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wiki/concepts/replenishment.md
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@@ -26,13 +26,13 @@ last_compiled: "2026-04-17"
## Overview
Replenishment is the process of moving stock from bulk storage locations to **picking dedicated locations (PDL)** to ensure that operators always have stock available to fulfill shipping orders without going to the main rack. It is a supporting process that feeds the picking operation — without replenishment, picking dedicated locations would run dry and order preparation would stall.
Replenishment is the process of moving stock from bulk storage locations to **picking dedicated locations (PDL)** to ensure that operators always have stock available to fulfill shipping orders without going to the main rack. It is a supporting process that feeds the picking operation - without replenishment, picking dedicated locations would run dry and order preparation would stall.
A **picking dedicated location (PDL)** is a location permanently or dynamically assigned to one item (sometimes one item per partition). PDLs are configured with a minimum (replenishment threshold) and maximum (capacity). When stock in the PDL drops below the minimum, the replenishment system detects the shortage and generates a replenishment task to refill from a source location.
Replenishment in EasyWMS operates at two levels:
1. **PDL replenishment** — refilling picking dedicated locations from bulk storage
2. **Sub-warehouse replenishment** — moving stock from one sub-warehouse to another to balance inventory
1. **PDL replenishment** - refilling picking dedicated locations from bulk storage
2. **Sub-warehouse replenishment** - moving stock from one sub-warehouse to another to balance inventory
## Picking Dedicated Locations (PDL)
@@ -45,15 +45,15 @@ A PDL is a location with an item assignment that designates it as the primary pi
| **Location** | Must have: allow item assignment, allow picking, allow replenish, allow putaway |
| **Item** | One item recommended per PDL (multiple items allowed but not typical) |
| **Owner** | Owner of the item |
| **Replenishment mode** | Container (move whole container) or Stock (move loose stock) — cannot mix both |
| **Replenishment mode** | Container (move whole container) or Stock (move loose stock) - cannot mix both |
| **Conversion** | Unit of measure in which replenishment level and capacity are expressed |
| **Logistic attributes** | Specific batch, color, quality, etc. — PDL will be replenished with matching stock only |
| **Logistic attributes** | Specific batch, color, quality, etc. - PDL will be replenished with matching stock only |
| **Maximum lots** | Limit how many different lots can be present in the PDL simultaneously |
| **Expired stock flag** | PDL can be configured to receive only expired stock |
| **Days of life** | Replenish with stock whose shelf life ≥ (detection date + days of life) |
| **Stock status** | Restrict to stock in a specific status |
**For stock-mode PDLs — threshold types:**
**For stock-mode PDLs - threshold types:**
| Threshold type | Description | Notes |
|---------------|-------------|-------|
@@ -68,15 +68,15 @@ A PDL is a location with an item assignment that designates it as the primary pi
- **Maximum containers**: capacity ceiling
- **Replenishment level %** (if max = 1): percentage of full-container quantity below which replenishment is triggered; allows exceeding the full quantity to absorb the incoming container's excess stock
### PDL — EasyS / SmartUI Configuration
### PDL - EasyS / SmartUI Configuration
**EasyS — Location setup**, check :
**EasyS - Location setup**, check :
- `Allow product location`
- `Allow replenish at source`
- `Allow picking`
**SmartUI — `Entrepôt → Emplacements consacrés au picking`** :
**SmartUI - `Entrepôt → Emplacements consacrés au picking`** :
- Enter the **replenishment level** (minimum threshold)
- Enter the **maximum capacity**
@@ -84,13 +84,13 @@ A PDL is a location with an item assignment that designates it as the primary pi
- Enter a **Texte personnalisé** (custom label)
- Print the PDL barcodes
> 💡 Labels display as `Code emplacement [Label]` (e.g. `B-1-4 [Clavier M]`). With many PDLs this is hard to scan through — Mecalux France standard is to **prefix labels with an ordered code** (e.g. `B-1-4 [01 Clavier M]`, `B-1-4 [02 Clavier L]`...) so the operator can sort them visually.
