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A Replenishment Configuration sets the unit of measure a pickface is replenished in. Instead of topping up to an exact quantity or bringing in whole pallets, Clarus rounds each replenishment to a whole number of Units, Cases, Inners, or Outers. This keeps cases intact when stock moves from racking to the pickface. Your existing triggers and account rules still decide when a pickface is replenished. The configuration only changes how much is moved.

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When to use it

Use a Replenishment Configuration when a product is handled in whole configurations from start to finish. That means it is received, stored, picked, and replenished in whole cases, inners, or outers. Pair it with Mixed UOM Picking so that picks from racking also take whole configurations. When every pick and replenishment moves whole configurations, the stock left in racking is always a whole number of them.
This feature is designed for racking stock held in whole configurations. If racking holds part cases, Clarus replenishes only the whole configurations and leaves the loose units behind. See Things to know for what happens then.

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How it works

When a replenishment is generated, Clarus:
  1. Works out the quantity the pickface needs, the same way it does today. For Continuous pickfaces that is the gap up to the Max Trigger. For Order Volume pickfaces it is the shortfall for the order.
  2. Rounds it up to the next whole multiple of the selected configuration.
  3. Caps it at the number of whole multiples available in racking.
The configuration sizes come from the product. Unit uses Output Quantity, and Case, Inner, and Outer use Units Per Case, Units Per Inner, and Units Per Outer.

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Examples

With Units Per Case set to 5 and the pickface set to Case:
Rounding up can take a pickface above its Max Trigger. Set the Max Trigger to a multiple of the configuration, or make sure the pickface can hold an extra case, inner, or outer.

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Set a Replenishment Configuration

1

Check the product configuration

Open the product and check that the quantity for the unit of measure you want is set: Output Quantity, Units Per Case, Units Per Inner, or Units Per Outer. Only configurations with a value here can be selected on a pickface.
2

Open the product's Pickfaces panel

Add a pickface with Add Line, or edit an existing one. See Set Up a Pickface if the location isn’t a pickface yet.
3

Choose the replenishment type

Set Replenishment Type to Continuous or Order Volume. Demand pickfaces always replenish a full pallet, so you can’t set a configuration on them.
4

Select the Replenishment Configuration

In the Replenishment Configuration column, select Unit, Case, Inner, or Outer. You can select one configuration per pickface.
5

Set Full Storage Units Only to No

Full Storage Units Only must be No for the configuration to apply. New lines default to Yes. See Full Storage Units Only below.
6

Save

Click Save. The next replenishment for the pickface uses the configuration.
To go back to the standard behaviour, clear the Replenishment Configuration and save. A pickface with no configuration replenishes exactly as it did before.
If you don’t see the Replenishment Configuration column, add it through the column manager.

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Location groups

When a location group is assigned as a pickface, you can set a Replenishment Configuration on the group line. Clarus copies it to every location in the group, including locations added to the group later. To change one location, click Manage on the group line and set or clear the Replenishment Configuration for that location. Each location replenishes using its own setting. If you clear a location’s configuration, that location replenishes without one, even when the group line still has a configuration.
Changing the group line updates any locations that still match the group’s previous settings. Locations you’ve changed individually keep their own configuration.

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Full Storage Units Only

With Full Storage Units Only set to Yes, the Replenishment Configuration is ignored. Clarus moves whole storage units as it does today, and the replenishment may not be a whole number of cases. The Replenishment Configuration field stays editable while Full Storage Units Only is Yes, so check both settings when you set up a pickface.

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Which stock is moved

The configuration decides how much is replenished. The account’s Pick Rule and Pick Optimisation decide which stock makes up that total. The total is always a whole number of configurations. Each replenishment task is not. When the total is made up from several storage units, Clarus may create one task for each, and those tasks don’t have to be whole cases. For example, the pickface is set to Case (10 units) and needs 20. Racking holds four pallets of 5. Clarus creates four replenishment tasks of 5, which together make 2 whole cases. How the total is made up depends on the account’s Pick Optimisation:
The default. Clarus moves the whole storage units that best fill the quantity, preferring fewer and larger ones, and only breaks one storage unit for whatever is left. When whole storage units fit, dates are not taken into account.Example: the pickface is set to Case (5 units), with Sell By Date as the Pick Rule. Racking holds 3 units with an earlier sell-by date and a full case of 5 with a later sell-by date. Clarus replenishes the whole case of 5 and leaves the 3 earlier units in racking.
Neither option guarantees both “earliest date first” and “never break a case”. Choose the Pick Optimisation that matters most for the account. See Pick Optimisation.

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On the handheld

Your HHD implementation can be configured to show the replenishment in the pickface’s configuration. With this configured, after scanning the Location To, the operator sees the Replenishment Product Configuration (for example Cases) and the number remaining to scan. They scan a barcode for each case, inner, or outer before the task completes. For example, a replenishment of 25 with Units Per Case set to 5 shows 5 cases, not 25 units. The count on the handheld assumes each task is a whole number of configurations. When a task isn’t, for example because a storage unit holds fewer units than a case, the count may not match the scans the handheld asks for.
Contact support to add the replenishment configuration steps to your HHD implementation.

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Removing a configuration from the product

If you clear Units Per Case, Units Per Inner, or Units Per Outer on the product, Clarus removes that configuration from every pickface for the product. That covers both Allowed Configurations and Replenishment Configuration. Clarus warns you before saving. Affected pickfaces go back to replenishing without a configuration.

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Things to know

  • Less than one configuration in racking means no replenishment. If racking holds less than one whole case, inner, or outer, Clarus doesn’t replenish. This applies even if it is the last stock for the product. The pickface stays as it is, and no message is shown.
  • Picks can be raised for more than the replenishment brings. If racking holds stock that isn’t a whole multiple of the configuration, an order can still be allocated and picked from the pickface for the full quantity. For example, with a case of 5 and 7 units in racking, an order for 7 raises a pick of 7 but a replenishment of 5. The remaining 2 units stay in racking.
  • Keep racking stock in whole configurations. The issues above only happen when stock in racking no longer matches the product’s configuration, usually after a manual transfer or stock adjustment. That isn’t supported. See When to use it, and contact support if it happens.
  • Match the replenishment configuration to how the pickface is picked. For example, if a pickface picks in outers but replenishes in units, every outer picked can create a separate replenishment.
  • A Max Trigger of 0 ignores the configuration. A Continuous pickface with a Max Trigger of 0 moves the first stock found, as it does today.
  • Not available on Demand pickfaces. Demand replenishment always brings in a full pallet.