What is Replenishment and how does it work?

What is Replenishment? This is one critical aspect of supply chain management is replenishment, which refers to the process of restocking products to maintain desired inventory levels. In this article, Viindoo will delve deeper into the concept of replenishment, its importance in supply chain management, and its various applications in different industries.

The Basics of Replenishment

In general, what is replenishment? Replenishment is the process of restocking products to maintain optimal inventory levels. It involves planning, executing, and monitoring the flow of goods from suppliers to retailers or end consumers. The goal is to strike a balance between having enough inventory to meet customer demand without incurring excessive carrying costs or experiencing stockouts that can result in lost sales and dissatisfied customers. Replenishment can occur at different stages of the supply chain, including raw materials, work-in-process inventory, finished goods, and retail shelves.

Replenishment of inventory is one critical aspect of supply chain management Replenishment of inventory is one critical aspect of supply chain management

Replenishment planning is a critical part of supply chain process management, as it ensures that products are available in the right quantities, at the right time, and in the right place. This requires accurate demand forecasting, inventory analysis, and supplier management to ensure that products are available when and where they are needed.

 By optimizing inventory levels, replenishment helps to minimize costs associated with excess inventory, carrying costs, and lost sales due to stockouts. It also improves customer satisfaction by ensuring that products are readily available, leading to increased sales and customer loyalty. Moreover, replenishment allows companies to respond quickly to changes in customer demand, market trends, and supply chain disruptions, ensuring business continuity

What is Replenishment Strategy?

 Several replenishment strategies are commonly used in supply chain management, depending on the industry, product characteristics, and customer demand patterns. Some of the popular strategies include:

  •  Continuous Replenishment: In this strategy, inventory levels are continuously monitored, and orders are automatically placed when inventory falls below a certain threshold. This minimizes stockouts and reduces the need for manual intervention.
  • Periodic Replenishment: In this strategy, orders are placed at regular intervals, such as weekly or monthly, regardless of inventory levels. This can help to consolidate orders, reduce shipping costs, and streamline the replenishment process.
  • Demand-Driven Replenishment: This strategy involves replenishing inventory based on actual customer demand data, obtained through point-of-sale (POS) systems, electronic data interchange (EDI), or other demand-sensing technologies. This allows for more accurate demand forecasting and inventory optimization.

See more: Optimizing Inventory Forecasting Demand: The Power of ERP Systems

There are several strategies for replenishment planning
There are several strategies for replenishment planning

Applications of Replenishment in Different Industries

Replenishment is a crucial process in various industries, and its implementation may vary depending on industry-specific factors. Let's take a look at some examples:

So, what is Replenishment in Retail?

 In the retail industry, replenishment is essential to ensure that products are available on store shelves to meet customer demand. Retailers use replenishment systems that take into account factors such as historical sales data, current inventory levels, lead times, and desired service levels to determine optimal replenishment quantities and timings. This helps retailers avoid stockouts and lost sales while minimizing excess inventory.

Replenishment in retail
Replenishment in retail

What is Replenishment in Warehousing?

 In the warehousing industry, replenishment is critical to maintaining smooth operations and efficient order fulfillment. Warehouse replenishment involves restocking items in their designated locations based on demand patterns, order volumes, and warehouse capacity. Automated systems, such as warehouse management systems (WMS), are often used to manage replenishment in warehouses, ensuring that the right products are available in the right quantities when needed.

What is Replenishment in Manufacturing?

 Replenishment is crucial to ensure uninterrupted production processes for the manufacturing industry. Manufacturers need to replenish raw materials, work-in-process inventory and finished goods to meet production schedules and customer orders. Replenishing inventory in manufacturing takes into account factors such as lead times, production capacity, demand forecasts, and supplier performance to optimize inventory levels and minimize stockouts or excess inventory.

And finally, what is Replenishment in E-commerce?

 In the fast-paced world of e-commerce, replenishment is essential to meet the ever-changing demand of online shoppers. E-commerce retailers rely on automated replenishment systems that integrate with their online platforms, considering factors such as real-time sales data, inventory levels, and delivery timelines to ensure that products are available for quick order fulfillment. This helps e-commerce businesses maintain high customer satisfaction levels and maximize sales.

