Quick Summary: Top-Up Orders allow planners to order the shortfall required to reach the Order Up To Level even when the item has not dropped below the Reorder Point. This supports container filling, discount thresholds, and flexible order sizing.
What Are Top-Up Orders?
Normally, the app will only recommend an order when an item’s Net Stock is at or below its Reorder Point.
The Top-Up functionality allows you to strategically override this rule.
When you are already placing an order with a supplier, you can “top up” that order with items that:
Are below their Order Up To Level, but
Have not yet triggered a reorder.
Unlike a standard recommended order (which covers a full replenishment cycle), a top-up order is usually for a smaller quantity.
The system calculates just enough to bring the item’s stock back up to its Order Up To Level.
➜ For more on this topic, read: Ordering Levels Explained
Why This Feature Matters
Top-up orders are a powerful tool for improving order efficiency. They are especially useful in these common situations:
Filling Up Containers
If your essential orders only fill 90% of a container, you’re paying for unused freight space.
Use top-ups to add additional items from the same supplier to fill the remaining capacity, maximizing your return on freight costs.
Reaching Supplier Minimums
Many suppliers set a Minimum Order Value (MOV) or offer discounts at certain spend thresholds.
If your order falls just short of a target, add top-up items to reach the threshold without over-ordering on items that already have recommendations.
➜ For more on this topic, read: Supplier Constraints Explained
Handling Infrequent Order Reviews
If you do not review orders for a particular supplier daily, you risk stockouts between reviews.
Using Top-Up Orders prevents this by identifying items that would otherwise trigger ordering before your next scheduled review. Unlike using Look Forward Days, Top-Ups do not generally result in excess stock.
This ensures critical replenishment signals are not missed, even if reviews occur infrequently.
➜ For more on this topic, read: Order Frequency (Review Period) Explained
The Impact on Inventory Levels
Top-Up Orders affect inventory differently from Look Forward Days. Their impact is clearer when broken into distinct points:
They do not create intentional excess.
A Top-Up only raises stock to the Order Up To Level, rather than pulling forward an entire Replenishment Cycle. This keeps inventory growth controlled and aligned with the immediate shortfall.
Supplier constraints may inflate the order.
If Minimum Order Quantities or Order Multiples apply, the Top-Up amount may be rounded upward. This can produce a larger-than-expected order and introduce excess stock.
They may generate small, inefficient orders.
Some items may only require a small Top-Up quantity. Although these orders are valid from a stock perspective, the administrative and handling effort required may outweigh the operational benefit.
They override the intended Replenishment Cycle.
The RC reflects a deliberate balance between ordering more and ordering less. When Top-Up Orders are used frequently, you are no longer bringing in one full RC at a time, which disrupts the ordering rhythm that the RC was designed to support.➜ For more on this topic, read: Long vs. Short Replenishment Cycles Explained
Look Forward Days vs Top-Up Orders
Feature | Look Forward Days | Top-Up Orders |
Primary Purpose | Time-Based Risk Mitigation. Designed to bridge a known gap in time where ordering is impossible (e.g., Supplier Shutdowns). | Logistics Optimization & Gap Filling. Designed to fill capacity (containers), meet value thresholds (discounts), or ensure availability between reviews. |
How It Works | Scans future demand and recommended orders, then consolidates them into the present. Temporarily extends the cover forward period. | Ignores the Reorder Point trigger and orders only the shortfall needed to reach the Order Up To level. |
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How To Use Top-Up Orders
➜ Read: How To: Use Top-Up Orders
⚠️ Watchouts
Supplier constraints may inflate Top-Ups: Minimum Order Quantities and Order Multiples can turn a small Top-Up into a significantly larger order.
Frequent Top-Ups disrupt the Replenishment Cycle: The RC is designed to balance ordering frequency and inventory levels, and overriding it repeatedly undermines this rhythm.
Small Top-Ups may be operationally inefficient: Some items require only minor increases, and the administrative and handling effort may outweigh the benefit.
💡 Tips
Use Top-Ups to support infrequent review cycles: They prevent missed replenishment signals without creating intentional excess stock.
Review supplier constraints before topping up: Understanding MOQ and OM values helps avoid unintended over-ordering.
Use Top-Ups strategically within supplier orders: They are effective for filling containers or reaching supplier minimum values while maintaining controlled inventory levels.
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