Replenishment moves stock from reserve to the pick faces before they run empty. The administrator enables it in Settings › Operating rules › Operations › Visible modules › Location replenishment.
Configure the pick faces
In Operations › Replenishment › Pick faces, each pick face is a pick-face location with a product and three values:
- Minimum: when the quantity reaches this value or falls below it, replenishment is created.
- Maximum: the quantity it is filled up to.
- Multiple: the unit in which it is moved (for example, boxes of 12).
Example: P-1001 in A-01-01-1 with a minimum of 24, a maximum of 96 and a box of 12. If the pick face is left at 24, the task is for 72 pieces; if it is left at 20, it rises to 84 to complete boxes.
When a task is created
-
On picking: each pick from a pick face checks it at that moment.
-
Sweep: Chainlink checks all pick faces every 15 minutes (you can change this in Operations › Replenishment), for example after a count adjustment.
-
Manual: Create replenishment on the board.
-
Emergency: if a picker reports a shortage at a pick face and there is reserve stock in the warehouse, a replenishment with priority 95 is created at that moment: "An emergency replenishment was requested for A-01-01-1. Continue to the next stop."
-
Overnight replenishment: at the warehouse time you select (for example 10:00 PM), Chainlink fills the pick faces that allow it with what the next day's open orders require.
Two tasks are never created for the same pick face: what is already on its way counts, and there is only one open emergency replenishment per pick face.
How much is replenished
In addition to the minimum, maximum and multiple, each pick face can have:
- Replenishment unit: a unit of the product, for example a box of 12. The task is shown as "2 boxes (24 pcs)".
- Capacity: the most that fits. Without a capacity, the maximum is used and the pick face shows the notice "Define the pick face capacity to calculate replenishment."
- Overnight replenishment: whether it is allowed and in which window (for example from 10:00 PM to 5:00 AM).
Board
In Operations › Replenishment, open tasks are sorted into lanes by origin: Urgent (blocks picking), Min-max and Overnight. Each card shows the pick face, the source, the quantity and the time it is due, for example "A-07-03 ← R-12-01-4 · 2 boxes (24 pcs) · due 3:40 PM". The overnight replenishment time of each warehouse is changed in Pick faces.
Where it is taken from
The source is selected by FEFO (what expires first), then by the oldest receipt; among equal sources, a full pallet that fits is preferred, and then the one closest to the pick face on the map. Always from reserve or storage locations, never from another pick face. That stock is reserved for the task: no pick list can take it while the task is open. If a pick face has no source to be replenished from, the board shows it under No stock in reserve.
Perform the replenishment on the handheld
- In My work › Replenishment, take the task: "Replenish A-01-01-1 with 48 pcs from R-12-04-3".
- Scan the source location and then the product. If the lot is not the allocated one, the app indicates it.
- Enter the quantity.
- Scan the destination pick face. On confirming, you see "Replenishment completed".
If you finish a put-away and there is a nearby replenishment with the same equipment, the app offers it: "Pending replenishment 8 m away", with Take and Pause. In SAP, each replenishment is recorded as a transfer between locations of the same warehouse.
If the expected stock is not at the source, tap Shortage, select the reason and enter what you found. Chainlink looks for another source for the rest ("Take the remaining 12 pcs from R-11-02-1."). If there is none, the task is left With exception on the board.