Replenishment Process

This guide walks you through the complete replenishment process from selecting a request to completing the task. Follow these steps to move products from storage to picking locations.

Quick Start

After selecting a replenishment request, scan or enter the bin location, enter the quantity, and tap Send. The app guides you through each step.

Overview of the Process

The replenishment process follows these main steps:

1. Search and select - Find and choose a replenishment request
2. Verify bin/location - Scan or enter the destination bin or location
3. Handle LPN - Enter or verify LPN if required
4. Enter quantity - Specify how much product you’re moving
5. Enter weight - Add weight information (optional)
6. Track serials - Scan serial numbers if the product requires it
7. Complete - Finish the replenishment and move to the next product

Step-by-Step Process

1. Search for a Product

   On the Replenishment screen, enter or scan:

   • SKU
   • UPC
   • Product ID
   • UOM barcode (if UOM mode is enabled)

   Tap OK or press Enter to search.

2. Select a Replenishment Request

   Review the list of matching replenishment requests. Each request shows:

   • Request ID (Reple#)
   • Supplier name
   • PO number
   • SKU
   • Lot number and expiration date
   • UOM and quantity expected
   • Tracking number (if available)

   Tap the replenishment request you want to process.

3. Review Product Details

   The app shows a dialog with product information:

   • Request ID and description
   • SKU, UPC, and Product ID
   • Account information
   • Quantity requested
   • Lot, expiration, and UOM (if applicable)
   • Product image (if available)

   Review these details to ensure you’re working with the correct product.

4. Enter Bin or Location

   In the Enter Bin or Location field:

   • Scan the bin barcode with your scanner or enter the bin ID manually
   • Scan a location barcode if moving to a location

   Note: If LPN is required, you’ll see Enter Location instead of Enter Bin or Location.

   Tap OK or press Enter after entering the bin/location.

5. Handle LPN (If Required)

   If the replenishment requires an LPN:

   • If LPN exists: Enter the LPN in the Enter LPN field. The app verifies it matches the product and location.
   • If creating new LPN: Enter the LPN number, then scan or enter the location where you’re placing the product.

   The app verifies the LPN and location before continuing.

6. Enter Quantity

   After the bin/location is verified, a new dialog opens for quantity entry:

   • Quantity field: Enter the number of units you’re replenishing
   • Weight field: Enter the weight (optional, but recommended)
   • Location and Category: Shows the verified bin location and category
   • Quantity Requested: Shows the expected quantity

   Tips:

   • Use the + and - buttons to adjust quantity quickly
   • If UOM mode is active, scan UOM barcodes directly in the quantity field
   • The app warns if quantity exceeds the expected amount

7. Handle Serial Numbers (If Required)

   If the product requires serial number tracking:

   • A serial number input screen appears automatically
   • Scan each serial number barcode
   • The counter shows how many serials you’ve scanned
   • Review the list of scanned serials
   • Tap Send when all serials are scanned

   Note: The quantity must match the number of serials scanned.

8. Send Quantity

   Tap Send to complete the replenishment:

   • The app processes the information
   • Shows “Successful update” when complete
   • Closes the quantity dialog
   • Returns to the product search screen

9. Process Next Product

   After completing a replenishment, you can:

   • Scan or enter the next product SKU/UPC/Product ID
   • Process another replenishment request
   • Close the screen to return to the main menu

Detailed Feature Explanations

Bin and Location Verification

The app verifies bins and locations before allowing replenishment:

Bin Verification:

• Checks if the bin exists in the system
• Verifies the bin format is valid
• Confirms the bin is available for the product
• Shows available bins with the same SKU (if any)

Location Verification:

• Validates location format
• Checks if location exists
• Confirms location category (HURT, GOOD, etc.)
• May require confirmation for new locations

Common Messages:

• “Bin no available” - The bin doesn’t exist or isn’t available
• “Bin or location with invalid format” - The format doesn’t match system requirements
• “Create bin” - The bin doesn’t exist; you can create it
• “Is free” - The bin is empty and available

LPN (License Plate Number) Handling

When LPN is Required:

• The Enter LPN field appears automatically
• You must enter or scan an LPN before entering the bin/location
• The app verifies the LPN matches the product and request

