# Replenish pick faces
URL: https://support.starshipit.com/articles/14700000000016-replenish-pick-faces
Canonical: https://support.starshipit.com/articles/14700000000016-replenish-pick-faces
Markdown: https://support.starshipit.com/articles/14700000000016-replenish-pick-faces.md
Updated: 2026-09-17

> For the complete documentation index, see [llms.txt](https://support.starshipit.com/llms.txt).

> Keep pick faces stocked using automated capacity-based replenishment and demand-driven job generation in Starshipit WMS.

**Replenishment** moves stock from bulk storage into pick faces so pickers always have accessible stock to fill orders. Without replenishment, pick faces run empty and picking stops — either because pickers can't find stock, or because allocation fails when no stock exists in pick-face locations.

Starshipit WMS supports four replenishment approaches:

* **Automated replenishment** — triggered by location capacity rules when a pick face drops to or below its minimum level.
* **Automatic demand replenishment** — creates work after pending-order demand is received.
* **Reviewed demand replenishment** — previews suggestions from pending orders before you create work.
* **Manual replenishment** — created ad hoc when you want to top up specific locations ahead of time.

## Setting up capacity rules

Capacity rules tell WMS when to automatically create a replenishment job for a pick face.

### Configuring min/max on a location

1. Open the location in the **Locations** section.
2. Set a **Minimum capacity** — the quantity at or below which a replenishment job should be triggered.
3. Optionally set a **Maximum capacity** — the target quantity to replenish up to. If not set, WMS uses the minimum as the target.
4. Save the location.

WMS only looks for replenishment stock in **bulk storage** locations. If no bulk stock exists for the product, no job is created.

### When replenishment is triggered automatically

Replenishment checks run as an event-driven process — not on a fixed schedule. Checks are triggered:

* After a stock movement that reduces pick-face quantity (such as a pick or stocktake adjustment)
* On some order-allocation failure paths where insufficient stock at pick faces is detected
* After a location is updated with changed capacity rules

When the check determines a pick face is at or below its minimum, WMS:

1. Looks for available stock of that product in bulk storage locations.
2. Creates a replenishment job targeting the minimum (or maximum, if set).
3. The job appears on the **Replenishment dashboard** for a picker to execute.

## Choose preferred bulk sources

Set a bulk location's **Priority** to control where replenishment takes stock from first.

1. Open the bulk storage location in **Locations**.
2. Set **Priority** from `0` (lowest) to `10` (highest).
3. Save the location.
4. Create replenishment work and check its source allocations before picking.

Manual, automatic and demand-generated replenishment use higher-priority bulk locations first. Within the same priority, WMS follows the product's allocation rule, such as FIFO or FEFO. If preferred stock is insufficient, WMS considers the next priority group.

All locations default to `0`. A higher priority can select newer or later-expiring stock ahead of a lower-priority source, so use equal priorities when stock rotation should decide between locations. Source priority does not change existing allocations, pick sequence, destination selection or job urgency.

## Demand-driven replenishment

Demand-driven replenishment can run automatically after order imports or as a reviewed action from the Replenishment dashboard. Both modes aggregate pending-order demand, deduct pick-face stock and open replenishment work, and cap quantities by destination capacity and available bulk stock.

### Create work automatically from order demand

Use this mode when pick faces should be prepared as pending orders arrive instead of waiting for picking or an operator review.

1. Go to **System > Settings > Replenishment**.
2. Set **Create replenishment work** to **When order demand is received**.
3. Set **Replenish destination to** to **Configured minimum** or **Configured maximum**.

WMS immediately checks existing pending demand when you save the setting. It then checks aggregate pending demand after relevant order imports and creates replenishment work for positive shortfalls. The default remains **When picking requires stock**.

If a demand check fails, the imported order remains in WMS. Review the replenishment dashboard and process logs, then correct the stock, location or capacity issue. A later order update triggers another check.

### Review demand before creating work

Use **Generate from Demand** when a supervisor should review or adjust every suggested quantity before jobs are created.

1. Go to the **Replenishment dashboard** and select **Generate from Demand**.
2. Under **Target after demand**, choose **Location minimum** or **Location maximum**. If a location has no maximum, the maximum option uses its minimum.
3. Review the demand, current pick-face stock and open work, projected stock after demand, location capacity, and available bulk stock for each line.
4. Adjust **Reviewed qty** where needed. Enter `0` to leave a suggestion out of the jobs you create.
5. Select **Create reviewed replenishments**.

