SyteLine Min/Max Reorder Point Planning Setup Guide
Min/max planning in SyteLine provides a straightforward replenishment method for items where demand is relatively stable or where full MRP is unnecessary. When on-hand inventory drops below the minimum (reorder point), the system generates planned orders to bring stock up to the maximum level. This guide covers the configuration of min/max parameters, order point calculations, and integration with the SyteLine planning engine.
Min/Max Parameter Configuration
Min/max planning is controlled at the item-warehouse level through the SLItemWhse IDO. The order_point (minimum) and order_point_max (maximum) fields define the replenishment triggers. The supply_type field must be set to Order Point for the planning engine to use min/max logic instead of full MRP. Additional parameters including reorder_qty, order_multiple, and fixed_order_qty provide flexibility in how replenishment quantities are calculated.
- Set supply_type to Order Point on the item-warehouse record to enable min/max planning for the item
- Configure order_point (minimum) as the reorder trigger level based on demand during lead time
- Set order_point_max (maximum) as the target stock level after replenishment order arrives
- Use reorder_qty for fixed replenishment quantities or let the system calculate as max minus current on-hand
- Apply order_multiple to round planned order quantities to vendor-required pack sizes or lot quantities
Order Point Calculation Methods
SyteLine offers multiple approaches for calculating min/max values. Manual entry lets planners set values based on experience. The Calculate Order Points utility analyzes historical demand and lead times to suggest optimal reorder points. For items with seasonal demand, the utility supports different calculation periods. The calculated values write to the order_point and order_point_max fields on the item-warehouse record for planner review and approval.
- Run the Calculate Order Points utility from the Planning menu to auto-calculate min/max from demand history
- Configure the calculation period (3, 6, or 12 months) to match the demand pattern for each item class
- The utility factors in average daily demand, supplier lead time, and a configurable safety factor
- Review calculated values on the Item Warehouse form before accepting to prevent overstock on slow-movers
- Schedule periodic recalculation to keep order points aligned with changing demand patterns
Planning Engine Integration
When the SyteLine planning engine runs (Generate Planned Orders), it evaluates order-point items separately from MRP-planned items. For each item-warehouse with supply_type Order Point, the engine compares projected on-hand (including open POs and in-transit) against the order_point. If projected on-hand drops below minimum, a planned purchase order or transfer order is generated to restore inventory to the maximum level.
- Generate Planned Orders evaluates order-point items using projected on-hand versus minimum threshold
- Planned orders specify quantity as (order_point_max minus projected_on_hand) rounded to order_multiple
- The plan respects open purchase orders and in-transit transfers as incoming supply in projections
- Planned orders appear on the Planned Orders form for planner review and conversion to firm POs
- Exception messages flag items where projected stock falls below minimum within the planning horizon
Optimize your SyteLine reorder points with data-driven min/max configuration—reach out to our planning specialists.
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