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Steven Canter

07/18/2019

Inventory Fulfillment from A to Z

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Agenda

• The Basics• Inventory Fulfillment States• Reservation/Allocation• Fulfillment Setup• Lead Times• Order Release• Order Picking• Picking Confirmation• Packing• Shipping/Issues• Defer Depletions• Undo Fulfillment

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Agenda (continued)

• Workbenches• Shortage Workbench

• Allocation Workbench

• Fulfillment Workbench

• Advanced Topics• Reservation/Backorder Rules

• Pegging

• Kits

• Troubleshooting

The Basics

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Inventory Fulfillment States

• Pending – The line is either incomplete, invalid, or on hold. Work Orders from Maintenance stay in Pending status. Non-Stock and Direct Ship Orders go from Pending straight to Shipped.

• Unfulfilled – The line may or may not be partially/fully reserved or allocated but it has not been released to move to the step in the process

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Inventory Fulfillment States (continued)

• Releasable – The line is ready to be released for picking. It may or may not be reserved, allocated, or promised.

• Released – The line has been assigned to a Pick Batch and available for picking.

• Confirmed – The Picking Confirmation process has subtracted the quantity from the Material Storage Location. The BU on-hand balance is not updated

• Shipped – The line has been recorded as shipped. BU on-hand balance not updated.

• Depleted – The Deplete On Hand process has run and the quantity is subtracted from the BU on-hand. Transaction History has been recorded. Point of no return.

• Canceled – The line has been canceled and cannot be further processed. Any action taken to this point has been undone.

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Stock Request Inquiry

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Reservation/Allocation Definitions

• Soft Reservation – Material is reserved for a Demand Line at the Business Unit level, but not for a Specific lot or Material Storage Location.

• Allocation – Material is reserved for a Demand Line, including Lot and/or MSL. Allocation prior to Picking is optional.• Standard Allocation – Allocation occurs at the time of Order

Release

• Pre-Allocation – Allocation occurs before Order is Released

• Lot Allocation – The specific Lot is Pre-Allocated but the MSL is not yet specified

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ATP and Non-Reserved Items

• Available to Promise – Calculation to promise inventory to a specific Demand Line based on a calculation of future supply and demand.

• Non-Soft Reserved/Non-ADP Items – Used for items where stock is assumed to always be plentiful. Inventory is not reserved to the order until the order is picked.

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BU Fulfillment Setup

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Fulfillment Task Options – From States

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Auto Processing Options

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Lead Times

• Lead times take Calendar Closure Days into account

• Reservation Lead Days – At the BU level, the number of days required to reserve, pick, pack, and ship the majority of the items in the business unit. It can be overridden and the Item level. Used to Reserve demand lines.

• ATP Lead Days - the number of days that the majority of the items in the business unit can be fully promised for shipment. Can be overridden at the Item level. Should be greater than Reservation Lead Days.

• Picking Lead Days and Minutes - the time required to process a demand line from the time that it is picked to the time that it is shipped. Used for Order Release and can be overridden.

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Item Fulfillment Options

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Order Release

• The Order Release Request takes orders in the unfulfilled and releasable states to the released state

• Output can potentially include:• A picking plan (SQR) report

• A picking extract file for downloading into an electronic data collection system

• The Shipping Order Release EIP to send order data to a third-party system

• Shipping carton labels

• Item usage labels to aid in the tracking of material usage

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Release Action Options

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Auto Processing Options

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Specific/Advanced Selection Criteria

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Date/Time Selection

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Additional Options

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Picking Feedback

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Picking with Mobile Inventory

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Picking Confirmation

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Packing Sessions

• Used to pack stock into shipping containers

• You can create multiple levels of shipping containers and to keep track of how each container is packed

• Must first establish basic attributes such as what types of containers exist

• Each container is identified by a unique shipping container ID

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Shipping Container Definition

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Packing Session

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Shipping Issues

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Shipping Issues – Detail Drilldown

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Defer Depletions Feature

• Used to delay the billing and costing of inventory shipments

• Often used when exact day for pickup at the dock is not known, such as with Customer Pickup orders

• Allows for shipments to take place and for batch depletions to run, but to prevent individual lines from being depleted until approved to do so

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Defer Depletion Options

• Default Defer Depletions to N – lines will not automatically defer, user can override

• Default Defer Depletions to Y – lines will automatically defer, user can override

• Do not use this feature –lines will never be deferred and user cannot overrride

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Removing Deferred Flag

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Undo Fulfillment

• Allows a demand line to be moved to a previous fulfillment state.

