Overview
In some operations, it may be preferable to only pick orders when the stock is found in specific location types (e.g. ground level or 1st level racking locations).
Where stock is found in higher bulk locations it may require the use of a forklift or other equipment to retrieve the stock and so is not an efficient way to pick orders in these locations.
The default logic in the system will automatically pick stock from the next available location if there is not enough in picking locations - however if you looking to avoid this happening and would rather hold orders until picking locations have been replenished, then setting up replen-only locations on this guide is the solution you require.
Setting up Replen within your Warehouse
Getting your warehouse ready to start using replen is split into two parts, part one is getting the Warehouse and Location set up then part two is getting the Product(s) set up. Scroll down for the step-by-step walkthrough.
Setting up Replen - Video Walkthrough
To set up replen points against a product and carry out replenishment within your warehouse, please watch the video below:
1. Warehouse and Location set up
The first stage is to set up the Warehouse and Location that will be used for Replen:
Click Warehouse then Extras.
Next, click Location Types then Add Location Type.
Existing Location Types can be changed to Replen Only but the Location(s) assigned to it need to be empty of stock first.
Turn Replen Only to ON.
Add a Name and provide a Priority.
Finally, click Save.
Once you have added the Location Type, click Warehouse then Manage Warehouses.
Find the Warehouse you will be using for Replen then click Locations.
Click Add New Location.
Assign the Zone, Aisle, Bay and Shelf.
Select the Location Type as the Replen Only type created earlier.
Provide a Name then click Create.
Click Warehouse then Manage Warehouses.
Find the Warehouse you will be using for Replen then click Edit.
Turn Include Allocated Stock In Replen Point to ON.
This is used to prevent replenishing more units than you can fit in the location by including the allocated stock in the Product's Replen Point.
Next, click the Replenishment Sources tab.
Tick the Warehouse(s) to replenish from if the selected warehouse doesn't have stock.
Any warehouse you tick, Proactive Replen will show stock from that warehouse and its locations as sources to replenish from.
If stock in the first warehouse dips below the replen point, you can use stock in another warehouse to replenish it if you've got it ticked as a source.
Click Update.
2. (3PL Only) Client Set up
Each client needs to be enabled to use the Replen feature:
Click Clients then Overview.
Find the Client you need to update.
Click Actions then Edit.
Next, click the Defaults tab.
Turn Use AWAITINGREPLEN Order Status For Replen Only Locations to ON.
Finally, click Update.
3. Default Pick Locations
You need to specify the default pick location ID for each item you want to run replenishment actions for. This location will be the one that shows up in the Replen Report.
Please see the relevant guides here if you are not sure how to do this:
4. Product Setup
To set replen reporting up, you must first specify replenishment points for each product. There are three ways to do this:
4.1 Add Product Replen Points - Manually
To add a Replen Point on a Product-by-Product basis, please do the following:
Click Products then Overview.
Search for the required product.
On the right of the product row, click Actions, Edit.
On the Defaults tab, click Replen Points.
LocationType: This needs to be the same Location Type as the Default Pick Location.
Size: This is the maximum number of units that can fit in the location.
Replen Point: When the stock is lower than the entered value, a replenishment will be generated.
Finally, click Update.
Example: You may have a product where a maximum of 50 units can fit in the picking location, but you want the system to warn you when the inventory level reaches 5 units.
4.2 Add Product Replen Points - In Bulk
To add Replen Points to multiple products in bulk, please do the following:
Click Products then Extras.
Next, click Upload Additional Info.
Select the Template as ProductReplenPoints to download.
Populate the CSV with the following information -
SKU: The Product the replen point is for.
LocationType: This needs to be the same Location Type as the Default Pick Location.
Size: This is the maximum number of units that can fit in the location.
Replen Point: When the stock is lower than the entered value, a replenishment will be generated.
Then, save the spreadsheet.
Back on Mintsoft, (3PL Only) Select the Client.
Select the Type as ProductReplenPoints to upload.
Click Choose File and browse for the CSV.
Finally, click Upload.
4.3 Default replen point against Location Type
This will add the same Replen Point to all Products stocked in the selected Location Type. To set this up, please do the following:
Click Products then Extras.
Next, click Default Product Replen Points.
(3PL Only) Select the Client.
Choose the LocationType.
This needs to be the same Location Type as the Default Pick Location.
Enter the Size: This is the maximum number of units that can fit in the location.
Enter the ReplenPoint: When the stock is lower than the entered value, a replenishment will be generated.
In the bottom right, click Add.