LPN Verification:

• Checks if LPN exists in the system
• Verifies LPN belongs to the correct product
• Confirms LPN location matches your entry
• Shows error if LPN doesn’t match

Creating New LPN:

• Enter the new LPN number
• Scan or enter the location where the product will be placed
• The app creates the LPN and links it to the location

Quantity Entry

Quantity Field:

• Enter the number of units you’re replenishing
• Use + and - buttons for quick adjustments
• Must be greater than 0
• Cannot exceed expected quantity (without confirmation)

Quantity Validation:

• Checks quantity is not empty
• Verifies quantity is greater than 0
• Warns if quantity exceeds expected amount
• Requires confirmation for over-quantity

Weight Field:

• Optional but recommended
• Enter weight in the system’s unit of measure
• Helps with inventory accuracy
• Can be left empty if not needed

Serial Number Tracking

When Serial Tracking is Required:

• Serial input screen appears automatically
• Must scan all serial numbers before completing

Serial Scanning Process:

1. Scan each serial number barcode
2. Counter increments automatically
3. Serial appears in the scanned list
4. Continue until all serials are scanned
5. Quantity must match serial count

Serial Management:

• View list of scanned serials
• Counter shows progress (scanned/total)
• Send when all serials are complete

HURT Location Handling

HURT Locations:

• Special category for damaged or problem products
• Requires confirmation before placing products
• Shows “Do you want to receive this sku in hurt location?” dialog
• Helps track damaged inventory separately

When HURT is Detected:

• App shows confirmation dialog
• Choose Yes to proceed with HURT location
• Choose No to select a different location
• Type is set to “HURT” for inventory tracking

Common Workflows

Standard Replenishment (No LPN, No Serials)

1. Search product → Select request
2. Scan bin → Enter quantity → Enter weight
3. Tap Send → Complete

Replenishment with LPN

1. Search product → Select request
2. Enter LPN → Scan location
3. Verify LPN → Enter quantity → Enter weight
4. Tap Send → Complete

Replenishment with Serial Numbers

1. Search product → Select request
2. Scan bin → Serial input screen appears
3. Scan all serial numbers → Review list
4. Tap Send → Complete

Replenishment to HURT Location

1. Search product → Select request
2. Scan HURT location → Confirm HURT placement
3. Enter quantity → Enter weight
4. Tap Send → Complete

Troubleshooting

”Bin no available” Error

Problem: The bin doesn’t exist or isn’t available.

Solutions:

• Check the bin ID spelling
• Verify the bin exists in the system
• Try creating a new bin if allowed
• Select from available bins list

”Invalid format” Error

Problem: The bin or location format doesn’t match system requirements.

Solutions:

• Check bin/location format rules
• Ensure proper capitalization
• Remove extra spaces or characters
• Scan barcode instead of typing

”Please enter lpn” Message

Problem: LPN is required but not entered.

Solutions:

• Enter or scan the LPN number
• Check if LPN is required for this product
• Verify LPN matches the product

Quantity Exceeds Expected

Problem: Entered quantity is higher than expected.

Solutions:

• Review the expected quantity shown
• Confirm if over-quantity is allowed
• Tap YES in warning dialog if proceeding
• Tap CANCEL to adjust quantity

Serial Count Mismatch

Problem: Number of serials doesn’t match quantity.

Solutions:

• Ensure all serials are scanned
• Check serial counter matches quantity
• Review scanned serials list
• Remove duplicate serials if any

💡 Best Practices

Verify Before Scanning

Always check product details (SKU, lot, expiration) before selecting a replenishment request. This prevents errors and saves time.

Complete Serials First

If serial tracking is required, scan all serials before entering quantity. The quantity auto-fills from serial count, reducing errors.

Confirm HURT Locations

Double-check before placing products in HURT locations. These are for damaged items and require special handling.

Review Before Sending

Review quantity, weight, and location before tapping Send. Once sent, changes require additional steps to correct.

Work Systematically

Process replenishments in order. Complete one fully before starting the next. This maintains workflow efficiency.

Related Features

Next Steps:

• Replenishment Overview - Learn about the Replenishment feature
• Inventory Control - Understand bin and location management
• Main Menu Navigation - Navigate between features efficiently