> 💡 Labels display as `Code emplacement [Label]` (e.g. `B-1-4 [Clavier M]`). With many PDLs this is hard to scan through - Mecalux France standard is to **prefix labels with an ordered code** (e.g. `B-1-4 [01 Clavier M]`, `B-1-4 [02 Clavier L]`...) so the operator can sort them visually.
> ⚠️ **Known limitations** documented by Mecalux France (2022 tests) :
> - The **destination is not displayed** when the WMS generates putaway tasks towards a PDL.
> - **Maximum capacity is not strictly enforced** at putaway — cases of 26 units put away in a capacity-15 PDL have been observed. Rely on replenishment threshold + periodic count rather than `max capacity` as a hard limit.
> - **Maximum capacity is not strictly enforced** at putaway - cases of 26 units put away in a capacity-15 PDL have been observed. Rely on replenishment threshold + periodic count rather than `max capacity` as a hard limit.
>
> Positive : **minimum-threshold replenishment works correctly** — a task is generated to top the PDL back up to its maximum once the minimum is crossed.
> Positive : **minimum-threshold replenishment works correctly** - a task is generated to top the PDL back up to its maximum once the minimum is crossed.
### PDL Creation Methods
@@ -99,16 +99,16 @@ A PDL is a location with an item assignment that designates it as the primary pi
| Web interface | Warehouse manager manually creates PDL assignments |
| RFT during putaway | Operator assigns item to location while unloading (if `UNLOAD_CREATE_PRODUCT_LOCATION` enabled) |
| RFT during counting | Item assigned during stock count (if `UNLOAD_CREATE_PRODUCT_LOCATION` and `REPLENISH_LEVEL_PERCENT_PRODUCT_LOCATION` enabled) |
| RFT — "Assign item to loc." | Dedicated menu option in Utilities |
| RFT - "Assign item to loc." | Dedicated menu option in Utilities |
| Automatically (dynamic replenishment) | System creates PDL on-the-fly for items in active shipping orders |
### PDL Partitions
A single physical location can be subdivided into **partitions** — labeled divisions each assigned to a different item. This enables high-density picking areas (drawers, shelves divided by bins).
A single physical location can be subdivided into **partitions** - labeled divisions each assigned to a different item. This enables high-density picking areas (drawers, shelves divided by bins).
Key partition rules:
- Each partition is identified by a unique QR label (code unique within the location)
- A partition is NOT a separate location — stock belongs to the location; the partition identifies which item occupies which physical space
- A partition is NOT a separate location - stock belongs to the location; the partition identifies which item occupies which physical space
- One partition can be shared across multiple items; one item can use multiple partitions
- A partition can be marked **full** to prevent further putaway to that partition
- **Maximum partitions per item**: configurable limit to prevent one item from monopolizing a location's partitions
@@ -133,7 +133,7 @@ Mecalux France uses three shortcut names that map to the strategy types below:
| FR label | Type below | Trigger | Typical usage |
|---|---|---|---|
| **"Routine"** | Stockout (automatic) | `TryToReplenishProductLocations` job every 1–2 min | Default — refill PDL when stock drops under the minimum |
| **"Routine"** | Stockout (automatic) | `TryToReplenishProductLocations` job every 1–2 min | Default - refill PDL when stock drops under the minimum |
| **"Conclure"** | Particular demand (top-off) | RFT menu **Réapprovisionnement** or SmartUI "Réapprovisionner maintenant" on the PDL view | Operator-triggered, high-priority replenishment |
| **"Exiger"** | Shipping demand (dynamic) | Order released with dynamic replenishment, or static flag `<EnableReplenishment>` on ROR | Create PDLs on the fly for items in released orders; also tops up when stock ≥ min but < order need |
@@ -142,14 +142,14 @@ Mecalux France uses three shortcut names that map to the strategy types below:
- Reserve (source) locations: `Allow replenish at source`
**SmartUI configuration checklist (routine, conclure, exiger):**
1. `Entrepôt → Gestion des emplacements picking` — create PDL assignments, set **min threshold** (per container: tick "Réapprovisionnement de conteneur", or in base UoM) and **max capacity**
