Pickface always stocked. Hot orders never wait.
Warehouse replenishment automation for Acumatica.
Thresholds monitored continuously, tasks created before a pick can fail, and hot orders that pull urgency all the way back to the dock.
The picker walks to the pickface, finds nine of the twelve he needs, and the order ships short.
Or he goes hunting in bulk and loses twenty minutes. Nobody knew the location was low because knowing was somebody's job to notice.
And when the truck carrying the missing lot finally arrives, it gets received and put away like any other pallet, while the order that was waiting for it sits another half-day.
Illustrative only. A pickface below its minimum creates a replenishment task on its own, filled from the oldest lot in bulk; a purchase order arriving for a waiting sales order is elevated at receipt and routed direct to a lot-verified hot lane rather than to general storage. Document numbers are examples, not a customer's.
How the pickface stays stocked.
The pickface fills itself
Continuous threshold monitoring
Every pickface in every active warehouse, on your schedule. Below minimum creates a task automatically.
Demand-driven tasks
A pick that can't be filled creates a replenishment task immediately and holds the session until it's done.
Fill to max, then follow up
Tasks fill to configured max, capped by available bulk. Short bulk queues a follow-up when stock lands.
Proportional equalisation
Not enough bulk for every pickface? Each is filled to the same percentage of max, priority breaking ties.
FIFO lot selection
Oldest lot pulled first. The scanner warns on a non-FIFO lot and demands an explicit override in strict mode.
When an order is waiting on a pallet
Hot lane, wrong lot rejected
A hot lane location is reserved for one lot and one order. Lot-verified with a hard reject — no override.
The HOT signal chain
A PO arrival that fills a hot order elevates receiving, banners the scanner, flags putaway direct-to-pickface, and re-runs the check.
What posts, and when.
Hot lane replenishment is driven by the Sales Order itself: the order and its shipment records arrive from Acumatica by webhook, so WMSi knows a specific lot is spoken for before the pallet carrying it comes off the truck.
Purchase order webhooks close the other half of the loop — the arrival that satisfies a waiting pick is recognised at receipt and escalated through putaway automatically rather than being noticed by a supervisor.
Replenishment moves that cross a zone boundary post to Acumatica as Transfer Orders and release automatically; moves within a zone update WMSi balances locally.
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