{"id":32345,"date":"2026-08-20T10:48:52","date_gmt":"2026-08-20T09:48:52","guid":{"rendered":"https:\/\/claruswms.ai\/?post_type=features&p=32345"},"modified":"2026-08-20T10:48:56","modified_gmt":"2026-08-20T09:48:56","slug":"how-to-automate-pickface-stock-continuously","status":"publish","type":"features","link":"https:\/\/claruswms.ai\/nb\/features\/how-to-automate-pickface-stock-continuously\/","title":{"rendered":"How to automate pickface stock continuously"},"content":{"rendered":"","protected":false},"excerpt":{"rendered":"","protected":false},"featured_media":33193,"template":"","meta":{"_acf_changed":false,"_angie_page":false,"inline_featured_image":false},"feature-type":[],"class_list":["post-32345","features","type-features","status-publish","has-post-thumbnail","hentry"],"acf":{"feature_badge":"Now Generally Available","feature_name_new":"Continuous Replenishment","feature_title_new":"Pickfaces that stay stocked automatically<\/span>","feature_description_new":"Set a minimum trigger and maximum quantity per pickface. Clarus handles the rest, every shift.","product_video":34795,"feature_benefit_1_new":"Replenishment tasks fire the moment min levels are hit","feature_benefit_2_new":"Picks and replenishments run in parallel, nothing waits","feature_benefit_3_new":"FIFO or Sell By Date stock selection built in","feature_before":"Only one pickface location per product, no way to add more\r\n\r\nStock had to be manually transferred in before picking could start\r\n\r\nReplenishment only ever topped up that single location\r\n\r\nPick tasks all routed to the same location, no rotation","feature_after":"Multiple pickfaces per product, stock spread automatically\r\n\r\nReplenishment task generates once stock drops below the minimum trigger\r\n\r\nPick tasks rotate evenly across all eligible pickfaces\r\n\r\nTops up to a set maximum, in full storage units if required","feature_product_video_1_new":"https:\/\/youtu.be\/EJrz2IUFPLM","feature_product_video_image_1_new":32510,"feature_product_video_1_title_new":"Replenishment that runs alongside your picks<\/span>","feature_product_video_1_description_new":"Continuous Replenishment monitors configured pickfaces in real time and generates a replenishment task automatically the moment stock reaches the minimum trigger. Stock is soft-allocated, so pick tasks are never blocked while replenishment is in progress. Operatives receive clear HHD guidance covering source location, destination, and quantity, with no manual coordination required from supervisors.","feature_result_1_title_new":"No empty pickfaces","feature_result_1_description_new":"Replenishment tasks fire automatically at the minimum trigger, so pickers are directed to stocked locations every time, with no manual checks needed.","feature_result_1_image":34494,"feature_result_2_title_new":"Zero picking delays from replenishment","feature_result_2_description_new":"Soft allocation means pick tasks and replenishment tasks run in parallel, so no pick is ever held up waiting for stock to arrive at the pickface.","feature_result_2_image":34495,"feature_result_3_title_new":"Controlled stock rotation","feature_result_3_description_new":"FIFO and Sell By Date selection rules ensure the correct pallet is always brought forward, with shelf life min\/max rules blocking unpickable stock from entering the pickface.","feature_result_3_image":34496,"feature_result_4_title_new":"Automatic hold and release","feature_result_4_description_new":"Pick tasks placed on hold due to shelf life requirements are released automatically in order once qualifying replenishment stock arrives at the pickface.","feature_result_4_image":34497,"feature_solutions_title_new":"Built for every role on the warehouse floor<\/span>","feature_wth_description_new":"Continuous Replenishment removes the manual overhead of pickface management for operations teams, operatives, and 3PL managers alike. The system handles monitoring, task generation, and stock selection so people can focus on throughput.","feature_solution_title_1_new":"Warehouse Operations Manager","feature_solution_description_1_new":"Set minimum and maximum quantities once per pickface and the system monitors levels, generates tasks, and releases held picks automatically throughout every shift.","feature_solution_image_1_new":32511,"feature_solution_title_2_new":"Warehouse Operative","feature_solution_description_2_new":"Replenishment tasks appear on the HHD with source location, destination, and quantity clearly displayed, removing any guesswork from moving stock forward.","feature_solution_image_2_new":32512,"feature_solution_title_3_new":"3PL Operations Manager","feature_solution_description_3_new":"Configure FIFO or Sell By Date pick rules and shelf life min\/max per product to keep each customer's pickface stocked with only compliant, pickable stock.","feature_solution_image_3_new":32513,"feature_case_study_video_new":"https:\/\/youtu.be\/EJrz2IUFPLM","feature_case_study_video_image_new":32514,"feature_case_study_title_new":"How Continuous Replenishment works in Clarus<\/span>","feature_case_study_description_new":"Each product pickface is configured with a minimum trigger quantity, a maximum quantity, a pick rule (FIFO or Sell By Date), and a Full Storage Units Only setting. While stock remains above the minimum, picking proceeds without interruption and no replenishment task is generated.\r\n\r\nWhen a completed or in-progress pick causes pickface stock to reach or drop below the minimum trigger, Clarus automatically creates a replenishment task. The system selects the appropriate source pallet from racking according to the configured pick rule, checking that the stock meets the product's default shelf life min\/max before it is eligible. Only compliant stock is ever brought forward.\r\n\r\nThe replenishment task is delivered to an available operative via HHD, displaying the source location, the destination pickface, and the quantity to move. The operative collects and transfers the stock; if Full Storage Units Only is set to Yes, only complete pallets are selected. Once the task is completed, the pickface stock level is updated in real time and the location is available for picking immediately.\r\n\r\nThroughout this process, pick tasks are never blocked. Stock is soft-allocated to the pickface, so pickers are directed to that location regardless of whether replenishment is still in progress. If any pick tasks were placed On Hold because the existing pickface stock could not meet shelf life requirements, the system automatically checks and releases them in the order they were held once the new qualifying stock is confirmed at the location.\r\n\r\nMultiple continuous pickfaces can be configured per product, with tasks assigned in the priority order set on the pickface panel, distributing pick volume across locations intelligently.","feature_case_study_button_name_new":"","feature_case_study_link_new":"","feature_faqs_new":"

