Floor Stock Replenishment Report

CAUTION: Depending on factors such as the number of jobs and production schedules, and depending on your hardware setup, this report can take a long time to complete. You might want to run this report at night or in a background queue.

The Floor Stock Replenishment Report lists quantities needed to fill existing work center floor stock locations to cover the production requirements you specify. The report also lists requirements for consolidated materials for the jobs and production schedules you specify.

You can include or exclude the current quantity at the work center floor stock location. To accommodate picking and filling personnel respectively, this report sorts by From Location or To Location.

NOTE: It is possible to define more than one location for a single work center, allowing two parts with uncommon locations to be assembled at a common work center.

Setup and System Processing

The Floor Stock Replenishment report is used to "refill" backflush locations for items. If a location is tied to a work center in the Locations form, and there is a backflushed part on an operation for that work center, the system finds the quantity in that location and compares it to the "unissued" quantity for that operation. If the quantity falls below zero, then it appears on the report.

Use this report only for locations with an associated work center. To associate a location with a work center, you select the work center on the Locations form. That location is then referred to as a floor stock location.

The following example illustrates this process.

Example

Item A is stocked in the following locations and quantities:

Location	Qty
Stock	500
Loc-1	10
Loc-2	25

Work center AS-500 is associated with location Loc-1, so Loc-1 becomes a floor stock location for work center AS-500.

There are two assembly lines for Item A. The assembly lines run through two different work centers. Each has its own floor stock location and therefore its own available on-hand quantity:

Assembly Line	Work Center	Floorstock Location	Quantity
Line 1	FA-400	Loc-2	25
Line 2	AS-500	Loc-1	10
N/A	N/A	(Stock)	500

Consider the following for this example:

If you want the system to consider a floor stock location when you run this report, you cannot designate the location as a transit or non-nettable location. See Item Stockroom Locations for more information.
The quantity in the item location that is considered available for replenishment is the difference between the on-hand quantity minus any reserved quantity:

AQ = OHQ - RQ where

AQ = Available quantity

OHQ = On hand quantity

RQ = Reserved quantity

The Net WC/Floor Location Qty Avail field includes or excludes the current quantity in the floor stock location. In this example, when running the report for work center AS-500, you could include or exclude the quantity of 10 from Loc-1 when calculating the new requirements.
The report suggests floor stock replenishment requirements only for those locations associated with a work center. In this example, if you run the report for work center AS-500, the report would suggest requirements for Loc-1 only.
This example assumes you have run the Floor Stock Replenishment Report only for AS-500, but you can run the report for all work centers.
The system does not consider floor stock locations tied to another work center as source locations (that is, From Locations) to satisfy replenishment requirements. For example, if you ran the report for work center AS-500, the system would not consider Loc-2 as a source of replenishment for Loc-1.

Processing Backflushed and Non-Backflushed Items

The report processes requirements for backflushed and non-backflushed items, if you have associated an item location with a work center location.

NOTE: Backflushing does not occur as a result of running this report. Backflushing occurs as a result of completing quantities.

Output

This report identifies consolidated quantities of inventory that must be moved to a floor stock location for pending production. To post a move transaction to move that inventory, select one of the following options in the Post Material Moves field:

Select All to move all available inventory.
Select Filled Only to move only enough material to meet all requirements for the current run.
Select None to move no inventory.

For more information on move transactions, see Item Stockroom Locations.

Handling Serial Number/Lot Tracking

This report provides information on the location and quantities needed to replenish floor stock locations. If you are using lot tracking or serial numbers, the report does not provide specific serial numbers or lots, only quantities needed.

Exception Messages

When there is inadequate stock to cover the requirements, exception messages display. These messages allow you to intervene and make adjustments.