The Replenishment Report is designed to help managers identify which products must be moved from bulk storage into picking locations to fulfill open orders. This report ensures that picking bins remain stocked so that fulfillment teams can work without interruption.
Why Use the Replenishment Report?
This report helps you:
- Identify SKUs at risk of stockouts in pickable locations.
- Prioritize replenishment work.
- See where available overstock inventory exists.
- Plan movement from bulk, overstock, staging, or other non-pickable bins.
Table of Contents
- How the Replenishment Quantity is Calculated
- Common Replenishment Workflows
- Navigating the Replenishment Report
How the Replenishment Quantity is Calculated
ShipHero calculates replenishment needs using the following logic:
- Analyze Demand: The system reviews open orders and allocated quantities.
- Check Pickable Stock: It subtracts the inventory currently available in picking bins.
- Locate Backstock: It scans non-pickable bins to identify the closest available inventory.
- Actionable Result: The system generates a list of "Items to Replenish" with specific location coordinates.
Required Inventory Conditions
There are specific conditions that must be met for a SKU to appear in the Replenishment Report:
- It has allocated orders and/or its pickable quantity is below its configured Min level.
- There MUST be inventory available in non-pickable locations.
Important
The Min/Max quantities only apply to a SKU's pickable locations. Check out this article for more information about using ShipHero's Replenishment Minimum/Maximum Feature.
Common Replenishment Workflows
By tailoring your filters and sorting, you can transform the Replenishment Report from a simple list into a specialized task sheet for your inventory team. Here are three common replenishment workflows:
- Demand-Based Replenishment (Allocation-Driven)
- Minimum Inventory Maintenance (Min/Max Maintenance)
- Aisle-Based Optimization (Location-Based)
Demand-Based Replenishment (Allocation-Driven)
This workflow is best for high-turnover environments or warehouses with limited picking space. It ensures you only move the inventory required to ship current orders.
Goal: Move only the stock required to fulfill existing open orders.
The Result: Your team avoids moving excess stock and focuses exclusively on items with active shipping labels.
| Filter Name | Required Setting |
|---|---|
| Allocation | Toggle "Show only allocated items." |
| Order Details | Select "Show only 'Ready to ship' orders." |
Pro Tip
To maximize warehouse efficiency, execute the Demand-Based Replenishment pull before the start of a picking shift. Filter by Ready to Ship orders and export the list as a CSV to provide the inventory team with a clear move list.
Minimum Inventory Maintenance (Min/Max Maintenance)
This workflow is best for maintaining high pick-density and preventing "out-of-stock" errors during a picking shift.
Goal: Refill pickable bins that have fallen below their configured Replenishment Level.
The Result: This surfaces critically empty picking bins first, allowing you to stay ahead of demand before orders are impacted.
| Action | Configuration |
|---|---|
| Sorting | Sort by "Inventory quantity low to high." |
Aisle-Based Optimization (Location-Based)
This workflow is best for large warehouses where travel time is a primary factor. This allows you to assign specific staff members to specific aisles.
Goal: Clear out all replenishment needs in one section of the warehouse at a time.
The Result: Your replenishment team can work systematically through the warehouse, reducing movement time and ensuring no bin in a specific aisle is skipped.
| Filter Name | Action |
|---|---|
| Location Prefix | Enter a specific aisle or zone (e.g., A or ZONE-1). |
Navigating the Replenishment Report
To access the Replenishment Report, go to the [Shipping.ShipHero.com](http://Shipping.ShipHero.com) platform, click Reports on the Left-hand menu then select Replenishment. The Replenishment Report focuses on inventory movements from non-pickable to pickable bins. If a SKU has no replenishment need, it will not show on the Replenishment Report.
Search and Filters
Refine the report using the search bar or the filter panel to focus on specific zones (locations) or priority orders.
Pro Tip
Filters are saved in the URL, allowing you to share specific views with other team members or bookmark the filtered report for easy access any time you need to pull it up.
| Filter Name | Description |
|---|---|
| Location Prefix | Filters products by bin locations starting with specific characters (e.g., A or A1). Use this to manage specific aisles. |
| Allocation | Enabled by default. Only shows products that are actively needed by pending orders. |
| Order Details | Allows you to include wholesale orders or limit the view to only Ready to Ship orders. |
| Order Tags | Filters demand by specific tags attached to orders. |
| Sort by | Prioritizes the list by lowest inventory levels or the oldest required ship dates. |
| Order Status | Filters results based on custom fulfillment statuses used in your account. |
Replenishment Report Definitions
The table displays real-time inventory levels across different bin types.
| Column Name | Definition |
|---|---|
| SKU | The unique identifier for the product. Clicking this opens the product details page. |
| On Hand | Total physical quantity in the warehouse (all bin types combined). |
| Allocated | Quantity reserved for open orders. |
| Replenishment Level | The minimum stock threshold set for picking locations. |
| Available in Pickable Bins | Stock currently in locations where pickers can access it. |
| Qty from Non-Pickable Bins | Stock currently in bulk or overstock storage available for transfer. |
| Items to Replenish | The calculated amount to move to meet current demand. |
| Top 3 Non-Pickable Bins | Displays source locations with the highest quantities available. |
Helpful Tips
- Click column headers to sort the data.
- Change which columns are displayed by editing the column visibility. Open the Columns menu in the top right-hand corner, check the columns you want to show and uncheck the columns you want to hide.
Exporting Data
You can export the current view to a CSV file. The export includes all table columns, with the bin suggestions formatted as a single list for easy reading in spreadsheet software.