minimum level (a medium priority replenishment priority is set)
3. Lower than the maximum quantity (a lower priority replenishment priority is set)
Each morning at 4:30am, minimum levels are recalculated and inventory levels are re-checked to switch on replenishment for relevant locations.

Basic Replenishment (233)

In a basic replenishment scenario, the operator searches for a pallet containing the item they wish to replenish (Menu option 233). This transaction shows the location of pallets holding the product along with the corresponding storage location. This model allows for one-off ad-hoc replenishments.

To replenish the picking location:

If you are emptying the whole pallet into the picking location, use transaction 264 (Pallet Breakdown). This transaction moves all inventory from the pallet into the picking location. The pallet record in Navigator is removed.
If you are transferring some of the stock from the pallet, use transaction 263 (Transfer from Pallet). Using this transaction means you must scan the product and enter the quantity of stock to remove. Replace the pallet in any free location and use transaction 242 (Transfer Pallet) to record the new location for the pallet.

Directed Replenishment (244)

Under a directed replenishment system, Navigator allows proactive management of the inventory levels in each location. Navigator automatically flags locations for replenishment as their inventory levels fall below the minimum level or the level of stock in the location is insufficient to cover the requirements of in-progress pick slips.

	Commence Replenishment Depending on how the replenishment section is configured, Navigator will ask you to: Enter for next item: This will give you the highest priority replenishment across the entire warehouse. This is the default behaviour. Enter Aisle: This will give you the highest priority replenishment - for items to be picked in the aisle specified. This is used in busy warehouses to allow forklift / replen operators to avoid other pickers. (Users on a Voice directed system may use the 'Skip Aisle' function to avoid workers performing replenishments). Enter Zone: This will give you the highest priority replenishment for the group of locations (zone). This may be used to replenish, for example, all products within specific freezer vs the cold room. Relevant configuration parameters include: REPLENISHMENT_METHOD: Set to 'SITE', 'ZONE' or 'AISLE'
	Select a Location to Replenish The operator is shown a list of locations which have been flagged for replenishment based on The list is sorted in order of priority - where each priority is assigned as follows: Highest: Open pickslips require more stock than is available in the location. Within this priority, products are sorted according to the number of pickslips requiring access to the item. Medium: Inventory level is within 20% of the minimum level. Low: Inventory level is not at its maximum level. The screen shows the location and part number to be replenished, along with the 'pick shortage' (the number of items on pickslips over and above the quantity in the location). In the example screenshot, there is Zero stock on hand, and a total of 40 units have been requested on pickslips.
	Scan Bulk Container Navigator displays a list of containers / locations holding this stock item along with the container's current location. This includes containers in bulk storage in addition to 'putaway' containers. Scan the container or location from which you will be removing stock. The oldest pallet is the container with the lowest reference number. It is recommended (although not enforced) that stock on the oldest pallet be used up before stock on newer pallets.
	Confirm Product and Quantities Once the correct pallet is scanned, Navigator displays the product to be replenished, the quantity on the container and details of the picking location including minimum / maximum levels and the number of items reserved on pickslips. Scan the product and enter the number of items which can be moved into the location. If you enter a quantity higher than the amount available on the pallet, Navigator will cancel the transaction with an error. If you have taken a container to the picking location, scan the picking location. Navigator will transfer the inventory from the container to the location and reset the replenishment flag. If the transaction empties the container, Navigator will also remove the container record from the system (does not apply to containers with the 'fixed' flag set). In addition to scanning the pick location, you may also scan another putaway tub. This action moves stock from the first bulk container into the putaway tub for processing by another user. This allows the replenishment process to be merged with the putaway process being carried out by another user.
	Replace the Bulk Container Once the location has been replenished, the pallet should be returned to a location in the warehouse. Scanning a location code will set the current location for the container to be the location scanned. While the pallet is removed from the racking, Navigator allows the container number to be passed through to the Directed Putaway screen. This screen allows picking locations to be topped up with stock taken from the current pallet (regardless of whether replenishment had been previously requested). Press F4 to run this function.
	Optionally Perform a Putaway Operation The Directed Putaway screen operates as per the normal Putaway process.
	Scan the Putaway Location Once the operator is finished with the container, scan the location into which the pallet is being moved. Navigator allows a pallet to be added into any location. Once the transaction completes, Navigator restarts the replenishment screen from the beginning. The list of locations to be replenished is updated to remove replenishments completed by other operators and to add locations for which replenishment has been requested recently.

Setting up Minimum Quantities

Navigator allows the minimum quantity associated with a product/location to be set manually or automatically. If you choose to set the minimum quantities manually, you should disable Navigator's automatic minimum calculations. To do this, change the system parameter 'REPLEN_AUTO_MIN' to 0 (zero).

Note: Minimum and maximum quantities may only be set for 'fixed' picking locations (created using the 931 or 932 transactions).

Using Navigator WMS Website

To manually set the minimum quantity, go to the Locate Inventory screen (Warehouse Operations -> Locate Inventory) on the WMS web interface and search for the product you wish to change. Click the Edit link next to the location / product you want to configure and adjust the minimum and maximum quantities. Press the Save button to

Using Navigator Scheduler

Navigator's scheduler calculates a suggested minimum quantity based on the highest number of items picked from the location per day in each of the last 30 days. Using this approach, Navigator will automatically ensure that items increasing in popularity have enough stock in the bin to cope with demand. If an item is decreasing in popularity over time, Navigator will reduce the number of replenishments triggered by reducing the minimum quantity in the bin.

This task is performed at 4:30am each day. Once the scheduler has completed this task, it automatically requests replenishment operations for locations which are below their new minimum stock balance figure. Note that Navigator will also switch off replenishment operations for items now above their new minimum stock balance figure.

Using Navigator WMS Mobile

To manually set the minimum quantity for a specific location/product combination, use the 931 transaction. Press the F8 option to enable 'advanced' options. Using this module, you may enter the minimum and maximum quantities for the bin.

Voice Directed Replenishment

Navigator Voice supports replenishment operations using voice. This module allows a worker with a voice computer to transfer stock from the oldest bulk location to the correct picking location.

For detailed instructions, please see here.