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What’s the fastest way to lose a sale? Having your best-selling item out of stock.Inventory replenishment methods, strategies, and models are the behind-the-scenes heroes of any product-based business. They ensure stock availability across locations and keep your shelves from being empty. When done correctly, replenishment helps you stay ahead of the competition by miles.In this guide, we’ll break down the core inventory replenishment strategies, show you how to pick the right one for your business, and walk you through the best models to keep your stock and profits right where they should be.
Before you can optimize anything, you need a game plan for inventory replenishment. This becomes the foundation for determining when to order, how much to order, and why, which is a critical part of effective stock control.
Periodic replenishment refers to the practice of restocking inventory at fixed intervals, such as weekly or monthly, regardless of actual demand. It’s a great starting point for businesses with predictable cycles and tight schedules.
Unlike periodic replenishment, continuous replenishment maintains a constant monitoring of inventory levels in real-time. Once stock dips below a certain point, it triggers restocking based on inventory thresholds automatically.This method is highly responsive because it adjusts to inventory changes in real-time, avoiding delays, stockouts, and disruptions in customer order management.
Push replenishment sends inventory based on forecasts, while pull replenishment relies on actual sales data to determine restocking needs.
You can also blend them. For example, use push to prepare for a product launch and pull to adjust once sales data comes in. A hybrid system works well to replenish stock in line with seasonal trends while still adjusting to real-time demand.
Just-in-Time (JIT) is exactly what it sounds like: inventory arrives right before it’s needed. This minimizes overstock through demand-based ordering.
With vendor-managed inventory, your suppliers are the ones who monitor inventory levels for timely replenishment. This creates smoother supply chain management and reduces guesswork.VMI ensures a supply-aligned approach to replenishment, syncing supplier actions with your inventory needs and sales velocity to support broader supply chain optimization.
Next, we need to choose our replenishment model. This depends on your product type, customer behavior, and operational capabilities. Choose a strategy that aligns replenishment with demand forecasts and data analysis so you avoid overstocking slow movers and understocking best-sellers.To do so, work on the following first:
Start simple. Use one model, track your performance metrics and KPIs, and adjust as you scale.
Now, let’s get into the models to choose from. These models use data-driven insights for order quantities, making restocking more predictable and precise.
EOQ helps you calculate the ideal order size that minimizes both holding and ordering costs. It’s great for stable, predictable demand.Formula: EOQ = √((2 × Demand × Ordering Cost) / Holding Cost)When used effectively, EOQ can significantly enhance your cost management and return on investment (ROI).
Reorder point models are straightforward: they trigger restockingwhen the stock level reaches a minimum threshold. The ROP formula takes into account average demand and supplier lead time.ROP = (Average Daily Usage × Lead Time) + Safety stockDynamic inventory software automatically updates reorder points based on sales velocity and inventory data, so fast-moving items never fall behind. That way, you’ll avoid stockouts while keeping your stock levels lean and efficient.
Many businesses use ABC classification or analytics tools that track item popularity for more accurate restocking. This classification sorts inventory by value. To do so, base your inventory plan on your item’s worth:ClassificationValueRecommended QuantityReplenishment StrategyA-itemsHigh valueLow quantityMonitor closelyB-itemsModerate valueModerate quantityPerform regular reviewsC-itemsLow valueHigh quantityManage in bulk
Safety stock is your insurance against supply delays or demand spikes. It helps maintain quality control and smooth order processing times.To calculate safety stock in the simplest way, use this formula:Safety Stock = (Maximum Daily Usage × Maximum Lead Time) – (Average Daily Usage × Average Lead Time)Keeping a buffer boosts customer satisfaction and avoids you telling your customers that you’re out of stock.
A solid replenishment strategy balances lead times with stock levels, helping you stay agile without overcommitting to inventory. In fact, having real-time inventory systems led to a 25–30% reduction in stockouts, 15–20% fewer overstock incidents, and a 30% increase in customer satisfaction, according to the Journal of Recent Trends in Computer Science and Engineering.Here’s why you should implement your own inventory replenishment strategy:
A proper resource allocation strategy helps you stay stocked, cut costs, and keep customers happy. So, don't just manage your inventory. Optimize it. ShipHero's fulfillment platform offers real-time inventory visibility, predictive stock replenishment, and seamless NetSuite integration to automate your workflows and eliminate costly stockouts. With over $8B in GMV shipped annually and a 99 %+ shipping accuracy rate, we’re the trusted partner for over 6,500 brands.Get a free quote today.
Yes. Demand forecasting is necessary for inventory replenishment because it anticipates future product needs. This enables businesses to align their inventory levels with expected demand, particularly in high-volume or seasonal markets, thereby reducing stockouts and excess inventory.
Yes. Automated replenishment reduces inventory costs by minimizing human error, streamlining decision-making, and preventing overstocking or last-minute orders. Automation leads to leaner operations and consistent stock availability.
Yes. All businesses that sell physical products need a replenishment plan to avoid stockouts or overstocking. While the tools and complexity may differ, a structured approach helps manage inventory effectively across all sizes and industries.
