Replenishment settings — thresholds, ABC classes, and scanner policy

Settings → Warehouse has four replenishment tabs: Location ABC zones, Product ABC classes, Replenishment scenarios, and Replenishment — scanner settings. Numeric thresholds are in a settings window opened from the Dashboard.

Every replenishment configuration save requires a fresh 2FA verification. These settings change how the entire warehouse works, so they cannot be changed from an abandoned session.

Step by step

Set recommender thresholds and limits

1. Open Warehouse & logistics → Replenishment → Dashboard.
2. On the health bar, click the gear on the right (Settings). The Replenishment Settings window opens.
3. Scanner scope → Monitored warehouses — blank means all company warehouses.
4. Scan controls (default): ABC: on / ABC: off, Default source zones — where to take goods from, and Default destination zones — where to put goods. If ABC is off and no destination zones are set, Save is disabled and warns ABC disabled requires default destination zones.
5. Replenishment scanner: Minimum quantity to move, Maximum quantity to move (blank = move the whole shelf), Scan automatically every night, and Move dead stock too.
6. Worklist limits: Maximum open tasks, Maximum tasks per scan, and Rotation window (days).
7. Stock coverage (days): Target coverage (days) and Demand window (days).
8. Further down are Put-away location selection strategy, Source location selection strategy, Batch picking and Maximum tasks in one batch route, plus Mix products on a shelf (a replenishment scenario can override the last setting).
9. Operator kiosk: Over-pick and Partial pick control whether the operator sees buttons for deviating from the plan. These are company defaults; a replenishment scenario can override them for its workers.
10. Click Save and confirm with a fresh 2FA code.

Set product ABC classes

1. Open Settings → Warehouse → Product ABC classes.
2. Set the Rotation window (days), Class A threshold (%), and Class C threshold (%). Class B is calculated automatically (Class B (%) — calculated); A plus C cannot exceed 100%.
3. Click Save parameters. The message reminds you: Parameters saved. Run “Classify automatically” to recalculate classes using the new thresholds.
4. Click Classify automatically to recalculate them now.
5. Enable Reclassify automatically every night if you want the nightly job to do this.
6. If the automatic result is wrong for one product, click Add manually. Manual exceptions survive every recalculation.

Set location ABC zones

1. Open Settings → Warehouse → Location ABC zones.
2. Click Add manually and fill in Rule name and ABC zone.
3. Narrow the rule using Warehouse, Zone, Access type, Position from / Position to, or Manual location selection. Conditions within one rule are combined with AND.
4. Check the result on ABC zone coverage. The first matching rule wins.
5. Enable Reclassify automatically every night to put new locations into zones without clicking manually.

Set scanner policy

1. Open Settings → Warehouse → Replenishment — scanner settings. Scanning, the MANUAL replenishment threshold, and display options are company defaults that a replenishment scenario can override. WMS Move thresholds (picking and put-away) are not overridden by scenarios.
2. Under Scanning, set Camera scanning and Require physical scan. The latter prevents confirmation by tapping a button.
3. Under Enter quantity manually, set Replenishment — enter quantity manually from (items). Below the threshold, one scan posts one item; from the threshold onward, a quantity calculator opens.
4. Under Picking screen, set Show cart contents and Show next items.
5. Changes save automatically shortly after you click. Save forces an immediate save. Every save asks for a fresh 2FA code; if you do not confirm it, the switch returns to the server value.

Set pick-face locations (min/max)

There is not yet a screen in the interface for creating pick-face locations. The only way is the API: replenishment/manager/pick-faces/. Without a min/max entry for a product + shelf pair, the recommender cannot calculate demand-based replenishment; it can only move products according to their classes.

Pick-face locations: min and max

These settings are central to replenishment based on demand. For each product + shelf pair, set:

• min — the threshold below which the shelf needs replenishment;
• max — the quantity to replenish up to.

min must be lower than max; otherwise, saving is rejected with “Max quantity must be greater than min quantity”. Without a pick-face entry for a product, there is no demand-based replenishment for it, only class-based movements.

ABC classes and zones

Products are assigned class A, B, or C from order history. Each class has a home zone: A → golden, B → mid, C → reserve. A product outside its home zone is a candidate for relocation.

• Class A threshold (20% by default) and Class C threshold (30% by default) together cannot exceed 100%.
• Hysteresis (5%) prevents a product from jumping between classes every night.
• You can pin a class manually for an individual product under Product ABC classes.
• You can disable ABC entirely. In that case a default destination filter is required: without classes there is no home zone, so you must specify where goods should go.

Analysis windows

• Analysis period (30 days) — the history used to calculate classes.
• Velocity window (7 days) — the shorter period used to calculate the current rate of sales.
• Target coverage (14 days) — how many days of stock you want at pick faces.

The first two windows cannot differ by more than a factor of two. Urgency uses both signals; if their windows are too far apart, they contradict each other. The system blocks the save.