1. `Entrepôt → Gestion des emplacements picking` - create PDL assignments, set **min threshold** (per container: tick "Réapprovisionnement de conteneur", or in base UoM) and **max capacity**
2. Activate automatic replenishment on the PDL (for routine)
3. `Configuration → Stratégie de réapprovisionnement` — create the strategy; pick filters (item, owner, item type, sub-warehouse, destination zone) and a **Mode efficacité** (see table below)
3. `Configuration → Stratégie de réapprovisionnement` - create the strategy; pick filters (item, owner, item type, sub-warehouse, destination zone) and a **Mode efficacité** (see table below)
4. **Activate** the strategy (to edit it later, deactivate first)
5. `Configuration → Processus` — ensure `TryToReplenishProductLocations` is enabled and runs on a 1–2 min cycle
5. `Configuration → Processus` - ensure `TryToReplenishProductLocations` is enabled and runs on a 1–2 min cycle
6. Confirm source stock is eligible (no blocking status, no location lock, not already assigned to shipping)
### Efficiency mode — SmartUI values
### Efficiency mode - SmartUI values
| FR field | Behaviour |
|---|---|
@@ -228,7 +228,7 @@ Strategies are sequenced to determine which sub-warehouses are replenished first
### 4b. Priority Location Replenishment
A fifth strategy type refills **priority locations** — locations associated with a PDL from which the PDL is replenished. This allows a two-tier system: primary storage → priority location → PDL.
A fifth strategy type refills **priority locations** - locations associated with a PDL from which the PDL is replenished. This allows a two-tier system: primary storage → priority location → PDL.
## Efficiency Modes
@@ -280,7 +280,7 @@ Dynamic replenishment runs periodically (or on manual trigger) and follows this
## Dynamic Picking Emptying Tasks (Vidage)
Dynamic PDLs created by the shipping demand strategy are temporary — they exist only for the duration of the order they were created for. Once the order is shipped, the dynamic PDL may still contain leftover stock that should be returned to bulk storage.
Dynamic PDLs created by the shipping demand strategy are temporary - they exist only for the duration of the order they were created for. Once the order is shipped, the dynamic PDL may still contain leftover stock that should be returned to bulk storage.
**Emptying tasks (vidage)** are generated automatically on a schedule to clear unused dynamic picking locations:
- The system identifies dynamic PDLs whose associated shipping orders are complete (shipped or cancelled)
@@ -326,21 +326,21 @@ When a single equipment cannot traverse from the reserve sub-warehouse to the pi
### Typical setup
- **Sub-warehouse A** (`WHST_ANCIEN_BAT`) — PDLs to replenish
- **Sub-warehouse B** (`WHST_TOUR`) — high reserves
- **Sub-warehouse A** (`WHST_ANCIEN_BAT`) - PDLs to replenish
- **Sub-warehouse B** (`WHST_TOUR`) - high reserves
- Equipment `CACES06` (only one certified for height) is **forbidden** in sub-warehouse A
### Key configuration points
| Element | Requirement |
|---|---|
| Automation element | Type **"Transport"** — mandatory even in 100% manual warehouses |
| Transport sub-location | Type **"Buffer"** (⚠️ defaults to "Automatic" when created — change manually); sub-warehouse accessible from both equipment types |
| Automation element | Type **"Transport"** - mandatory even in 100% manual warehouses |
| Transport sub-location | Type **"Buffer"** (⚠️ defaults to "Automatic" when created - change manually); sub-warehouse accessible from both equipment types |
| Equipment types | `PICKING` (access work zones of picking + both sub-warehouses) and `RESERVE` (access reserve work zone + sub-WH B only) |
| Equipment groups | Two groups, one per equipment type |
| Routes | Transport → sub-WH A ; each group → Transport ; `EqGroup PICKING` → both sub-warehouses ; `EqGroup RESERVE` → sub-WH B only |
> ⚠️ Routes are created by default with the **"Galileo"** transport — switch them to **"RF"** manually.
> ⚠️ Routes are created by default with the **"Galileo"** transport - switch them to **"RF"** manually.
