Replen Locations / Forced Replen - Setup warehouse to only pick orders from picking locations

Overview

In some operations, it may be preferable to only pick orders when the stock is found in specific location types (e.g. ground level or 1st level racking locations).

Where stock is found in higher bulk locations it may require the use of a fork lift or other equipment to retrieve the stock and so is not an efficient way to pick orders in these locations.

The default logic in the system will automatically pick stock from the next available location if there is not enough in picking locations - however if you looking to avoid this happening and would rather hold orders until picking locations have been replenished, then setting up replen-only locations on this guide is the solution you require.

Location Type Setup

First stage is to assign your required location types to "Replen Only".

Navigate to: Warehouse > Extras > Location Types

Then toggle on Replen Only next to your required types:

Note: if you are editing existing location types & you have stock allocated to location IDs for that type then you will not be able to change the location type to replen only.

You will need to unallocate all stock for orders that is currently held in those locations before changing the type.

Assign Locations to Replen-Only

If you have edited an existing location type - then all existing location IDs that were assigned to that type will move over to Replen Only automatically.

But if you are adding new locations - simply assign the Replen Only type to them when creating or uploading location data:

Client Setting

Each client needs to be enabled to use this feature.

Go to Clients > Overview > Defaults

Then enable the setting

Awaiting Replen Order Status

Where stock is only available in Replen-Only locations - orders will be held in Awaiting Replen status:

Stock will also show separately under manage inventory on the product as awaiting replen:

Replen Tasks

Any orders that are held in awaiting replen will perform a replen task to transfer the inventory.

Navigate to Warehouse > Replen Tasks

The system will display a list of replen tasks that need to be completed and the locations you want to move the stock to:

There is a PDF button if you want to bulk print the replen tasks off if you want to complete them manually but then come back to a PC or Tablet to complete the tasks.

Once the tasks have been completed - the orders will release in new status to allow you to pick.