The replenishment cycle in e-commerce is often agile The replenishment cycle in e-commerce is often agile

Viindoo empowers the Replenishment in Inventory and Warehousing industry

Viindoo trao quyền bổ sung trong ngành hàng tồn kho và kho bãi

 Viindoo Inventory is one of the top supply chain management software for SMEs. The software provides businesses with a centralized platform that enables collaboration among different teams, including procurement, inventory management, etc. It allows for real-time communication, data sharing, and coordination, ensuring that all stakeholders are aligned toward the same replenishment goals. This improves communication, minimizes errors and  bullwhip effects in supply chain, and ensures that replenishment plans are executed smoothly.

The Replenishment rules in Viindoo:

The Replenishment rules in Viindoo:

  •  Minimum and Maximum stock rule

 By creating Reordering Rules, the users can add the information of Min Quantity and Max Quantity. While Min Quantity is the threshold below which the on-hand quantity of a product should not fall, Max Quantity is the upper limit of inventory that a business wants to hold for a particular product.

Quy tắc tồn kho tối thiểu và tối đa Minimum and Maximum stock rule in the Replenishment rule in Viindoo

 When the on-hand quantity of a certain product in the stock drops to the minimum level (this number is self-defined), an automated process, often driven by inventory management software like the one you mentioned, generates a replenishment order in order to reach the maximum stock level.

An example of the Purchase order generated as a result of the Replenishment rules in Viindoo An example of the Purchase order generated as a result of the Replenishment rules in Viindoo

Thereby, this Replenishment rules helps businesses avoid stockouts, maintain optimal inventory levels, and streamline their supply chain operations. It ensures that products are available when customers need them without incurring excessive carrying costs associated with overstocking.

  •  Replenish on Order (MTO)

 Replenish on Order (also known as Make to Order or MTO) is a production and inventory strategy where products are manufactured or replenished only in response to customer orders. In this approach, products are not produced until there is a confirmed order from a customer, as opposed to producing goods in anticipation of future demand. When applying the MTO rule, the on-hand quantity of a product will not be checked. Instead, the replenishment order will automatically be generated to fulfill the quantity in the Sales order related to the product.

An example of the Purchase order generated by MTO in Viindoo 
An example of the Purchase order generated by MTO in Viindoo

 The Replenish on Order (MTO) strategy offers several advantages. Firstly, it diminishes inventory holding costs as production aligns precisely with confirmed orders, eliminating the need for excessive inventory levels and reducing associated carrying expenses. Secondly, MTO enables product customization to cater to individual customer preferences, fostering heightened satisfaction. Additionally, the strategy mitigates the risk of product obsolescence since manufacturing occurs based on current orders, rather than speculative future demand projections. 

 Apparently, the mentioned features can play an important role in Inventory and Supply Chain Management. Efficient SCM ensures operational smoothness, enhances customer satisfaction by providing products when needed, reduces costs through proper inventory control, nurtures supplier relationships, facilitates just-in-time manufacturing, and plays a pivotal role in sectors like e-commerce and retail by ensuring timely order fulfillment and accurate stock management, ultimately bolstering operational excellence and competitive advantage.


Common replenishment methods include periodic replenishment, where stock levels are checked at regular intervals, and continuous replenishment, where stock levels are monitored in real-time, triggering automatic orders when thresholds are reached. Other methods include min-max replenishment and just-in-time (JIT) replenishment.

Technology plays a vital role in replenishment by automating processes, collecting and analyzing data, and providing real-time visibility into inventory levels. Inventory management software, demand forecasting tools, and automated ordering systems can streamline replenishment operations and improve accuracy.

Demand forecasting involves predicting future customer demand based on historical data, market trends, and other relevant factors. Accurate demand forecasting enables retailers to plan their replenishment efforts more effectively, reducing stockouts and excess inventory.

Replenishment strategies may vary depending on the characteristics of the products. For example, perishable goods may require more frequent replenishment due to their limited shelf life, while slow-moving items may require more careful demand forecasting and ordering.

In conclusion, what is replenishment? It is a critical component of efficient inventory management in various industries. It ensures that products are available when and where they are needed and maintains a smooth flow for the supply chain. Understanding and implementing effective replenishment practices are essential for maintaining a competitive edge and achieving success in today's complex supply chains. Hopefully, this article by Viindoo provides readers with informative knowledge.

>>>> Continue With: What is Supply Chain? Components in the supply chain

Jun Nguyen December 14, 2023