How do I enable Continuous Replenishment for my operation?<\/h4>\r\nContinuous Replenishment is controlled by the Continuous Pickfaces feature flag, which is enabled per customer subdomain by the Clarus team. Once enabled, pickfaces are configured individually with minimum trigger quantity, maximum quantity, pick rule, and Full Storage Units Only setting via the pickface panel in the WMS.\r\n

Can I configure more than one pickface per product?<\/h4>\r\nYes. Multiple continuous pickfaces can be configured per product. Replenishment tasks are assigned in the priority order defined on the pickface panel, so pick volume is distributed across locations in a controlled sequence.\r\n

How does the system decide which pallet to replenish from?<\/h4>\r\nThe pick rule set on the pickface controls stock selection. FIFO selects the oldest received pallet first; Sell By Date selects the pallet with the shortest remaining shelf life within the product's configured shelf life min\/max range. Only stock meeting those shelf life requirements is eligible for replenishment.\r\n

What happens if a pick task cannot be fulfilled due to shelf life?<\/h4>\r\nThe pick task is placed On Hold automatically. Once qualifying replenishment stock arrives at the pickface and is confirmed, Clarus checks all held tasks and releases them in the order they were placed on hold, oldest first.\r\n

Does replenishment block picking while it is in progress?<\/h4>\r\nNo. Stock is soft-allocated to the pickface, so pick tasks are directed to that location regardless of whether a replenishment task is still being completed. Picks and replenishments run in parallel without blocking each other.\r\n

What is the Full Storage Units Only setting used for?<\/h4>\r\nWhen set to Yes, the system will only generate a replenishment task that moves a complete pallet or storage unit. When set to No, the system will top the pickface up to the maximum quantity regardless of whether that requires a partial quantity. This setting is typically used where racking space or handling constraints make partial moves impractical.","test":"","feature_result_widget_test_":""},"aioseo_notices":[],"aioseo_head":"\n\t\t\n\t\n\t\n\t\n\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t