Search
Close this search box.

Warehouse Replenishment – The Best Approach (Part 2)

Categories

Warehouse Replenishment – The Best Approach (Part 2)

We covered most of the different types of Replenishment in Part 1. Here we’ll finish talking about Top-off Replenishment and give examples and tips for using the methods that might work best for your operations.

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

Top-off replenishment can be run on a set schedule or be batch released by area, product and line in order to add inventory to forward pick locations or areas before they reach their minimum threshold. These configurations typically follow or share a similar min and max threshold (often called a budget) to triggered or routine replenishment. Releasing a batch of top-off replenishment to a pick line will help prepare that line for the next wave of picks. Further, releasing a batch of top-off replenishments introduces new work to the floor to be performed. In turn, that creates an opportunity for greater task management and interleaving and allows your crew to work more efficiently by performing existing work along with the new replenishment tasks. This also decreases the amount of time that equipment is deadheading. You can also use this method as a means of creating work to consolidate partial pallets in reserve locations to a forward pick line. This creates more available real estate within the distribution center for putaway.

What’s an Example of an Operations Using all Three Styles of Replenishment?

Company Type: A multi-temperature controlled DC servicing a retail chain of grocery stores with several commodities and value-added services
Employees: Multiple shift operation

Incorporating a blend of static pick face assignment areas, dynamic floating pick face areas, tempered forward pick lines and ad-hoc, demand replenished pick areas might work best for this type of operation.

  • Routine
    • Set up static pick faces with well thought out min and max budgets for the staple items that are well-known and seldom see a change in economic demand. Routine replenishment tasks would sustain the pick locations and ensure the picking team always has enough product to fulfilled the forecasted orders.
    • Seasonal items such as novelty ice-cream may require a shorter-term duration pick face with the same parameters.
  • Demand
    • Goods with more dynamic spikes, like fruitcake, may be better accommodated with a demand replenishment configuration and a dynamic pick face.
    • Goods that have peak or routine tempering services where an item needs to be moved from a freezer reserve area to a cooler/temper location for a period of time prior to being picked and shipped.
  • Top-off
    • Could be released at opportune times between picking shifts or to bring additional work to the floor for the Routine replenishment areas. This would create more efficient workflows by introducing more interleaving potential.

What’s the right method for my operations?

Typically operations use all three styles but at different times in operations. Your best method may be a combination of one or two of these styles (or all three).

  • Take a close look at goals, real estate, throughput and pick density. These will help you make the best decision. You’ll want to tweak these methodologies over time, benchmark, fine tune, etc. Always look for opportunities to better slot pick lines.
  • Experiment with a combination of styles to determine what gets the best results. Never consider the work complete as everything changes from operations and team members to equipment, etc. Keep looking for those opportunities to improve.

Related Articles

Jason Milbrandt

Ask the Expert – Jason Milbrandt

Jason Milbrandt, Senior Director at Open Sky Group, focuses on client engagement, team support, and operational efficiency. With 20 years in supply chain, he emphasizes the importance of clear communication and employee retention.

Read More

It’s time to elevate.

Discover how Open Sky Group
can help you reach new heights
of supply chain efficiency.

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.

Alan Prillaman

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.

Mike Noble

Senior Vice President of Technology

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

CEO

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.

Skip to content