The DATASCOPE WMS software includes a full and comprehensive replenishment system that controls the movement of stock from one warehouse to another as well as from bulk locations to pick face locations.
The replenishment module allows for various calculation selections or custom calculations. This custom calculation can include a huge range of logic to ensure that the replenishment requests are optimal for the business requirement.
The replenishment calculation is set to run at standard intervals. The run uses pick face min and max levels and a sales order or job demand on the warehouse. Then based on the rules, it will calculate the requirements offset against any existing replenishment currently in process. The net balance is loaded as a new requirement for action.
An advanced replenishment releasing screen allows a warehouse controller to release replenishments in logical batches. As an example, all replenishments can be grouped for zone, area or aisle and then released as a packing slip which is allocated to a replenisher for action.
This is normally implemented on a typical pick face. As the stock is picked for orders the available stock in the pick face bins drops to the point where replenishment is automatically created on the scanner to move stock from a bulk location to the pick face bin. This is often used to trigger replenishment dropdowns from bulk locations above the pick face bins.
In some warehouses, the stock is held in a bulk location at the far end of the warehouse or in another warehouse close by. A four-hourly replenishment is triggered to move full pallets from this bulk around to the breakbulk area close to the pick face, and the above simple replenishment is then used to trigger movements down into the pick face.
TWO-STAGE REPLENISHMENT WITH FETCH AND PUT AWAY.
In some warehouses, the fetch from the bulk area or VNA (Very Narrow Aisle) area requires a replenishment where many cartons of the different products are picked in a zone and placed on a pallet. This pallet then flows to the pick face area, where it is unloaded into the pick face. In some cases, a number of the pallet picked in the bulk area is moved to a staging area where they are repacked in the pick face zone and then moved into the pick face for putting away.