Auto-Replenishment

How replenishment works in Waresify

You set a minimum and a maximum quantity on each pick-face location. The minimum triggers a refill. The refill quantity is the maximum minus what is on hand, so the task never asks for more than the shelf can hold.

Waresify looks for source stock in bulk or reserve locations, taking the location with the most available stock. It skips lots that are not active and reserves the chosen stock when it creates the task, so a wave cannot allocate it in the meantime.

Each pick face and item can have one open replenishment task at a time, whatever triggered it.

What triggers a replenishment task

Four triggers run side by side.

• Pick and putaway: after a pick or a putaway completes, the pick face is checked against its minimum.
• Demand: when an order or transfer reserves stock and leaves the pick face below its minimum, a task is created before anyone picks.
• Nightly scan: a scheduled sweep checks every pick face, at 02:00 by default.
• Manual: a supervisor creates a task for an item and pick face, and can choose the source location or let Waresify find one.

What the worker scans

On the scanner app or the browser terminal, the worker scans the source location and the license plate, then scans the pick face. The quantity moved is prefilled with the planned quantity and can be lowered.

If the move would break the destination's capacity or mixing rules, the task is blocked and the supervisor is notified. A completed task writes a REPLENISH movement to the stock ledger.

What happens when reserve stock runs out

If no bulk or reserve location holds the item, Waresify creates a purchase suggestion instead of a task and notifies the supervisor. A repeat trigger for the same gap updates the open suggestion.

The supervisor acknowledges or dismisses each suggestion. The operations dashboard shows pick faces by fill level, worst first, with the count of open suggestions.