• Reasons may include:

• Reallocate material to a higher-priority customer

• Update the order when a customer changes the requested quantity

• To change the material storage location from which stock was picked

• To correct errors made during any of the demand fulfillment steps.

• Limitations if lines have been packed or added to a delivery

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Undo Fulfillment Page

Workbenches

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Shortage Workbench

• Enables the user to monitor and control stock shortages and other fulfillment issues.

• Users can view shortages and take action to fill the outstanding orders.

• The Shortage Workbench only selects demand lines that are in the unfulfilled or releasable states.

• Template(s) must be set up before the workbench can be used.

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Examples of Workbench Actions

• Soft-reserve stock.

• Set a demand line from the unfulfilled state to the releasable state.

• Set the demand line back to the unfulfilled state from the releasable state.

• Unreserve demand lines that are in an unfulfilled or releasable state.

• Create, cancel, or approve backorders.

• Approve stock requests.

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Creating a Template

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Assign Template Permissions

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Search for Releasable Orders

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Unreserve and Set To Unfulfilled

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Reserve Stock to a Line and Release

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Allocation Workbench

• Used when Allocations are needed prior to Order Release

• Allows the user to create a standard allocation

• Enables the user to update, or remove an existing pre-allocation or lot allocation

• Unlike Fulfillment and Shortage Workbenches, there is no customizable template

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Allocation Workbench Selection

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Search Results

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Manually Allocating Quantity

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Order is now Pre-Allocated

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Fulfillment Workbench

• Enables the User to enter requests to move Demand Lines directly from one fulfillment state to another

• You can skip the intermediate fulfillment steps and place an order directly in the state that you need

• Since this workbench allows the skipping over of many of the standard processes, care should be utilized

• Very handy when doing some fulfillment “outside the system” and then need to get the transaction recorded

• Like the Shortage Workbench, a template must be set up

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Selection Criteria with Simple Template

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List of Eligible Orders

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Specify Lot/Location/Serial

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Update Shipping/Picking Flags

Advanced Topics

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Reservation/Backorder Rules

• Determine under what conditions an Order or Demand Line can move forward in fulfillment

• Determine under what conditions backorders will be generated

• Rules are applied at Reservation and Shipping stages

• Rules can exist at the Line or Order level

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Reservation Rules

• Determine when a Backorder is created

• Determine when a Backorder is canceled

• Notify the proper user of the condition to make a manual Backorder decision

• Allow a shortage to release, thus deferring the Backorder decision until shipping time

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Backorder Rules

• Control when an Demand Line is or is not Releasable

• Notify the proper user of an issue needed attention, such as a shortage

• Determine whether or not to reserve available inventory to the Demand Line

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Apply Rules to Stock Request – At the BU Level

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Apply Rules at the MSR Level

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Applying Rules to a Sales Order

• Arbitration Plans are used to determine how rules will be applied

• One Arbitration Plan must be the Default

• Additional Arbitration Plans can be created and assigned by BU if needed

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Example Arbitration Plan

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Formula Assignment

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Assign Arbitration Plan to BU

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Manually Add Rules to Order

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Rule Examples

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Pegging

• Pegging links demand to incoming supply.

• Demand can be either of the following:

• Sales Order

• Interunit Transfer going out

• Supply can be any of the following:

• Purchase Order

• Production ID

• Interunit Transfer coming in

• Peg prevents the incoming supply from being reserved to another Demand Line

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Using Pegging Workbench

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Peg SO to PO

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View Pegging Information

• From the Sales Order Line, you can see the PO or PID that is Pegged

• From the PO Schedule, you can see the Sales Order that is Pegged.

• From PID Maintenance, you can see the Sales Order that is Pegged.

• From the Stock Request Inquiry, you can see the Pegging Information.

• From the Pegging Inquiry screens, you can also directly transfer to the other transaction.

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Pegging Inquiry in PO

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Product Kits

• A product kit consists of a fixed set of components that are sold as a unit. A product kit is not a stocked inventory item, however its components may or may not be.

• Product Kits are defined in the Product Definition -Definition page when you select the Product Kit check box.

• When an order with a product kit is placed in the demand fulfillment table the product kit ID is not a demand line. Instead, each kit component that is an inventory item is placed as a separate demand line with a field identifying the product kit ID.