### Flow
@@ -348,7 +348,7 @@ When a single equipment cannot traverse from the reserve sub-warehouse to the pi
2. The reserve equipment (e.g. `CACES06`) picks up the support and drops it on the **intermediate Buffer location**
3. The picking equipment (e.g. `PIK01`) picks up the task from **Tâches → Tâches de réapprovisionnement** and drops the stock on the destination PDL
> Troubleshooting — "support n'existe pas" when scanning the buffer location: verify that the transit sub-location is of type **"Buffer"** (not "Automatic").
> Troubleshooting - "support n'existe pas" when scanning the buffer location: verify that the transit sub-location is of type **"Buffer"** (not "Automatic").
Upstream MSSCC documentation: `replenishments/intermediate_stations.md` and `EasyS/configurations/IntermediateET/index.md`.
@@ -380,23 +380,23 @@ In automatic warehouses, the picking conveyor (PK) generates demand that drives
| Interface | Path |
|---|---|
| Web — replenishment strategies | "Configuration" → "Replenishment strategies" |
| Web — sub-WH replenishment strategies | "Configuration" → "Replenishment strategies between sub-warehouses" |
| Web — picking dedicated locations | "Warehouse" → "Picking dedicated locations" |
| Web — enable/disable automatic replenishment | "Warehouse" → "Picking dedicated locations" → "Enable replenishments" |
| Web — delete when empty | "Warehouse" → "Picking dedicated locations" → "Delete when empty" |
| Web — label printing | "Warehouse" → "Picking dedicated locations" → label action |
| Web — shipping demand replenishment | "Shipping" → "Shipping orders" → "Enable replenishment" |
| RFT — particular demand replenishment | Menu "Replenishment" → specific location/aisle |
| RFT — shipping order demand | Menu "Replenishment" → "For shipping orders" |
| RFT — assign item to location | Menu "Utilities" → "Assign item to loc." |
| Web — automatic job | "Control" → "Jobs" → TryToReplenishProductLocations |
| Web - replenishment strategies | "Configuration" → "Replenishment strategies" |
| Web - sub-WH replenishment strategies | "Configuration" → "Replenishment strategies between sub-warehouses" |
| Web - picking dedicated locations | "Warehouse" → "Picking dedicated locations" |
| Web - enable/disable automatic replenishment | "Warehouse" → "Picking dedicated locations" → "Enable replenishments" |
| Web - delete when empty | "Warehouse" → "Picking dedicated locations" → "Delete when empty" |
| Web - label printing | "Warehouse" → "Picking dedicated locations" → label action |
| Web - shipping demand replenishment | "Shipping" → "Shipping orders" → "Enable replenishment" |
| RFT - particular demand replenishment | Menu "Replenishment" → specific location/aisle |
| RFT - shipping order demand | Menu "Replenishment" → "For shipping orders" |
| RFT - assign item to location | Menu "Utilities" → "Assign item to loc." |
| Web - automatic job | "Control" → "Jobs" → TryToReplenishProductLocations |
## Related
- [Picking](picking.md) — replenishment feeds PDLs that picking tasks consume; PDL stock assignment depends on replenishment being current
- [Putaway](putaway.md) — putaway engine checks PDLs first and can auto-create PDL assignments during container placement
- [Stock](stock.md) — stock status and logistic attributes are key criteria for replenishment eligibility
- [Container (LPN)](container.md) — container-mode PDLs replenish by moving whole containers; source containers must allow replenishment
- [Task](task.md) — replenishment generates Container replenishment or Stock replenishment tasks; also Picking tasks for inter-sub-warehouse replenishment
- [Location](location.md) — PDLs are locations with item assignment; "Allow replenishment source/target" logics control eligibility
- [Picking](picking.md) - replenishment feeds PDLs that picking tasks consume; PDL stock assignment depends on replenishment being current
- [Putaway](putaway.md) - putaway engine checks PDLs first and can auto-create PDL assignments during container placement
- [Stock](stock.md) - stock status and logistic attributes are key criteria for replenishment eligibility
- [Container (LPN)](container.md) - container-mode PDLs replenish by moving whole containers; source containers must allow replenishment
- [Task](task.md) - replenishment generates Container replenishment or Stock replenishment tasks; also Picking tasks for inter-sub-warehouse replenishment
- [Location](location.md) - PDLs are locations with item assignment; "Allow replenishment source/target" logics control eligibility