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Warehouse Management

(Part 2)

EGN 5622 Enterprise Systems Integration

Fall, 2015
Process Management and Control
and
Physical Inventory

SAP Implementation
WM Part 2 Overview
 WM Process Management and Control
◦ Logistics Execution: Goods Issue (outbound
delivery)
◦ Goods movement: Stock transfer and
transfer posting
 WM Physical inventory procedures
Logistics Execution - Process Overview:
Goods issue
Goods Issue Process for Outbound
Delivery Steps
Goods Issue Process for Outbound Delivery
The next step after sales order is to create an
Outbound delivery.

•During creation of outbound delivery, a picking


storage location is determined for each item in the
outbound delivery. If the storage location has been
assigned a warehouse number, the outbound
delivery displays the warehouse number.

•Inaddition, the system assigns an overall picking


status and a stock removal status.
Outbound Delivery Status 1:
Outbound delivery created

OPS: Overall Pick status; WM: Overall WM status; C: Pick status; GM: Total gds mvt status;
BS: Billing status; TS: Trns Plan status; POD S: Proof of delivery status
Goods Issue Process for Outbound Delivery:
Transfer order
•Afteroutbound delivery, the removal from storage is
carried out using transfer order.

•Thereis no transfer requirement for creating a


transfer order for a delivery.

•The completion of picking process is reported to


the system through confirmation of the transfer
order.
Goods Issue Process: Good Issue
After confirmation of transfer order (TO), the next step is
to post the goods issue for the outbound delivery in
inventory management (IM).

 Goods issue is a goods movement activity in which we issue


goods from our inventory system.

 During goods issue, we need to reference that sales order


and retrieve data from the sales order to verify material,
quantity, and so on.

Effects of Goods:
1) Update physical inventory and stock value.
2) Update inventory G/L account automatically.
3) Update sales order history with the good issue.
Goods Movements
Goods Movement: Transfer posting and
stock transfer
Transfer posting: A change in the stock ID
(material number) or the stock category of a
material (unrestricted, under QA, or blocked).
Transfer posting is not necessary to involve an
actual (physical) goods movement.

Stock transfer: Movement of materials from a


particular storage location into another storage
location. Stock transfer can take both within the
same plant and between two plants. The two
plants can be in the same company code or
between different company codes. Physical
goods movement is involved.
Goods Movement: Transfer posting and
stock transfer
Example of Transfer posting:
- Stock to stock (Under QA to unrestricted)
- Material to material

Example of Stock transfer:


- Storage location to storage location
- Plant to plant
Transfer Posting/Physical Stock Transfer

Only for unrestricted stocks and Only for unrestricted stocks and
one FI document is created two FI document are created
Goods Movement: Transfer posting and
Stock Transfer
One-Step and Two-Step Procedures:
A stock transfer/transfer posting consists of a
goods issue from issuing point and a goods
receipt at a receiving point.

For one-step procedure, a transfer posting or


stock transfer can be done with a single posting
for all transfer posting or stock transfer.
- Advantage of one-step procedure is that only a
single transaction is generated.
Goods Movement: Transfer posting and
stock transfer
Two-Step Procedures:
For some stock transfers, two-step procedure
may be selected and two separate postings will
be created.
- Advantages for two-step procedure are enable
to monitor stock status. Once goods issue has
been posted from the issuing point, the stock is
regarded as in transfer as the receiving point.
- In the case of stock transfers between plants,
the two-step procedure must be used if users have
operation authorization only for one plant.
One-Step/Two-Step Procedures
Goods Movement: Transfer posting and
stock transfer: Financial Accounting
For a plant-to-plant transfer, both financial
accounting and material requirement planning are
affected.
- A cross-plant stock transfer (in the same
company code) leads to a value update in the stock
accounts. An accounting document is generated
parallel to the material document for the stock transfer.
The stock transfer is valued at the valuation price of
the material in the issuing point.
- in the case of a cross-company-code stock transfer,
two accounting documents are created: one for
each company code. The offsetting is then made to a
company code clearing account.
Cross-Plant Stock Transfer

In the case of a plant-to-plant stock transfer, the two plants can


be belong to the same company code or to different company
codes.
Plant to Plant: One-Step/Two-Step Procedures

In the case of one-step procedure, the goods issue and goods receipt are posted in a
single material document. In two-step procedure, valuation always take places at
the time of the first step.
Goods Movement: Stock Transport Order
1) Stock transport order is similar to a purchase
order, but the vendor is replaced by a supply plant.
2) Stock transport order is integrated with MRP. A purchase
requisition generated by MRP can be converted into stock
transport order.
3) The receipt by stock transport order can be planned at
the receiving plant.
4) Can add delivery costs and a forward/carrier in the stock
transport order
5) Goods receipt can be posted directly to consumption.
6) In the case of a goods receipt into the warehouse, you
may post the material to stock in quality inspection or
blocked stock.
7) The entire process (goods issue and goods receipt) can
be monitored via the PO history.
Stock Transport Order
Physical Inventory
Reasons for physical inventory:

- Material requirement planning: for correction of incorrect stock


quantities.

