Replenishment

Replenishment moves good stock from a storage location that is not available for picking into a storage location where operators can pick products for orders.

This page is not for receiving goods from suppliers and it is not for correcting inventory differences. If goods are still in receiving, first move them into a location through Putaway. If the product is physically missing from the displayed location, handle it as a stock issue, not as a successful replenishment.

Where It Appears In The Application

The flow starts from Warehouse operations -> Replenish.

The page has two main areas:

Area	What It Shows
Products for replenishment	Products where open orders need pickable stock, but available stock is in non-pickable storage locations.
Replenishment lists	Created lists, status, creation date, completion date, user, and item progress.

From the header, press Start replenishment. If the user already has an active list in the current warehouse, Putaway WMS resumes the existing list instead of creating a new one.

When A Product Appears For Replenishment

Putaway WMS checks products needed for open standard orders in the selected warehouse. It includes orders that still have quantity to prepare and are in a stage where stock can affect picking.

For each product, Putaway WMS compares:

Quantity	What It Means
Demand	Quantity still needed for open orders.
Pickable stock	Good quantity already in locations available for picking.
Shortfall	The difference between demand and pickable stock, after quantities already included in active replenishment lists are subtracted.
Available non-pickable stock	Good quantity in non-pickable storage locations, not blocked and available to move.
Planned quantity	Quantity the list can propose for movement, limited by available non-pickable stock.

A product is useful for replenishment only when there is a shortage in the picking area and good stock exists in a non-pickable storage location.

What Does Not Enter Replenishment Directly

Replenishment does not use these as source locations:

• receiving locations;
• returns locations;
• quarantine locations;
• deleted locations;
• blocked locations or areas;
• damaged or quarantine stock;
• stock already reserved in another active replenishment list.

If the product exists only in receiving, first use Putaway to move it into a storage location. After that, the product can enter replenishment if it is still in a non-pickable area.

Extra Quantity

In Warehouse settings, the Replenish extra units setting can add extra units above the calculated shortfall.

The purpose is to bring slightly more stock into the picking area so operators do not need to repeat replenishment immediately after the next orders.

Example:

5 units short + 3 extra units = 8 units proposed for replenishment

The proposed quantity cannot exceed the good stock available in non-pickable locations.

Choosing Locations

For the source, Putaway WMS looks for good stock in non-pickable storage locations. For perishable products, lots that expire sooner have priority. For other products, warehouse entry date and the order from Picking strategy are used.

For the destination, Putaway WMS looks for a storage location available for picking. Priority is:

1. a pickable location that already contains the same product;
2. an empty pickable location;
3. another valid pickable location if no better location exists.

If no valid destination can be found, the product appears with No destination and cannot be included in a working list until locations are corrected.

Creating A List

The flow is:

1. Open Warehouse operations -> Replenish.
2. Check the Products for replenishment tab.
3. Press Start replenishment.
4. Press Create replenishment list.
5. Follow the scan steps shown on screen.

If no products are available for replenishment, the list is not created.

An active list is tied to the user who started it and to the selected warehouse. If the same user opens the flow again in the same warehouse, Putaway WMS resumes the active list.

Working The List

For each item, the screen shows the product, quantity, source location, destination location, lot, serial number, and handling unit when present.

The normal order is:

1. scan the displayed source location;
2. if the product is inside a handling unit, scan the displayed unit;
3. scan the product, SKU, or accepted barcode;
4. scan the displayed destination location;
5. Putaway WMS moves the quantity from source to destination and marks the item as Replenished.

Order matters. If another location, handling unit, product, or destination is scanned, the item is not confirmed.

If the source is inside a handling unit, the unit is scanned to verify the source. After movement, the quantity enters the destination location as stock available for picking.

Missing Product

Use Product missing only when the product is physically not present in the displayed source location.

When you mark the product as missing:

1. the replenishment item becomes Missing;
2. no quantity is moved;
3. the list continues to the next item;
4. at the end, the missing product appears in the list summary.

After marking an item as missing, check the source location. If the product is found, restart the operational process correctly. If the shortage is real, use stock check, inventory counting, or inventory adjustment so the difference is recorded correctly.

Completing The List

When no pending items remain, Putaway WMS completes the list.

After completion:

• the list becomes Completed;
• moved items remain marked as Replenished;
• missing items remain visible in the summary;
• stock moved into pickable locations can be used by the Picking flow.

The New replenishment list button resets the screen for another list. It does not modify the already completed list.

List Detail And History

In Replenishment lists, users can see lists created in the current warehouse. Each list shows status, creation date, completion date, user, and progress.

The list detail shows:

• product and SKU;
• source location;
• destination location;
• lot and serial number when present;
• handling unit when present;
• planned quantity;
• replenished quantity;
• item status;
• date and user who confirmed the item.

Item statuses are:

Status	What It Means
Pending	The item has not been worked yet.
Replenished	The quantity was moved into the destination location.
Missing	The operator indicated that the product is not in the source location.
Cancelled	The item is no longer worked in that list.

Blocked Or Refused Cases

Putaway WMS stops replenishment when:

• no warehouse is selected;
• the user does not have access to the selected warehouse;
• the user does not have replenishment permission;
• there are no products available for a list;
• the list is no longer active;
• the item is no longer pending;
• another user or process changed the list meanwhile;
• the scanned source location is not the displayed one;
• the source location no longer has enough stock;
• source stock is no longer available for replenishment;
• the scanned handling unit is not the displayed one;
• the scanned product does not match the displayed product;
• the scanned destination location is not the displayed one;
• the destination location is no longer available for picking.

In these situations, do not force the process forward. Check the physical location, product, lot, serial number, handling unit, and stock history before making a correction.

Simple Rules

1. Replenishment moves existing stock; it does not create new stock.
2. Do not use replenishment for goods that are still in receiving.
3. Scan exactly the displayed location, unit, and product.
4. Do not mark Product missing if the product is only in another location.
5. Do not treat the product as pickable until the item is confirmed as replenished.
6. After replenishment, return to Picking for orders that were waiting for pickable stock.