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Inventory replenishment

Workflow: inventory replenishment and van stock health

ABC rules, staging, consumption capture, returns discipline, and dispatch-visible readiness.

Quick answer

Quick answer

Replenishment is a loop: classify SKUs, set min/max by route archetype, stage for known jobs, consume on closeout, process returns weekly, and review dead stock.

Workflow overview

Van stock without governance becomes shrink and false stockouts.

Treat returns as operational debt—process them or forecasts lie.

Visual workflow steps

Ordered phases your team can operationalize as SOPs, dispatch rules, and automation triggers.

  1. Step 1

    ABC classification

    Criticality and velocity tiers.

    Different rules for A vs C items.

  2. Step 2

    Set min/max profiles

    Per route archetype, seasonally adjusted.

    Document surge kits with sunset dates.

  3. Step 3

    Stage for tomorrow

    Pick against scheduled high-confidence jobs.

    Exception list for missing picks.

  4. Step 4

    Consume on closeout

    Structured parts usage on work orders.

    Audit samples weekly.

  5. Step 5

    Returns sweep

    Weekly cadence.

    Investigate shrink when variance spikes.

Operational objectives

  • Higher fill at dispatch decision time
  • Cleaner job costing

Recommended KPIs

First-trip complete

Segment by route.

Role responsibilities

Warehouse lead

Owns pick accuracy and staging SLAs.

Technician

Honest consumption and timely returns.

Automation opportunities

  • Low-stock alerts for A SKUs.
  • Dead stock report monthly.

Common failure points

Black-hole vans

Transfers without records distort stock and margin.

Related Equipify features

Related SOPs (Help Center)

Implementation checklist

  1. Route profilesDefine archetypes; assign min/max sets.

FAQ

Warehouse or vans first?
Start with A SKUs that drive callbacks.