Replenishment Control

The task of replenishment is to supply picking areas, shops or assembly lines with goods out of the reserve storage. At the same time the capacities and stock level in all areas should be optimized.

The biggest challenge comes from the direct interconnection between the picking and replenishment processes when volatile demands lead to temporary peaks of replenishment (which exceed the maximum supply chain capacities).

Modern systems therefore require smart concepts and algorithms which can fullfil the needs of highly dynamic material flows.

  • Optimal calculation of a coverage controlled target stock level
  • Intelligent order sequencing / prioritization of replenishment orders
  • Preventive replenishment caused by foreseeing the highly demanded articles to prevent overloading during the peak period
  • Optimal assignment of bins considering picking and replenishment times
  • Reduction of picking effort by avoiding missing articles
  • Increase of service level and adherence to delivery dates by avoiding order halts (because of bottlenecks in replenishment)

Applying the current product the assignment costs of rearrangement and transport can be essentially reduced. Moreover, the use of modern concepts based on intelligent algorithms will make better use of the available capacities and increase the service level simultaneously.


The graphic shows the dynamics of picking and replenishment on a single day. Typically the peaks in the goods dispatching zone are passed time delayed to the picking and replenishment zone (red framed area). These bottlenecks can be avoided when under-load times are being used purposefully for replenishment (green framed area). Intelligent algorithms can identify the relevant articles to be demanded in the nearest future.