Infor SyteLine3 min readNetray Engineering TeamUpdated March 4, 2025

How to Set Up Min-Max Planning in SyteLine

Min-max planning in SyteLine provides a straightforward replenishment strategy where the system triggers purchase or production orders when inventory drops below a minimum level and orders up to a maximum quantity. This approach works well for stable-demand items, MRO supplies, and consumables where full MRP planning adds unnecessary complexity. This guide covers setting up min-max parameters, configuring automatic order generation, and optimizing safety stock levels.

Configure Min-Max Parameters on Items

Navigate to the Item Planning Parameters form (ItemPlanParms IDO) under Inventory > Planning for each item-warehouse combination. Set the Planning Method field to Min-Max. Enter the Minimum Quantity (reorder point) and Maximum Quantity (order-up-to level). The Order Quantity equals the difference between max and current on-hand stock. Set the Safety Stock field to buffer against demand variability—typically 1-2 weeks of average consumption. Configure the Lead Time field accurately as it determines when planned orders are triggered relative to the need date.

Set Planning Method to Min-Max on Item Planning Parameters form
Enter Minimum Quantity as the reorder trigger point based on lead time demand
Set Maximum Quantity as the target stock level after replenishment
Configure Safety Stock as buffer quantity—typically 1-2 weeks of average usage

Run Min-Max Planning and Generate Orders

Execute min-max planning from the Plan Generation form (PlanGen) under Planning > Generation. The planning engine compares current available inventory (on-hand minus allocations plus on-order) against the minimum level. When available falls below minimum, the system creates a planned order for the difference between maximum and current available. Review planned orders on the Planned Orders form (PlannedOrders IDO). Convert planned purchase orders to actual POs using the Planned PO to PO Conversion form, or planned production orders to jobs using Planned Job to Job Conversion.

Run planning from Plan Generation form with item or product code filters
Review generated planned orders on Planned Orders form before conversion
Convert planned POs to actual purchase orders via Planned PO to PO Conversion
Convert planned production orders to jobs via Planned Job to Job Conversion

Optimize Min-Max Levels with Historical Data

Use the Min-Max Calculation utility under Planning > Utilities to automatically calculate optimal min-max levels based on historical consumption data. The utility analyzes transaction history over a configurable period—typically 6-12 months—and calculates recommended levels using average daily demand, lead time, and a service level factor. Review recommendations on the Min-Max Review form before applying changes. Set up periodic recalculation schedules through the SyteLine Event system to keep levels current as demand patterns shift seasonally.

Run Min-Max Calculation utility using 6-12 months of historical demand data
Adjust service level factor to balance stock availability against carrying cost
Review and approve calculated recommendations on Min-Max Review form
Schedule periodic recalculation via SyteLine Events to capture seasonal demand shifts

Frequently Asked Questions

When should I use min-max planning versus MRP in SyteLine?

Use min-max planning for items with stable, independent demand such as MRO supplies, office materials, and consumables. Use full MRP for manufactured items with dependent demand driven by BOMs and production schedules. Min-max works best for items with 10-20% demand variability and short lead times under 2 weeks. Items with lumpy demand, long lead times, or complex BOMs benefit more from MRP's time-phased planning logic.

How does SyteLine calculate available inventory for min-max comparison?

SyteLine calculates available inventory as: On-Hand Quantity minus Allocated Quantity plus On-Order Quantity (open POs and scheduled production). This available quantity is compared against the minimum level. If available falls below minimum, a planned order is generated. The calculation considers all warehouses within the item's planning site unless warehouse-specific planning is configured, which restricts the calculation to individual warehouse balances.

Can I set different min-max levels per warehouse in SyteLine?

Yes, min-max parameters are set at the item-warehouse level on the Item Planning Parameters form. Each item-warehouse combination can have independent minimum, maximum, and safety stock quantities. This allows central distribution warehouses to hold 4-8 weeks of stock while satellite locations maintain 1-2 weeks. The planning engine evaluates each item-warehouse independently and generates separate planned orders for each location requiring replenishment.

Key Takeaways

1Configure Min-Max Parameters on Items: Navigate to the Item Planning Parameters form (ItemPlanParms IDO) under Inventory > Planning for each item-warehouse combination. Set the Planning Method field to Min-Max.
2Run Min-Max Planning and Generate Orders: Execute min-max planning from the Plan Generation form (PlanGen) under Planning > Generation. The planning engine compares current available inventory (on-hand minus allocations plus on-order) against the minimum level.
3Optimize Min-Max Levels with Historical Data: Use the Min-Max Calculation utility under Planning > Utilities to automatically calculate optimal min-max levels based on historical consumption data. The utility analyzes transaction history over a configurable period—typically 6-12 months—and calculates recommended levels using average daily demand, lead time, and a service level factor.

Want to optimize your SyteLine min-max parameters for better inventory turns? Netray can analyze your demand patterns and configure planning rules that reduce stockouts and excess inventory.

Talk to an Expert See a Demo

Related Resources

Infor SyteLine