Task 07 - Inventory Tracking

In Inventory Control (module 5), Warehouse master (Task 19) each item has a picking sequence. This picking sequence is the spot the item is located in the warehouse. When you receive the merchandise it should be put away in this picking sequence. When you sell the item it should be physically taken out of this picking sequence. Sometimes the warehouse picking sequence doesn’t have enough room for the inventory. In this situation the excess inventory is kept in another reserved area in the warehouse. The inventory tracking system allows inventory to be moved from a “picking sequence slot” to a “reserve slot”. This is a way to know where the excess inventory is located.

The inventory tracking system posts a date & time (down to seconds) of when an item is received. The inventory tracking system assumes when inventory is sold it is physically taken out of the oldest receiver. This gives the current quantity on hand from each receiver. So the inventory tracking system can be a valuable tool even if “reserve slots” aren’t used.

The inventory tracking system is located in Inventory control (module 5)

Inventory tracking (Task 7)
- Warehouse tracking master maintenance WTKMNT (Sub-task 1)
- Move inventory WTMENT (Sub-task 2)
- Print warehouse bin labels BINLAB (Sub-task 3)
- Slot master maintenance SLTMNT (Sub-task 4)
- Empty / negative slot report SLTEMT (Sub-task 5)
- Drop Overstock report SLTDRP (Sub-task 6)
- Purge zero qty tracking master records WTPURG (Sub-task 7)

Parameters to consider: These parameters are located in I/C (Module 5), System management functions (Task 32), Modify parameter files (Sub-task 22), 1 I/C General.

USE'WTKMAS=YN

Y/N use warehouse tracking master file - reserve overflow bins
- 1st digit Y/N - use warehouse tracking? (default=N)
- 2nd digit Y/N - wtment entry by terminal (default=N)
  - YY – Will enable a move inventory WTMENT edit list and posting by terminal.

VALID'SLOTS'ONLY=W

Y/N/W - Validate all new slot references against the Slot master maintenance SLTMNT (Sub-task 4).
- Y- yes-must be a valid slot in the Slot master maintenance SLTMNT
- N - no checking
- W - warn but allow if not in the Slot master maintenance SLTMNT

ENFORCE'PICK'SLOTS=

Y/N/W - Only TO "Pick" slot allowed is warehouse match
- Y- Yes - TO "Pick" slots must match whs
- N -No checking
- W - Warn only

AUTOMATICALLY PURGE ZERO QUANTITY TRACKING MASTER RECORDS (WTPURG):

When a warehouse tracking master transaction CURRENT quantity is zero the transaction may be automatically purged depending on the parameter:

MONTHS'TIL'PURGED=0

Automatically purge zero quantity warehouse tracking slot records (wtkmas.dat) after how many months?
Blank means purge ALL zero records nightly.
If this is set to 1 or greater, an improper zero current quantity may be corrected with an inventory move.
To purge the zero quantity records manually go to I/C (module 5), Inventory tracking (Task 7), Purge zero qty tracking master records WTPURG (Sub-task 7). Read instructions on screen.

HOW IT WORKS:

Task 19 Warehouse master “quantity on hand” (field 3) works the way it always worked.
- When a receiver is posted in the PO module the quantity on hand in the warehouse master (Task 19) is updated just like always.
  - The quantity received will also be posted into the Warehouse tracking master maintenance WTKMNT under the picking sequence slot.
- When an item is sold on an order entry invoice the quantity automatically comes out of the warehouse master on hand quantity just like always.
- The quantity sold will update the Warehouse Tracking Master maintenance WTKMNT for the picking sequence slot current sell-by & stock-by quantities.

For example:

Item #100-61 SCREWDRIVER

Sell by EACH

Stock by CASE

Master Units 12

Picking sequence 408D

Reserve Slot #409C

PO #3355, Receiver #1522 1000 cases.
- This receiver posts a new slot record to the Warehouse Tracking master maintenance WTKMNT using the picking sequence slot 408D.
Move inventory WTMENT (Sub-task 2) The warehouse manager posted an inventory move from slot 408D (picking sequence slot) to 409C (reserve slot) of 500 cases.
- The warehouse master (Task 19) still shows a total of 1000 cases.
- The Warehouse tracking master maintenance SLOT 408D shows current quantity 500 cases & reserve slot 409C shows 500 cases.
Order entry invoice of 100 cases.
- Now the warehouse master (Task 19) shows 900 cases on hand just like always.
- The warehouse tracking master maintenance SLOT 408D (picking sequence slot) shows 400 cases.
- The warehouse tracking master maintenance Slot 409C (reserve slot) still shows current quantity of 500 cases.
Order entry invoice of 500 cases
- The warehouse master (Task 19) shows 400 cases on hand just like always.
- The warehouse tracking master maintenance slot 408D (picking sequence slot) shows -100 cases.
- The warehouse tracking master maintenance slot 409C (reserve slot) shows current quantity of 500 cases.
Move inventory WTMENT (Sub-task 2). The warehouse manager posted an inventory move from slot 409C (reserve slot) to 408D (picking sequence slot) 500 cases.
- Now the warehouse master (Task 19) shows 400 cases on hand.
- Now warehouse tracking master maintenance slot 408D (picking sequence slot) shows current quantity of 400 cases.
- Now warehouse tracking master maintenance slot 409C (reserve slot) shows current quantity of zero. This slot will be automatically purged according to the MONTHS'TIL'PURGED= parameter.

ANOTHER EXAMPLE:

PO #3358, Receiver #1525 1000 cases
- This receiver posts a new slot record to the Warehouse Tracking master maintenance WTKMNT for 1000 cases using the picking sequence slot 408D. This warehouse tracking master transaction will have the date & time the receiver was posted (or added to the warehouse tracking master).
PO #3359, Receiver #1526 5000 cases
- This receiver posts a new slot record to the Warehouse Tracking master maintenance WTKMNT for 5000 cases using the picking sequence slot 408D. This warehouse tracking master transaction will have the date & time the receiver was posted (or added to the warehouse tracking master.)
Order entry Invoice #17018 2000 cases
- The warehouse tracking master maintenance slot 408D (picking sequence slot) for PO #3358 & receiver #1525 CURRENT QUANTITY zero cases. This warehouse tracking master transaction will have the date & time it was changed & the program name that changed it ORDENT order entry. It will also have the terminal # of the change. Since this transaction has a current quantity of zero, it will be purged automatically (depending on the MONTHS’TIL’PURGED parameter).
- Now the warehouse tracking master maintenance slot 408D (picking sequence slot) for PO#3359 & receiver #1526 shows CURRENT QUANTITY 4000 cases. This warehouse tracking master transaction will have the date & time it was changed & the program name that changed it ORDENT order entry. It will also have the terminal # of the change.

See the following documents:

Task 07 - Inventory Tracking - Sub-Task 1 Warehouse tracking master maintenance WTKMNT

Task 07 - Inventory Tracking - Overview