Letdown Replenishment
Pull full quantities from bulk or reserve storage to refill pick locations. Priority-based task assignment ensures critical locations are replenished first, with scan validation at every step.
What is Letdown Replenishment?
Letdown is a replenishment methodology where the full quantity is pulled from a reserve or bulk storage location to refill a pick location. Unlike partial replenishment methods, letdown moves complete pallets or cases in one task—keeping pick faces fully stocked with minimal transactions.
When a pick face runs low or triggers a replenishment threshold, JASCI creates a letdown task. Operators working in the bulk zone see these tasks prioritized by urgency—ensuring critical pick locations are refilled first to prevent stockouts during order fulfillment.
Full Quantity = Efficiency
By moving full quantities, letdown minimizes the number of replenishment trips. One trip to refill a pick face completely is more efficient than multiple partial refills. This is especially important for high-velocity SKUs that burn through inventory quickly.
The letdown workflow is simple: receive task, scan source location, pick full quantity, scan destination, place product. If the source location doesn't have the full quantity, a trouble workflow handles the exception. After each task, the next letdown displays automatically.
Replenishment Methods
JASCI supports multiple replenishment approaches for different scenarios
Letdown
Full quantity from reserve to pick face. One complete pallet/case moved at a time.
Restock Pick
Partial quantity from reserve to pick face. Fills only what's needed.
Restock Putaway
Move excess inventory back to reserve storage after replenishment.
Key Capabilities
Efficient bulk-to-pick replenishment with full validation
Full Quantity Pulls
Letdown pulls the entire quantity from a reserve location to the pick face. No partial moves—complete replenishment in one task.
Priority-Based Assignment
Tasks are assigned by priority. Highest-priority replenishments (critical pick locations) display first to operators.
Work Zone Filtering
Operators select a work zone (e.g., BULK area) to see all open letdown tasks for that zone. Efficient travel paths.
Scan Validation
Location and product scans are validated at every step. Wrong scans trigger immediate errors preventing mistakes.
Trouble Workflow
If the full quantity isn't available at the source location, a trouble process handles the exception.
Continuous Task Flow
After completing one letdown, operators are automatically prompted with the next task. No returning to menu.
Letdown Workflow
Simple, scan-validated process from reserve to pick face
Open Letdown on Mobile
Navigate to the Letdown function on the mobile device. Scan the work zone (e.g., BULK) to see open tasks.
Receive Task Assignment
JASCI displays the highest-priority letdown task: source location, product, and quantity to pick.
Scan Source Location
Travel to the source location and scan the location barcode. Invalid scans show an error.
Pick Full Quantity
Pick the displayed quantity. If full quantity is available, select PICK. If not, enter the trouble workflow.
Scan Destination
Mobile displays the replenishment location (pick face). Travel there and scan to confirm.
Complete & Continue
Place product, inventory updates automatically. If more tasks exist, the next letdown displays.
Operational Impact
Keep pick faces stocked with efficient, accurate replenishment
Ready to Optimize Replenishment?
See how JASCI's Letdown Replenishment keeps pick faces fully stocked with priority-based, scan-validated workflows.