WMS can cap a suggestion when the pick face does not have enough capacity or there is not enough available bulk stock. It checks current stock, capacity, product compatibility, and source allocation again when you create the jobs, because warehouse activity may have changed since the preview loaded.

Running demand generation again does not duplicate or reprioritise open work that already covers the demand.

Use this before a high-volume picking run to ensure pick faces are stocked before pickers start. This is particularly useful for:

* End-of-day waves
* Flash sales or promotions
* Any time you have more demand than current pick-face stock can satisfy

## Working a replenishment job

Replenishment jobs are executed in two steps — pick from bulk, then place into the pick face:

**On desktop:**

1. Go to the **Replenishment dashboard** and select a pending job.
2. Review the product, source (bulk) location, destination (pick face), and quantity.
3. Confirm the movement.

**On mobile:**

1. Open the replenishment job in the WMS app.
2. **Phase 1 — Pick**: Navigate to the bulk storage location, confirm the product and quantity.
3. **Phase 2 — Move**: Confirm the destination pick face and submit the putaway.

Both phases are guided step-by-step with barcode scanning support.

The job detail keeps the source, destination, equipment, quantity and batch information visible while the replenishment is in progress.

![A replenishment job moving batch-tracked stock from bulk storage to a pick face](/uploads/articles/starshipit-wms/web/inventory-management/replenishment-job.png)

## Adjust the quantity while picking on desktop

For non-serial stock, use the scan counter or quantity buttons to pick more than the suggested source quantity. For example, you can scan a carton of 100 against a suggestion of 96. Select **Continue** to submit the actual quantity.

WMS checks that the extra units are available from the same source, batch and expiry. Scanning alone does not reserve the extra stock. Serial-tracked stock keeps its fixed-unit limit.

The counter warns when you exceed the suggestion because the pick face may be full. Check the destination before continuing and review any capacity warning returned after the movement. If the pick fails, adjust the retained counter and retry after resolving the reported issue. After success, check the refreshed job quantity before placing the stock.

To finish a line below its target, the applicable workflow policy must allow **Partial/Manual Completion** and the line must have some stock already picked. See the [WMS settings reference](/articles/14700000000031-wms-settings-reference) to check the policy. Then:

1. Commit any pending scanned quantity with **Continue**.
2. Select **Finish at [picked quantity] of [target quantity]**.
3. Review the gathered quantity and the unpicked remainder, then select **Confirm finish short**.
4. Check the updated line quantity and complete placement into the destination.

Finishing short releases that line's unused reservations. It does not pick pending scans or change other lines. If WMS reports a conflict or an uncertain result, refresh the job before attempting another action.

## Manual replenishment planner

The **Manual Replenishment Planner** lets you create replenishment jobs on demand — useful for proactively topping up pick faces before a busy period without waiting for the automated trigger.

1. Open the replenishment or inventory view and select **Manual Replenishment Planner**.
2. Add one or more replenishment lines:
   * Product (searchable dropdown)
   * Destination location (pick faces only)
   * Quantity to replenish
   * Priority
3. Submit to create the jobs.

Rules that apply:
* SKU restrictions are enforced on destination locations — if a pick face is locked to specific SKUs, only those can be replenished to it.
* Quantities are validated and rounded to integers before submission.

## Assigning and prioritising replenishment jobs

You can assign replenishment jobs to specific team members and set their priority. Higher-priority jobs appear at the top of the queue on the Replenishment dashboard and in the mobile app.

Use **Allocate Now** from an eligible job's dashboard row menu to reserve source stock. This action is hidden when the job already has usable allocations; it does not assign a staff member.

## Best practices

* **Set capacity rules on all active pick faces.** Even simple min levels (for example, 5 units) ensure you are notified before a face empties.
* **Use max capacity for high-velocity SKUs.** Without a max, replenishment consistently targets the minimum. For fast movers, a higher max reduces how often replenishment is triggered.
* **Use Generate from Demand before high-volume runs.** This catches shortfalls proactively, before pickers start walking and find empty picks.
* **Keep bulk stock topped up.** Replenishment can only create jobs when bulk stock exists. Monitor bulk locations for products with capacity rules to ensure there is always reserve stock available.