Getting Warehouse Replenishment Right

Warehouse managers have a lot of factors to consider, and while picking strategies tend to get a lot of focus, replenishment tactics deserve equal weight. Here is a look at four practices that can help managers master warehouse replenishment.


The layout of many warehouses makes it hard to leave all items in a place where every picker can access them. In this case, using smaller locations close to the ground level with a wide range of products is a good approach, leaving overstock up high or in a bulk area of the warehouse. Once these small locations are picked down to a lower threshold, they can then be restocked from the overstock areas.


Make the most of the information on orders, inventory and incoming products provided by warehouse management software to make sure that the top-selling items get put away first, while those that are not experiencing much demand are put away later. This avoids a situation where the picking team is stuck waiting for a single item in order to fulfill a bigger order. Some warehouses leave high-priority items in a special zone near the receiving dock to get them in the hands of the picking team faster.

WMS Triggers

By taking advantage of warehouse management systems’ ability to set re-order thresholds for individual items, refilling a location can happen automatically once a picker has brought the number of available items below the threshold. This helps avoid customers finding items out of stock because of an unexpectedly high volume of sales and keeps inventory more stable.

FIFO Enforcement

FIFO standards can be implemented with the help of warehouse management systems by having the system direct pickers to the most easy-to-access bins first so that the oldest products can be pulled before a particular bin gets restocked from the overflow section.

This blog post was based off of an article from Archon Interactive. View the original here.