Stock Replenishment
Fast, reliable, fully automated stock replenishment solutions
Intelligent Automated Stock replenishment Solutions
Reduce downtime, improve accuracy, and maintain optimal stock levels with intelligent conveyor systems.
By automating your stock replenishment functions, you can ensure that stock is checked in and relocated to the correct picking or storage location as quickly as possible with the minimum amount of manual labour and intervention.
Improve stock replenishment
CSL Automation can help you improve how you manage your stock replenishment with a range of proven technologies, including:
- Inbound operator stations
- Scanning and routing technology
- Roller and belt conveyors
- Spiral conveyors
- Diverts
- Tote returns
Automated Stock Replenishment
Stock replenishment can refer to either inbound product being replenished directly to the pick face, or internal stock movements from reserve or bulk storage locations to ensure pick faces remain fully stocked and operational.
Up to 60% of warehouse labour time can be consumed by manual inbound and replenishment activities without automation
Poor inbound replenishment is responsible for 30–40% of pick face stockouts, directly impacting order fulfilment
Automated or well-designed inbound replenishment can improve putaway accuracy by up to 99.9%
Optimised replenishment strategies can reduce replenishment travel time by 25–40%
Facilities with structured inbound-to-pick-face replenishment see 15–30% faster order picking rates
Real-time replenishment control can cut emergency replenishment events by over 50%
Efficient inbound flow design can reduce dock-to-stock time from hours to minutes
Discuss your automation Project
Thank you for your interest in CSL Automation. As one of the UK’s leading conveyor and automation integrators, we can help design and install a system to help you take your business to the next level.
Start your automation journey today.
replenishment trigger
Reduce downtime, improve accuracy, and maintain optimal stock levels with intelligent conveyor systems.
- Pick face monitoring: WMS tracks min threshold
- Storage item picked and scanned
- Data capture – WMS updates inventory status as ‘moved to pick face’
- Item placed on conveyor in own packaging or in a LPN assigned tote bin
- Routed to put away location
- Confirmation – scan on location to confirm put away
Options and Enhancements
- Put-to-light or voice-directed replenishment
- Buffer management (dynamic lane assignment)
- Pallet/tote hybrid flows
- Automated labelling and dimensioning
- Auto kitting consolidation and auto packing
Benefits
- Prevent stockouts & overstocking with dynamic triggers from WMS/ERP and real-time sensors.
- Increase pick-face availability and reduce picker downtime.
- Reduce manual touches and forklift movements for safer, faster operations.
- Scale with your growth from a single line to multi-zone facilities
- Lower errors & returns – verified replenishment accuracy
- Energy savings – zoned drives and smart sleep modes
- Faster ROI – modular upgrades to match budget and growth