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Kit Processing Options

• Can be placed on a sales order within PeopleSoft Order Management and then posted to PeopleSoft Inventory for fulfillment.

• Can be placed on a material stock request in PeopleSoft Inventory.

• Can be altered by the Kit Re-Explode process.

• Can be released for picking component by component or held back until complete kits can be released together.

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Example of a Kit Setup

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Component Options

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Sales Order for a Kit

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Kit Stock Request

Troubleshooting

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General Issues

• Ensure that if BU security is enabled, that the user running the process has the needed access

• Check to see if the Demand Line is locked

• Verify that the Storage Location is not undergoing a Physical or Cycle Count

• Unit of Measure modified to only allow Whole Number after demand with decimal quantity has been created

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Reserve Materials process (IN_FUL_RSV)

• PS_IN_DEMAND.IN_FULFILL_STATE = '20' (= Unfulfilled) or (PS_IN_DEMAND.IN_FULFILL_STATE = '10' (= Pending) and RESERVE_STATUS = '99' (= Invalid))

• PS_IN_DEMAND.APPROVED_FLAG = 'Y' (= Approved)

• PS_IN_DEMAND.LOT_ALLOC_FLG = 'Y' (= Lot Allocated) or (PS_IN_DEMAND.LOT_ALLOC_FLG = 'N' and PS_IN_DEMAND.CONFIG_CODE = ' ' and PS_DF_SETUP_IT_INV.ONLINE_RES_FLAG = 'N' (= 'Reserve Online' option is not selected at the Setup Item Fulfillment level if exist)

• PS_DF_SETUP_IT_INV.ALLOC_LEAD_DAYS > 0 at the Setup Item Fulfillment level if exist

• PS_IN_DEMAND.SCHED_DTTM <= Current date/time

• PS_IN_DEMAND.IN_PROCESS_DATE <> NULL/empty

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Order Release process (IN_FUL_RLS)

• PS_IN_DEMAND.IN_FULFILL_STATE = '30' (= Releasable)

• PS_IN_DEMAND.FULFILL_FLAG = 'Y' or PS_IN_DEMAND.IN_ZERO_PICKED_FLG = 'Y'

• PS_IN_DEMAND.PEG_STATUS <> '10'

• PS_IN_DEMAND.TMS_PROCESS_FLG <> 'Y'

• PS_IN_DEMAND.PICK_BATCH_ID = '0'

• PS_IN_DEMAND.HOLD_FLAG = 'N'

• PS_IN_DEMAND.DEMAND_SOURCE = 'RT' (= Material Return) or (PS_IN_DEMAND.DEMAND_SOURCE = <> 'RT' and the Item must exist in the PS_BU_ITEMS_INV table (Business Unit Item table) and ITM_STATUS_CURRENT (Current Status) must be = '1' (= Active) or '3' (Discontinue))

• PS_IN_DEMAND.SCHED_DTTM <= Current date/time

• PS_IN_DEMAND.IN_PROCESS_DATE <> NULL/empty

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Picking Confirmation process (IN_FUL_CONF)• PS_IN_DEMAND.IN_FULFILL_STATE = '40' (= Released)

• PS_IN_DEMAND.CONFIRMED_FLAG = 'Y'

• PS_IN_DEMAND.IN_PROCESS_DATE <> NULL/empty

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Deplete On Hand Qty process (IN_FUL_DPL)• PS_IN_DEMAND.IN_FULFILL_STATE = '60' (= Shipped)

• PS_IN_DEMAND.DEPLETE_INV_FLG = 'Y'

• PS_IN_DEMAND.SHIP_DTTM <= current date

• PS_IN_DEMAND.IN_PROCESS_DATE <> NULL/empty

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Checking/Clearing Inventory Locks

• Most commonly caused by batch processed ending abnormally and not running to completion.

• Rows in use by the incomplete process might still be locked.

• Should only be used by Administrators to ensure that active running jobs are not unlocked

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Wrap Up

• PeopleSoft Inventory Fulfillment is very configurable with many options

• In most cases, there is more than one way to dosomething, meaning that the processes can be optimizedfor your specific business

• Some of these topics are far to complex to cover everything in a 90 minute session

• Hopefully there was something today that you hadn’t seen before that you can play with when you get back to your office

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Any

Questions?

Please complete a session evaluation

Session ID: 100370

Contact Info:

Steve.Canter@SmartERP.com

Tel: 312-560-4373

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