PICK-FACE PLANNING
Setting Pick-Face Replenishment Levels
A pick face should hold enough stock to bridge replenishment cycles without consuming more prime space than the item deserves.
SHORT ANSWER
Start with the inputs you can verify
A pick face should hold enough stock to bridge replenishment cycles without consuming more prime space than the item deserves.
What the estimate means
Use demand during the replenishment interval rather than average daily demand alone.
Include a buffer for variability, delayed replenishment, and case-pack constraints.
Where estimates go wrong
Review fast movers more often because stale averages create avoidable stockouts and congestion.
Keep the source measurements and assumptions with the result so another person can review or update the estimate later.
A practical workflow
- Choose a realistic replenishment interval.
- Calculate expected demand and variability during that interval.
- Round to feasible case or inner-pack quantities and monitor exceptions.