- Accounting: Determination of material stocks for current assets.


Physical Inventory
Physical inventory is carried out on the basis of stock
management units, or stock keeping unit (SKU).

A stock management unit is a non-divisible part of a stock of


materials for which a separate book inventory exists. A stock
management unit is uniquely defined by:
1) Material
2) Plant storage location
3) Stock type
4) Batch
5) Special stock, such as consignment stock
Each stock management unit of a material is counted separately,
and the inventory differences are posted per stock management
unit.
For example, you must record the quantities of unrestricted-use
stock, stock in quality inspection, and blocked stock of a
material at a storage location of a plant separately in each case.
Phases of the Physical Inventory
The physical inventory process comprises three phases:
1). Creation of physical inventory documents
2). Entry of count
3). Posting of inventory difference

1. In the first phase, you create the physical inventory (PI)


documents and print out the documents in order to start the
counting process.

2. In the second phase, you enter the count results in the system.
System then determines the inventory differences. If some of the
results seem doubtful, you can arrange for a recount of the stock
management units affected. In this case, further PI documents are
generated.

3. In the third phase, you post the inventory differences that have
been identified. In the process, the stock quantity and stock value
are updated and the stock accounts are updated in accounting.
Phases of the Physical Inventory
Physical Inventory Document
PI document is created per plant and storage location.

For special stocks, PI document may be created per plant, storage


location, special stock, and vendor or customer or project.

Storage bin or material group may be specified as futher grouping


values.

The status of an item indicates whether or not the item has been
processed, counted, posted, or recounted. You can use the status
of a PI document item as a selection criterion in searches for
physical inventory documents.
Physical Inventory Document

Figure 256
Blocking Goods Movements

1. Block all goods movements


The system blocks all the stock management units of the
relevant PI document by means of the Posting Block
indicator in the PI document header.

2. Freeze the book inventory


If it is not possible to block the goods movement for
organizational reasons, you can freeze the book inventory
in the PI document at the time of the count.
To do so, you set the Freeze Book Inventory indicator in
the PI document. This prevents goods movements from
changing the book inventory figure.
Blocking Goods Movements
Freezing the Book Inventory
Physical Inventory Status of an Item
For physical inventory count, you must print out the PI
document and distribute to the persons responsible for the
count.

When entering the physical inventory count, you can enter a


percentage variance of the count quantity from the book
inventory, above which the system issues a warning
message.

When the entered data is saved, the system determines the


book inventory in the system. The difference between the
count result and this book inventory is the inventory
difference.
Physical Inventory Status of an Item
You can analyze this difference via the list of differences. The list
of differences contains the following information on each item:
1) Quantity counted
2) Book inventory
3) Difference quantity
4) Difference dollar amount

You can perform the following functions with the list of


differences:
1) Enter, change, display count
2) Post difference
3) Display or change document
4) Recount document or item
Physical Inventory Status of an Item
Posting of Inventory Differences
You can post the inventory differences either via the list of
differences or via separate transactions. When an inventory
difference is posted, the system creates a material document
that corrects the stock figures, and an accounting document
recording the necessary account movements.

If a document exceeds the document tolerance defined for


the user group, a user who is assigned to this physical
inventory tolerance group may not post an inventory
difference for this document. If the total value of the
document lies below the document tolerance, but certain
items exceed the maximum amount per item, the user may
not post the differences for these items. User can process
the other items.

Figure 260
Posting of Inventory Differences

Figure 260
Global Bike, Inc.
WM
Organizational Structure
Outbound Delivery Status 1:
Outbound delivery created

OPS: Overall Pick status; WM: Overall WM status; C: Pick status; GM: Total gds mvt status;
BS: Billing status; TS: Trns Plan status; POD S: Proof of delivery status
Outbound Delivery Status 2:
after Transfer order created
Goods Issue Process for Outbound Delivery
– Transfer order
Outbound Delivery Status 3:
after Transfer order confirmed
Outbound Delivery Status 4:
after goods issued
Outbound Delivery Status 4:
after Billing
WM Multiple Choice Question
Name: ________________________

How can you assign organizational levels in SAP Warehouse


Management? Please choose the correct answer. (One correct
answer)

a) O You can assign a plant-storage location and a storage


area combination to one warehouse number.
b) O You can assign several plant-storage location
combinations to one warehouse number.
c) O You can assign the plant-storage location
combination to several shipping points.
d) O You can assign a plant-storage location to multiple
warehouse numbers.
Exercises: (Due Date 10/17/2015)
Case Study 3: Process outbound delivery

1. Create sales order


2. Display materials inventory
3. Create outbound delivery
4. Display material inventory
5. Pick materials with transfer order
6. Run Bin status report
7. Confirm transfer order
8. Run bin status report
9. Display materials inventory value
10. Ship material
11. Display materials inventory
12. Display materials inventory Value
13. Create invoice
14. Receive payment