Most warehouses have a "pick face" where fast movers are picked: waist height, at the head of the aisle, within easy reach. The rest of the stock sits higher up or behind in reserve locations. When the face empties, the picker either waits or walks to the reserve themselves; both break the tour.
Good practice: minimum and maximum quantity
The common method in warehouse management systems is to give the face two limits. When face stock falls below the minimum, replenishment opens; the quantity brought tops the face up to the maximum. When choosing the reserve lot, the one with the nearest expiry goes first (FEFO, first expired first out). The face never runs dry, and stock nearing expiry is not forgotten at the back.
How replenishment works in iyibir WMS
- On the Pick Faces screen of the web panel, the manager makes a shelf an item's pick face and enters the minimum and maximum; the system also calculates suggested limits.
- A shelf in the quarantine, goods-receipt or dispatch zone cannot be a pick face.
- The face's estimated stock starts from the warehouse snapshot and is updated with what tasks took and placed since.
- When the estimate drops below the minimum, a replenishment suggestion opens; the quantity tops up to the maximum, rounded up to the replenishment multiple. An empty face counts as urgent.
- When the suggestion is applied, source shelves are chosen from Logo's live stock: nearest-expiry lot first, then the fullest shelf. The replenishment task joins the operator queue.
The replenishment task on the floor
The operator scans the source shelf, the item and the quantity taken, then scans the target face. The replenishment target is fixed; scanning another shelf raises a mis-scan alert. When the task ends, the shelf transfer opens as a draft for Logo and is written on approval.
Open replenishment suggestions appear as their own row in the manager's morning briefing, and the wave preview lists faces needing replenishment before release. Replenishment goes ahead of picking, not behind it.
Where to start
Not every shelf needs to be a pick face. Starting with the fastest-moving items, opening the limits with the system's suggested values and adjusting them after a few weeks is usually the easiest path.
Step by step: Defining a pick face and starting replenishment
- In the web panel, add a new face under Warehouse › Pick Faces: choose the shelf and the item.
- Check the suggested limits, enter the minimum and maximum, and set the replenishment multiple.
- When face stock drops below the minimum, a suggestion opens on the Recommendations › Replenishment tab.
- Turn it into a replenishment task with Apply; source shelves are chosen in FEFO order.
- The operator runs the task on mobile and approves writing the shelf transfer to Logo when done.
Frequently asked questions
- Is a replenishment suggestion applied automatically?
- No. A suggestion becomes a task on the manager's approval; recommendations do not write to Logo.
- How is the source lot chosen?
- From Logo's live stock at the moment of applying: nearest-expiry lot first, then the fullest shelf.
- Is pick-face stock kept separately in Logo?
- No. The face and its minimum and maximum are WMS's own records; Logo owns the stock record, and WMS tracks face stock as an estimate.