What is replenishment in a warehouse?
Replenishment is moving stock from reserve locations to pick faces so pickers find stock where they expect it.
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Why replenishment matters
A picker who reaches an empty pick face has to wait, skip the line or fetch a forklift driver. Replenishment refills the pick face before that happens.
The usual trigger is a minimum level. When stock falls below it, the pick face is filled back up to its maximum.
Worked example
In this example, a pick face has a minimum of 60 and a maximum of 240. A pick leaves 50, so the system creates a task to move 190 units from reserve.
Ten minutes later a wave reserves 30 more units from that face. The demand check runs, finds the open task and creates no duplicate.
How Waresify handles it
Replenishment is a module on every plan. Tasks come from four triggers: a pick that leaves a face below its minimum, a nightly scan, a reservation that drops a face below its reorder point, and a manual request from a supervisor.
A location can only have one open replenishment task per item, whatever triggered it. If there is no reserve stock to move, the supervisor gets a purchase suggestion, and picks depending on that face are marked at risk.
Questions
Is replenishment the same as reordering from a supplier?
No. Replenishment moves stock inside the warehouse. Reordering buys more from a supplier. Waresify raises a purchase suggestion when there is nothing left in reserve to move.
When should replenishment run?
Many sites refill overnight for the next day and react to picks during the day. Waresify supports both.