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Warehouse Replenishment – The Best Approach (Part 1)



Warehouse Replenishment – The Best Approach (Part 1)

If you have a warehouse that performs case or each picking, you’re likely performing some kind of warehouse replenishment. The decision to use a particular method or mix of methods is generally driven by two factors:

  1. Priorities
  2. Restrictions

In this first part, we’ll cover the primary types of warehouse replenishment methodologies. We’ll finish talking about the different methods as well as offer tips and examples as to what might work best for you in Part 2.

The primary types of warehouse replenishment methodologies are:

  • Demand
  • Triggered
  • Top-Off

When does it work best to use Demand Method of Warehouse Replenishment?

Demand tends to be the favored approach if there are significant restrictions for the number of available picking locations. It moves only the inventory that is needed to fulfill an order or group of orders. The thinking generally goes like this, “I can’t afford to dedicate a picking location to inventory unless I already have a pick requested for at least some of that inventory.” It also supports strict rotation of inventory. This is helpful to ensure that newer inventory isn’t picked and shipped with older inventory that might remain in a pick location as a result of improper rotation of inventory during replenishment. As you begin to set up your pick face, consider factors such as dynamic pick slotting, limited real estate and products that experience unexpected demand spikes.

When does it work best to use the Triggered Method of Warehouse Replenishment?

Triggered replenishment, often called routine or opportunistic, is used when inventory reaches a minimum threshold within a forward pick face or location. Triggered replenishment can help ensure that a picker always has enough inventory in the most efficient picking location. This method is best suited where the product has a predictable throughput or known seasonal demands that allow it to be slotted statically for longer periods of time. This method also requires that the right amount of real estate is available for the product. It works best when the forward pick location has enough room for full pallets of inventory to be replenished to the pick face.

When does it work best to use Top-Off Method of Warehouse Replenishment?

Top-off replenishment can be used for times when picking operations are less active to bring the stock up to acceptable levels. It works well when you have a shortage of work to complement or promote interleaving opportunities in active areas. It also works well when you’re expecting a large wave of pick work or volume and you want to be proactive and top off your pick face in advance (providing you have the proper workforce available to prepare).

Discover more in Part 2.

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Jeremy Hudson

Vice President of Client Services

Jeremy’s focus is on the products and services clients need to stay competitive. Open Sky Group’s mission is to deliver technology-enabled solutions that allow our customers to achieve more while having the flexibility to adapt to change. Jeremy lives the core values and mission by bringing the best experience possible to our clients. He is an essential member of implementation teams, working alongside clients, and encouraging them to use innovation and best practices instead of customizations for success.

Jason Yantiss

Vice President of Client Services

Jason provides leadership to a variety of teams focused on implementation and integration. With 27+ years of experience holding operational and technical management roles in transportation, billing, and warehousing across a vast array of industry verticals, Jason is adept at driving multiple complex projects, understanding customer needs at all levels of the operation and providing viable solutions. Jason’s resume of 150+ implementation projects include Warehouse, Labor, Transportation, Yard Management and multiple AR/AP Freight Pay and Customer Billing systems. 

Eric McPherson

Vice President of Client Services

Mac works to oversee implementation and integration projects. A former Marine officer and military police officer, he brings over 27 years of supply chain experience, including 11 years at Blue Yonder in both delivery and service sales. Mac is a dedicated, team-oriented professional with a background in business management, professional services, customer service, and supply chain technology. His specialties include sales support, supply chain execution systems, project management, fulfillment operations, distribution operations, and GSA contracts.

Shannon Caflisch

Senior Vice President of Sales and Marketing

Shannon is responsible for the strategy and management of all sales, business development, and marketing programs. With over 25 years of sales experience and 15 years focused in the supply chain space, Shannon focuses on building strong relationships with clients and partners and strives to deliver the right software solutions to help conquer supply chain challenges. Shannon believes in learning by listening to understand clients’ goals, struggles, and what is important to their business to build lasting, successful relationships.

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Senior Vice President of Client Services

As Senior VP of Client Services, Alan oversees all consulting services and account management at Open Sky Group. Possessing over 30 years of combined industry and consulting experience, Alan leverages his unique background in IT, logistics, quality management systems, manufacturing and distribution operations, and facility and strategic account management to provide clients with creative resolutions to complex challenges. His core philosophy and passion are to deliver tangible value for and establish long-term trusted partnerships with our clients.

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As Senior Vice President of Technology, Mike leads Open Sky Group’s Managed Services, Software Services, Infrastructure Services, and Information Technology teams bringing 35+ years of experience in Supply Chain Execution and Information Technology. Mike and his teams ensure we maintain the highest levels of customer service in a secure and reliable environment, constantly reviewing and evaluating new technologies, their appropriateness and applicability so we can safely and securely transact our own business – and help our clients accomplish the same.

Chad Kramlich


Joining Open Sky Group in 2015, Chad, served as Chief Revenue Officer for three years prior to his appointment to CEO in 2022. With over 25 years of experience delivering results for high-growth software and consulting organizations, Chad is leveraging his background in building efficient and effective implementation teams, establishing high-impact services operations, achieving revenue growth, and deepening executive-level client relations to help propel Open Sky Group into a very successful future.

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