In the everyday operation of the warehouse things can go wrong, for example, a picker cannot find all of the materials they need to pick in a bin; a scanner which is part of the MFS cannot read an HU label; a bin that is supposed to be empty is not; when putting away a pallet, less material is on the pallet than there should be.
Whenever an exceptional situation arises in the warehouse, an exception code is needed to describe in the system what the reason or cause for the exception is, and to trigger the action. Such an action can be highly automated (for example, a delivery can be changed or a physical inventory document created), or very basic (someone is informed that the exceptional situation occurred).
Exception Codes
Whether a warehouse employee cannot fulfill the assigned task, or a sensor picks up an issue, or the system can not process the next step, an exception code is triggered. This exception code is always assigned to a business context and an execution step. The business context describes during which process the exception can be used, for example, during a warehouse task confirmation for a putaway, during a quality inspection, or coming from the MFS. The execution step describes the work environment, for example, if you work with a desktop transaction or with RF, if you confirm the source or target bin, if it is a manual selection, or if it is triggered in the background. While the assignment is important for the possible follow-on actions, the assignment is also necessary to reduce the possible exception codes a user can select. It is not helpful to offer workers dozens of exception codes on the small display of their handheld device, because they are not always able to decide which one is correct.
You assign the follow-on actions to the business context and execution step. Which follow-on actions can be used depends on the business context. The following is a list of the possible follow-on actions:
Internal process codes:
The internal process code controls internal program reactions after an exception code is entered, for example, a new bin can be found when the required material cannot be picked from the original bin, or replenishment can be triggered. Some internal process codes can also change deliveries. Then additional settings for the delivery adjustment are also required.
Trigger a workflow:
SAP delivers sample workflows, for example, to trigger a physical inventory document.
Use the status management:
With the status management, a bin or a HU can be blocked.
Trigger an alert in the Alert Monitor:
The Alert Monitor is an SCM-based tool in which you can monitor all of the alerts that have occurred and navigate directly to the relevant application function to resolve the problem.
Examples of Exception Codes
SAP delivers several exception codes for all kinds of warehouse situations. The following are examples of exception code situations:
- BIDP, Partial Pick Denial:
- The user cannot find the required quantity in the bin. When entering the exception in the mobile device, the system brings up a screen where the user has to confirm the quantity they can pick. The system then tries to trigger a new warehouse task to pick the missing quantity from another bin. Additionally, you can set up the system to:
- Trigger a workflow so someone is informed about the situation
- Create a physical inventory document
- Block the bin for putaway and picking
- BIDF, Full Pick Denial:
- The user cannot access the bin where they need to pick from. This exception is entered in the mobile device. The system can create a new warehouse task to pick from a different bin. Additionally, you can set up the system to trigger a workflow so someone is informed about the situation; that a physical inventory document is created; and that the bin is blocked for putaway and picking.
- DIFD, Difference as Charges for Inbound Delivery:
- During putaway the material in the final bin is counted and a difference is found. The full quantity was not delivered from the vendor. The exception is raised, the quantity in the inbound delivery is adjusted, and the goods receipt is corrected.
- DIFW, Difference as Charges for Warehouse:
- During putaway a piece falls from the pallet and is broken. The correct quantity was delivered, but in the end there is less than delivered. The difference is posted to the Difference Account.
- MCAP, Capacity Bottleneck:
- An MFS resource, a conveyor segment, or a communication point is full and cannot take any more tasks. However, by triggering the exception code, the system knows that no further warehouse tasks can be sent to the element until the exception is solved. Such an exception is triggered through an internal exception code.
Internal Exception Codes:
The system can trigger internal exception codes. These are assigned to external exception codes, which are codes that can also be entered manually. The internal exception code does not offer settings for the follow-up actions — this is set up in the external exception code.
An example is pick denial. A pick denial can be entered by a warehouse worker when a bin is not accessible or the required quantity is not available. In this case, the worker has to enter the correct exception code. The system can also trigger a pick denial. When creating a warehouse task in the background, but the required quantity cannot be found by the system in the warehouse, the system can trigger a internal pick denial exception code. This triggers the connected external exception code and the assigned follow-on action is started.