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This module has been designed to monitor your pick face bin locations and to automatically generate replenishment orders based on the min, reorder, and max levels of each pick face bin. This module has a number of important settings that allows your replenishments to generate based on one of five rules. Some of these rules replenish the bin based on actual stock levels, while others replenish the bin to a level that includes future demand. This demand can be run off released picking slips or sales order lines in SYSPRO with a ship date before a set cut-off.

The replenishment orders are automatically generated and displayed on a PC-based review screen and on the scanners on the warehouse or factory floor. A time tolerance can be set to turn any line red if the order has not been actioned within a set number of hours. The replenishment staff moves through the warehouse selecting replenishment lines on the scanner. These lines are presented to the user in date and time sequence so that the oldest replenishment orders are actioned first. A single-step or two-stage replenishment can be processed on the scanner. The single-step screen expects the user to fetch the bulk stock and scan it directly into the pick face. this is often used when the bulk location is above or close to the pick face. The two-stage process is used where the replenishment user builds up a pallet of multiple SKUs in the bulk area and then transfers the full pallet to the pick face area and offloads the products into the various pick face bins.