Continuous Replenishment keeps your pickface locations consistently stocked and ready for high-volume picking. You can now configure, replenish, and pick from multiple pickfaces for the same product, with stock replenished as soon as it hits a minimum threshold.
- Consistent Availability: Stock is replenished before you run out.
- Balanced Workload: Pick tasks are automatically shared across all active and eligible locations, preventing bottlenecks at a single rack.
- Efficiency: Multiple pickers can work the same SKU simultaneously from different locations.
The Core Change: "On Hold" Logic for BBD
For customers using Best Before Date pick rules, the system now enforces stricter validation. This ensures that a picker is never directed to a location to pick stock that doesn't meet the customer's specific shelf-life requirements.
- Validation: The system checks if the stock in the pickface meets the required BBD range for the pick task.
- The Hold Status: If the current pickface stock is too "old" (or too "new") based on your shelf life rules, the pick task will go On Hold.
- Visibility: Pick tasks that are on hold, can be viewed via the HHD.
- Automatic Release: The task stays on hold until a replenishment brings compliant stock into the pickface. As soon as the replenishment is completed, the system re-validates and releases the pick task automatically.
How It Works: Step-by-Step
1. Stock Trigger: When stock in a pickface drops below your defined Minimum Trigger, a replenishment task is generated to bring more stock forward.
2. Date Matching: The system selects replenishment stock based on your account's pick rule (e.g., Earliest Best Before Date).
3. Task Assignment: When a sales order is processed, the system checks all active pickfaces.
- If a pickface has stock that meets the BBD criteria, the task is Available.
- If no pickface has compliant stock, the task goes On Hold.
4. Completion: Once the correct stock is replenished into the location, the held pick task is released for the picker.
FAQs
Why is my pick task "On Hold" when there is physical stock in the pickface?
The task is on hold because the stock currently in the pickface does not meet the Best Before Date requirements for that specific order. The system is waiting for a replenishment of "compliant" stock to ensure the customer receives the correct shelf life.
How do I see the reason for the Hold?
Go to the Tasks page or Picking List. Add the "Status" column to your view. If you hover over the "On Hold" status, a tooltip will appear explaining that the system is waiting for replenishment stock that meets requirements.
Does the order of my pickface locations matter?
Yes. The system cycles through your pickfaces (e.g., Pickface A → B → C) to balance the workload. If you have a preferred picking sequence, use the arrow controls in the Product Setup to reorder them.
What happens if I have "Full Storage Units Only" toggled ON?
The system will ignore your "Max Trigger" and bring in a full pallet or box. If your Max Trigger is 100 but a full pallet is 120, the system will replenish 120 to avoid breaking down a storage unit.
Will the system automatically release the task once I replenish?
Yes. Every time a replenishment is completed to a continuous location, the system automatically checks for any "On Hold" tasks for that product and releases them if the new stock fits the criteria.
Quick Setup:
- Navigate to Products: Within the product, scroll down and open the Pickface panel.
- Assign location: select a location to be assigned as a pickface for the product.
- Set Replenishment Type: Select Continuous.
- Define Triggers: Min Trigger is the level that "asks" for more stock. Max Trigger is the target capacity for that location.
- Active Status: Ensure the "Location Active" toggle is Yes.