Replenishment Bottlenecks Aren’t a Task Problem—They’re a Thinking Problem

If you’re noticing delays between when inventory runs out and when it’s restocked, you’re not alone. Last week, someone submitted this:

“Jim, our pickers are constantly waiting on stock to be replenished. The WMS shows the bin as empty, and by the time replenishment hits, we’ve already missed SLA windows.”

This is a classic warehouse replenishment bottleneck—and it’s more common than you think.

The One Fix That Works: Trigger-Based Replenishment

Many warehouses still rely on scheduled replenishment—once per shift, hourly, or at the end of the day. That can work… until it doesn’t.

A trigger-based replenishment system activates replenishment tasks automatically once the inventory in a pick location drops below a set threshold.

Example: When a pick bin hits 10 units, a replenishment task is auto-generated in your WMS.

This change alone can:

• Prevent “empty bin” panic

• Reduce picker wait time

• Eliminate manual checks

• Keep your pick rates consistent

Bonus Tip: Slot Based on Replenishment Frequency

If your fast movers are in small bins across the building, you’re wasting time.
Start by asking:

Are my most frequently replenished SKUs in the most efficient pick slots?

Try this:

• Use larger pick faces for fast movers

• Slot fast movers near reserve locations

• Reduce daily replenishment touches

This won’t just reduce bottlenecks—it will make your entire slotting strategy more efficient.

Beware of the Unknown Known

Be very aware that your shipping profiles can change daily—even hourly. We all know that.

But here’s the danger: when your Units Per Order (UPO) jumps from 1.9 to 4.4, you’ll feel it before you see it.

Suddenly:

• Your pick faces are empty too soon

• Replen can’t keep up

• SLAs are at risk
  And nobody knows why… yet.

You better make sure you’re monitoring the right data points to achieve balance.
More pickers, fewer packers?
More shippers, fewer replenishers?
You’d better know—or you’ll be unknown. (Sorry, couldn’t resist.)

Final Thoughts

Fixing warehouse replenishment bottlenecks doesn’t always require new software or expensive automation. Sometimes it’s just about tuning your triggers and slotting strategy.

🧠 Need Help with a Warehouse Problem Like This?

This post came from a real question submitted through my help form.

If you’re facing a similar bottleneck—or any warehouse challenge—submit your question here:
👉 Contact Jim.
No pressure. No pitch. Just help.