Overview
Proactive Replenishment automatically generates replenishment tasks when stock in your pick locations drops below a defined threshold (called a Replen Point). This guide explains how to configure your warehouse and products to use this feature.
Video Walkthrough
Prerequisites
Before setting up Proactive Replenishment, ensure you have:
Warehouses created: At least one warehouse configured in Mintsoft.
Location hierarchy defined: Warehouse locations set up with Location Types (for example, "Pick Face", "Bulk Storage", "Reserve").
Products added: Products must exist in the system with SKUs.
Default Pick Locations configured: Each product should have a Default Pick Location assigned (the primary picking location for that product).
If you haven't completed these steps, please refer to the relevant warehouse setup and product setup articles first.
Quick Start Summary
Set up your warehouse: Configure which warehouses to use as replenishment sources.
Define replenishment points: Set Size and Replen Point for each product (manually, in bulk, or by default).
Monitor: The system automatically generates replenishment tasks when stock drops below the Replen Point.
Complete: Warehouse staff fulfil replenishment tasks via the mobile app or web interface.
1. Warehouse Setup
The first step is to configure the warehouse that will use Proactive Replenishment.
Click Warehouse then click Manage Warehouses.
Find the warehouse you'll be using for Proactive Replenishment then click Edit.
(Optional) Turn Include Allocated Stock In Replen Point to ON.
What this does: When enabled, the system considers stock that's already allocated to orders when calculating whether replenishment is needed.
With this setting OFF: The system sees 15 available units, which is above the 10-unit replen point, so no replenishment is triggered.
With this setting ON: The system sees 15 - 8 = 7 effective units (accounting for allocated stock), which is below the 10-unit replen point, so replenishment is triggered.
When to use: Enable this if you want to ensure your pick location stays above the replen point even after considering orders that will consume that stock. This helps prevent stock-outs during order fulfilment.
Example: You have a pick location with:
Size: 50 units (maximum capacity)
Replen Point: 10 units
Current Available Stock: 15 units
Current Allocated Stock: 8 units (assigned to open orders)
(Optional) Click the Proactive Replen Sources tab.
Tick the warehouse(s) to use as replenishment sources for this warehouse.
What this does: When a Proactive Replenishment is generated, the system will look for available stock in the selected source warehouses to suggest as replenishment sources.
Example: You're setting up Warehouse A (your main picking warehouse):
Tick Warehouse A itself: Allows replenishment from bulk storage locations within the same warehouse to pick locations.
Tick Warehouse B: Allows replenishment from Warehouse B if Warehouse A doesn't have bulk stock available.
Finally, click Update.
Tip: The system will prioritise replenishment sources based on the order of warehouses in your list. If the first warehouse has no available stock, it will check the next ticked warehouse.
2. Product Setup
To set Proactive Replenishment up, you must specify replenishment points for each product. There are three ways to do this.
Understanding Key Terms
Before you begin, it's important to understand these terms:
Default Pick Location: This is the primary location where warehouse staff pick this product from when fulfilling orders. Each product can have a Default Pick Location configured (found under Products > Edit > Defaults tab > Default Pick Location field). The Location Type for your replenishment point must match this location's type to ensure replenishments go to the correct location.
Example: If your Default Pick Location for a product is "A-01-A" with Location Type "Pick Face", your replenishment point LocationType must also be "Pick Face".
Size: The maximum number of units that can fit in the location.
Replen Point: When stock falls below this value, a replenishment will be generated.
Important: Your Replen Point must be less than the Size. For example, if your location can hold a maximum of 50 units (Size = 50), you might set the Replen Point to 10 units. This gives the system time to replenish before you completely run out.
Tip: Set your Replen Point to 10–25% of the Size for fast-moving products, or 5–10% for slower-moving products. This balance ensures you don't replenish too frequently whilst avoiding stock-outs.
2.1 Add Product Replen Points - Manually
To add a Replen Point on a product-by-product basis:
Click Products then click Overview.
Search for the required product.
On the right of the product row, click Actions then click Edit.
On the Defaults tab, click Replen Points.
Complete the following fields:
LocationType: This must be the same Location Type as the Default Pick Location.
Size: The maximum number of units that can fit in the location.
Replen Point: When stock is lower than this value, a replenishment will be generated.
Click Update.
Examples:
High-Turnover Product: You sell 100 units per day of "Product A".
Size: 50 units (maximum that fits in pick location)
Replen Point: 10 units (represents half a day of sales)
Result: System generates replenishment when stock drops to 10, giving time to move more stock from bulk before running out.
Low-Turnover Product: You sell 5 units per week of "Product B".
Size: 20 units
Replen Point: 3 units (represents about half a week of sales)
Result: Less frequent replenishments, avoiding unnecessary stock movement.
2.2 Add Product Replen Points - In Bulk
To add Replen Points to multiple products in bulk:
Click Products then click Extras.
Click Upload Additional Info.
Select the Template as ProductReplenPoints to download.
Populate the CSV with the following information:
SKU: The product the replen point is for.
LocationType: This must be the same Location Type as the Default Pick Location.
Size: The maximum number of units that can fit in the location.
Replen Point: When stock is lower than this value, a replenishment will be generated.
Save the spreadsheet.
Back on Mintsoft, (3PL Only) select the Client.
Select the Type as ProductReplenPoints to upload.
Click Choose File and browse for the CSV.
Click Upload.
Tip: Ensure your CSV file uses the exact SKUs as they appear in Mintsoft (case-sensitive), and that Location Type names match exactly.
2.3 Default Replen Point Against Location Type
This will add the same Replen Point to all products stocked in the selected Location Type.
Click Products then click Extras.
Click Default Product Replen Points.
(3PL Only) Select the Client.
Choose the LocationType. This must be the same Location Type as the Default Pick Location.
Enter the Size: The maximum number of units that can fit in the location.
Enter the ReplenPoint: When stock is lower than this value, a replenishment will be generated.
In the bottom right, click Add.
Note:
3PL users: If you operate as a Third-Party Logistics (3PL) provider managing inventory for multiple clients, you'll see a "Client" selection dropdown in various screens. Always select the appropriate client before configuring replenishment points, as these settings are client specific.
Multi-Channel: If you're not a 3PL provider, the client selection steps won't appear in your interface – simply skip those steps.
3. What Happens Next?
After completing the setup above, Proactive Replenishment will automatically begin monitoring your stock levels:
Automatic monitoring: The system continuously checks stock levels in pick locations against the configured Replen Points.
Replenishment generation: When stock falls below the Replen Point, a Proactive Replenishment task is automatically created.
Task visibility: View generated replenishment tasks by going to Warehouse > Replenishment Tasks or via the Mintsoft Mobile App.
Completing replenishments: Warehouse staff can complete these tasks to move stock from bulk/reserve locations to pick locations.
Next steps:
See Proactive Replenishment - Overview for details on how the system generates replenishments.
See Access Mintsoft app - Proactive Replenishment to learn how warehouse staff complete replenishment tasks on mobile devices.
Monitor your replenishment activity in the first few days to ensure Replen Points are set appropriately.