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SAP WMS Integration with WCS systems

Former Member
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Hi All,

We are rolling out ERP as a Global template on SAP ECC. We are using SAP ECC6.0 EHP7 and the template covers both manufacturing plants and DCs. Out Warehouses (Manufacturing as well as DCs) are currently designed on SAP WMS (and no plan for EWM yet). Some of our Warehouses are highly automated with ASRS systems. I have following questions related to SAP WMS integration with WCS systems. Hope to get some expert advice from this esteem group.

  • Movement and Management of empty pallets or containers – is this managed by the ERP, WMS system, the WCS or in another place?
    • Specifically how are requests for empty pallets / containers handled, automatically or manually and if automatically by what system? This is specific to pallets and containers within warehouse for use within the warehouse.
    • Is status of a pallet or container managed in the ERP or WMS or in another system (such as available, used, clean etc)?
    • Are empty pallets / containers moved and stored in the automated warehouse or in another area?
  • Cycle counting
    • How is the material that is stored in the highly automated warehouse e.g. high bay warehouse cycle counted? Since a user cannot go to the bins for counting, are the pallets brought to a specific area for counting purpose? Can you pls think of seq of steps that needs to be performed between WMS and WCS to handle this?

Any pointer or best practice shared across the industry would be really appreciated.

We are in a Life Science business.

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Answers (1)

JL23
Active Contributor
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This looks like pretty basic questions camouflaged under a complex integration scenario.

1) Movement and Management of empty pallets or containers

You can't have any inventory management in WM only (except you are considering inconsistencies as feature)  In a usual scenario the movement is first carried out in Inventory Management and only if it hits a storage location with a WM assigned then it will trigger some activities in WM.

1a) how are requests for empty pallets / containers handled

Requests for what, building Handling Units? packing deliveries? moving to production?

1b) Is status of a pallet or container managed in the ERP or WMS or in another system (such as available, used, clean etc)?

Where have you seen such statuses? ERP knows unrestricted use, quality, blocked , and WM nothing different.

1c) Are empty pallets / containers moved and stored in the automated warehouse or in another area?

This is rather a question to the warehouse manager where he stores or want to store those items. If it is physically in the area where everything is automated, then you actually have the answer. A system must be able to deal with all kind of materials, I don't see a difference between an empty and a full container in SAP, its basically a number with a description.

2) Cycle counting

Material in high bay warehouses is usually counted with a putaway. Since no human can rearrange the materials on a pallet in a high bay it can be considered as 100% accurate.

If you want count the materials at a different time then you have instruct the system to remove the products from the bin, then you count and let the system move the stock back into the bin. This is quite time intensive and only done for exceptional checks but not for regular counts

Former Member
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Thanks Jurge. I have also referred your responses in many IM WM related queries. Thanks for your inputs on this topic as well.

Let me try to reply back to your queries below :

1a) how are requests for empty pallets / containers handled

Requests for what, building Handling Units? packing deliveries? moving to production?


<HP> There are primarily three request we are looking at:

     a) Pallets for Palletizers at Receiving Dock.

     b) Pallets for Palletizers at the output of Packaging Line (Usually our Fill-Finish plants)

     c) Containers for Production Wastes to be stored in warehouse. (We are planning to use EHS-WM to handle generation and disposition of waste) but need to store them in dedicate ares till it gets disposed off.

     d) Currently our design is restricted to manufacturing plants so once Output of fill-finish line is generated to are already on pallets and moves to the DC on the same pallet (Full Pallet transferred) so currently no requirement of request for Empty Pallets for Outbound Deliver. But, it would be good to hear your inputs.

1b) Is status of a pallet or container managed in the ERP or WMS or in another system (such as available, used, clean etc)?

Where have you seen such statuses? ERP knows unrestricted use, quality, blocked , and WM nothing different

<HP> Business requirement is to be able to track the physical pallet status in system so that only cleaned pallets are transferred to palletizers when requested. And all used Pallets always move to Pallet washing room and then after cleaning moves to Pallet Storage area in Warehouse. So basically we would like to make these sets of pallet status in system like Clean Pallet, Under Use, Dirty Pallets. I think based on your suggestion we can explore Blocked stock status for a pallet if it actually gets damaged but how can we handle others. Any suggestion. Are there any Status available like through status provided by Status Profiles.

1c) Are empty pallets / containers moved and stored in the automated warehouse or in another area?

This is rather a question to the warehouse manager where he stores or want to store those items. If it is physically in the area where everything is automated, then you actually have the answer. A system must be able to deal with all kind of materials, I don't see a difference between an empty and a full container in SAP, its basically a number with a description.

<HP> Got it. So it seems your suggestion is to in fact have pallets as materials in ECC. Just a question on best practice on this practice, are pallets usually stored and managed in ERP systems? Do you have any such inputs?

2) Cycle counting

Material in high bay warehouses is usually counted with a putaway. Since no human can rearrange the materials on a pallet in a high bay it can be considered as 100% accurate.

If you want count the materials at a different time then you have instruct the system to remove the products from the bin, then you count and let the system move the stock back into the bin. This is quite time intensive and only done for exceptional checks but not for regular counts

<HP> Our Inventory Count procedures are currently aligned with GAAP requirement. Now according to that we need to make sure that system is able to provide the Inventory was counted (Annually once or Cycle counted). With your proposal, will this procedure generate any system entries that can help meet this requirement? OR are there any provisions in GAAP for automated warehouses for not counting due to the points you have mentioned? If yes, we may have to redefine our counting procedures.

Sorry for posting such a long response and appreciate your can provide your valuable inputs.