See the pick face.Plan the refill.Keep stock moving.

Mark each zone forward-pick or bulk reserve.

Set a reorder point for each forward-pick bin.

Do it once in warehouse setup.

Setup

Zones and bins are part of warehouse setup.

Good reorder points come from your own pick rates.

Warehouse Setup

Zones

Zone A

Forward-pick

Zone C

Bulk reserve

Bin A-02-3

Reorder at 100 kg

Bin A-02-4

Reorder at 40 kg

Set by

Warehouse admin

Reorder points are set per bin.

Every forward-pick bin is compared with its reorder point.

Bins below it are listed.

Bins above it are left alone.

Counts

Cycle counts keep the on-hand figure honest.

When the scan runs follows your setup.

Replenishment Scan

Forward-pick

A-02-3

80 kg · point 100

A-02-4

55 kg · point 40

A-03-1

12 units · point 30

Below point

2 bins

Checked

All forward-pick

Below its reorder point means a refill.

A transfer is staged for each bin below its point.

Operators move the stock with the usual scan flow.

The lot stays with every move.

Moves

See put-away & transfers for the scan flow.

Which reserve lot is used follows your lot rule.

Staged Transfers

Bulk → pick

C-12-1 → A-02-3

Starch · R-4410-1

C-08-2 → A-03-1

Labels · L-2207

Status

Staged

Moved by

Operator · scanned

Lot

Kept on move

Operators carry out the move.

Recompute ABC velocity classes for items.

Use them to decide where items should live.

The same classes drive cycle-count schedules.

Counting

Class A items can be counted more often.

V5 classifies; your team decides what to re-slot.

ABC Recompute

Items

Class A

18 items · move closest

Class B

41 items

Class C

126 items

Used for

Slotting · counts

Moves

Your team decides

Fast movers near the pick path.