Reservations to pack size on customer orders in a database schedule

​@Jimf83 at least for me, your issue is not very clear, sorry. Just by your title, I thought of ‘Default Packing Instructions for Customer Order’,  however, I feel there’s more depth to your issue, if you care to explain please?

Not sure what you are using for keeping track of the pack size? Do you use the Input UoM concept? Are the stock with full pack size and those broken in the same location / stock record? One option could perhaps be to split the stock using W/D/R Number. E.g. the quantity in stock that is not full pack size could have a specific W/D/R No, then the you can add a part availability control to this that blocks it from auto reservation. However I guess you would like this to be considered in the auto reservation for the internal need, so it might be a problem form that angle?

Just some quick thoughts without not knowing the issue that deep.

Hi, thank you for coming back to me, in answer to your questions I added answers below hopefully it may clear up some bits. 

Not sure what you are using for keeping track of the pack size? - we have a field in IPIS showing inner pack size and we also have pack sizes in our inventory part.

Do you use the Input UoM concept? - I haven't seen this and am unsure how it works.

Are the stock with full pack size and those broken in the same location / stock record? -

Yes as we pick by batches so if a pack is split we would be reliant on staff moving the difference to a new location which could be missed. 

One option could perhaps be to split the stock using W/D/R Number. E.g. the quantity in stock that is not full pack size could have a specific W/D/R No, then the you can add a part availability control to this that blocks it from auto reservation. However I guess you would like this to be considered in the auto reservation for the internal need, so it might be a problem form that angle?

we have various quantities that need to be picked out of pack size so I’m not sure how we could make a W/D/R no work as that wouldn't be automatically applied when a pack was split. 

Ideally I’d like to think there was a way of using some coding or a string attribute in the reservation database schedule that would be able to pick up available parts for customer order reservations = to inner pack size from either ipis or the actual inventory part or if it can be done using a filter within the manual reservation screen.

Hi,
The issue we're facing is that our finished goods are sold in predefined pack sizes—typically packs of 10. However, we also use these same goods for internal orders, which often require quantities that don't match the standard pack size.

For example, if I take 4 pieces from a pack for an internal order, the system, when processing a customer order reservation, will generate two separate pick lists:

• One for the remaining 6 pieces from the partially used pack

• Another for 4 pieces from a new, full pack

Since customer orders must be picked in full pack sizes, we then have to manually:

1. Zero out the system-generated pick lists

2. Re-reserve stock to match full pack quantities

3. Reissue the correct pick list

This manual process is becoming more frequent as our operations grow, and it's inefficient. Ideally, I want the system to reserve customer order stock strictly in full pack sizes, and allow any broken packs or partial quantities to be picked for internal orders during our internal kit runs.

It is very hard to help based on this information.  “we have a field in IPIS showing inner pack size and we also have pack sizes in our inventory part.” Is this a field in core or custom field?

It reminds a bit about how we can handle reservation with handling units. You can set up the reservation priority with different perspective:

• Storage Zone Ranking - here you can also have priority of pallets in bulk
• Optimal from HU perspective
• FIFO

You can choose how you prioritize between those perspectives. You can acheive things like:

• First reserving pallets in bulk area
• Then reserve complete HUs in picking area
• Then reserve loose parts in picking area

Was thinking if you can use HU for this and new you break the package you un-attach the rest from the HU. Of course you need to evaluate this from a performance perspective and how it impact the rest of the execution. When you create pick list you can control if you would like one for only complete HU or not.

You can read more in the About Reservation Management.

Many customers are using the Input UoM concept as the pack size, but I think it might be challanges to achieve what you are requiring regarding reservation and pick list.