Limits

• Maximum tasks per scan — 100.
• Maximum open tasks — 200.
• Minimum/maximum quantity to move — a blank maximum means no upper limit.

Nightly automation

• Automatic classification — on.
• Automatic zoning — on.
• Automatic scan that creates tasks — off. Enable this deliberately: from then on, every morning you will see tasks that nobody ordered manually.

Scanner policy

A scenario can override every setting here except batch routes; see below.

If settings cannot be loaded, the terminal uses the most restrictive option. A network failure must not silently loosen company policy.

Scenarios

A scenario combines the warehouse route with a put-away policy: locked destination, suggested location, or any shelf. Resolution order: user scenario → warehouse scenario → company default. Tasks planned by a recommendation scan always have a fixed destination, regardless of the scenario.

Scenario screen

Settings → Warehouse → Replenishment scenarios is a list of scenarios showing the name, who they cover (assigned workers, warehouse, and default flag — every configured assignment, not only the one that wins), route, quantity-entry threshold, and number of rules that differ from the company. Filter by status and warehouse; sort by name, route, quantity threshold, or status. Clicking a row or pencil opens the editor in place of the list; use the arrow in the header to return.

At the top of the editor, a sentence describes the scenario, for example: “Applies to: Anna Nowak. Picker follows the route, enters quantities from the keypad starting at 12 units, and puts goods away on the planned shelf.” Each highlighted phrase takes you to its field. Warnings appear beneath it: an enabled scenario assigned to nobody; a worker assigned to two scenarios (showing which wins); or two default scenarios for one warehouse.

Tabs:

• Who it covers — workers, warehouse, and default scenario. There can be only one default; the toggle is locked while another scenario is the default (the Open link takes you to it). The precedence diagram shows resolution order, and Check worker tells you which scenario a selected worker gets in a selected warehouse and why.
• Picking — route (follow warehouse route, by shelf code, or by product), direction (from the start or end) with a preview of the order on example shelves, and Enter quantity from keypad starting at. Following the warehouse route uses each location’s Position field in ascending order. Set it on the location itself, with list arrows (Show position controls), or in bulk with Configure priorities. A blank quantity threshold inherits the company value; 1 means “always show the calculator.”
• Put-away — destination shelf policy (locked, suggested, or any shelf), Suggested shelf (only used in suggestion mode — “any” suggests nothing), and Put away on occupied shelf. This applies to manual tasks, an employee’s own transfers, consolidation, queue returns, and order tasks. Replenishment from the plan always puts goods on the shelf selected by the plan. Put away on occupied shelf applies in every mode, including locked-shelf mode: it determines whether a manager can choose a shelf with another product for a manual task and whether a picker may scan it for their own transfer.
• Flexibility and handheld — the remaining picker rules, described below.

You can also attach a scenario to a task when creating it (the Put-away scenario field in the new-task dialog). For that task, put-away rules come from the attached scenario, not from the precedence chain; route, quantity threshold, and picker rules still come from the worker’s scenario. A blank field means use the worker or warehouse scenario. Thus a scenario assigned to nobody is not useless — the editor only warns that it works through task assignment.

Each rule has a toggle showing what the picker will actually get. A grey toggle with a lock on its knob inherits company settings; changes to those settings flow through automatically. Switching it creates a custom scenario value (in either direction): the toggle turns colored, a custom badge appears, and the Restore company setting arrow resets it. Hover over the building icon beside the toggle to see the company value and where to set it: scanning, camera, cart, next items, and quantity threshold are under Settings → Warehouse → Replenishment — scanner settings; over-picking, partial quantities, and occupied shelves are under Replenishment → Dashboard → Settings, in Operator kiosk.

Rules are Over-pick, Finish with a partial quantity, Require code scan, Camera scanner, Cart contents summary, Next items, and — on the Put-away tab — Put away on occupied shelf.

The editor header also has Copy (the copy is disabled and is not marked as the default) and Delete.

Example: the company allows over-picking, but new workers have a scenario where Over-pick and Finish with a partial quantity are disabled (marked custom). They take exactly the planned quantity — the terminal hides deviation buttons, and the system rejects every unit above the plan.

Rules follow the worker: first the scenario assigned to them, then the scenario for the warehouse selected on the terminal, then the company default. The terminal displays the same rules that the system enforces. Switching warehouses cannot bypass them: you cannot switch with goods on the cart, and you cannot take tasks from another warehouse. Exception: Put away on occupied shelf is a put-away policy for manual and personal tasks; when a scenario is attached to the task, that scenario decides. Saving a scenario requires a fresh 2FA code, just like the company settings it overrides.

Permissions

Separate permissions are assigned under Roles and permissions: managing settings, zone rules, classification, pick-face locations, and scan templates; and, for warehouse work, changing a task destination, self-picking, and archiving a session.