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TikTok Shop is discontinuing "seller shipping" on February 25, 2026, a move that will halt fulfillment for any 3PL using non-integrated legacy technology. ShipHero's WMS is fully integrated and approved to support TikTok Shop’s new logistics requirements, allowing you to generate compliant labels and avoid a total operational lockout. By migrating to ShipHero before the deadline, 3PLs can eliminate onboarding fees and ensure their clients’ businesses remain active and profitable.
Starting February 25, 2026, TikTok Shop is officially discontinuing "seller shipping" (also known as "bring your own label") for all U.S. local sellers.
This means your clients can no longer use their own carrier accounts for TikTok orders.
As their 3PL, you will be unable to generate labels unless your WMS is directly integrated with TikTok’s new ecosystem. To keep your clients' businesses running, you must transition them to TikTok Shop Logistics Services through a verified partner.
ShipHero can keep your 3PL orders flowing from February 25 onwards.
If you are running your warehouse on legacy systems, you are at risk of a complete TikTok Shop lockout. Your fulfillment—and your revenue—will simply stop that day.
TikTok's latest policy creates a massive bottleneck for 3PLs using legacy technology.
To help 3PLs transition quickly and stay compliant, we are waiving all onboarding fees for new customers who join ShipHero before February 25.
There are only 6 approved ERP/WMS providers globally that meet TikTok’s new integration standards. ShipHero WMS is on that list. Most legacy WMS providers are not currently approved. To avoid a total operational blackout for your clients, you must move to a verified partner like ShipHero.
No. Starting February 25, TikTok will discontinue seller shipping. All shipping must go through TikTok Shop Logistics Services.
No. You can still manage fulfillment from your own 3PL warehouse using ShipHero’s direct integration, which pulls the required TikTok labels and logic directly into your existing workflow.
You will lose the ability to generate shipping labels for any TikTok Shop order. This will result in immediate fulfillment backlogs, client dissatisfaction, and potential loss of contracts.
Yes. ShipHero is the only U.S. based WMS currently supporting these requirements, allowing 3PLs to continue shipping without interruption.
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TikTok Shop is introducing mandatory logistics changes that will stop fulfillment for unprepared sellers on February 25, 2026.
ShipHero's WMS is fully integrated and approved to support TikTok Shop’s new logistics requirements, ensuring your orders keep moving without interruption. By switching to ShipHero before the deadline, brands can maintain compliance and eliminate onboarding fees during this transition. Here’s everything brands need to know to continue fulfilling orders.
Starting February 25, 2026, TikTok Shop will discontinue "seller shipping" for all U.S. local sellers. This means you can no longer use your own carrier accounts to generate labels for TikTok orders. To stay compliant and keep selling, brands must transition to TikTok Shop Logistics Services.
Relying on legacy systems like Extensiv, Deposco, or Logiwa puts your business at risk of account suspension and shipping delays that kill customer loyalty.
If your current WMS or 3PL is not integrated with TikTok Shop Logistics Services, you will face a total fulfillment blackout on that date. Failure to adapt to these changes risks shipping delays that kill customer loyalty and can lead to account suspension on the platform.
For brands onboarding on or after February 9, 2026, these restrictions are already in effect.
ShipHero has done the due diligence and has built a direct integration to ensure that merchants can fulfill TikTok Shop orders themselves while remaining fully compliant with TikTok’s new label requirements.
To help brands and 3PLs transition quickly and stay compliant, we are waiving all onboarding fees for new customers who join ShipHero before February 25.
Currently, there are only 6 approved ERP/WMS providers globally that meet TikTok’s new integration standards. ShipHero WMS is on that list. If you are using legacy providers like Extensiv, Deposco, or Logiwa, they are not currently approved to support these specific TikTok Shop requirements. To avoid a total operational blackout, you must move to a verified partner like ShipHero before the deadline.
No. Starting February 25, TikTok will discontinue seller shipping. You must use TikTok Shop Logistics Services.
You can use Fulfilled by TikTok (FBT) to store and ship items through their network, switch to one of the six approved ERP/WMS systems, or use ShipHero's direct integration.
You must use TikTok Shop Logistics Services, but with ShipHero, you can still manage the fulfillment from your own warehouse using TikTok’s required labels and logic.
This connection type will not support the new label requirements. You must switch to a direct TikTok Shop connection within ShipHero to avoid fulfillment interruptions.
Yes. ShipHero is currently the only U.S. based WMS that supports these requirements, allowing our customers to continue shipping without interruption.
Imagine running a warehouse where orders are picked quickly, inventory is accurate, and all operations run smoothly without any errors or delays. Thanks to Artificial Intelligence, this can now become a reality with ease.
AI is transforming warehouse management by enhancing efficiency, intelligence, and the ability to meet the rapid demands of today’s eCommerce-driven market.
ShipHero is pioneering this revolution with its AI-powered warehouse solutions, setting new industry benchmarks. This article explores ShipHero’s AI Picking feature, highlighting how it’s transforming warehouse management and enhancing operational efficiency.
The integration of AI technologies, including machine learning, robotics, and predictive analytics, is revolutionizing warehouse operations, driving significant improvements in efficiency, accuracy, and overall performance. These innovations are optimizing processes across various areas, from inventory management to order fulfillment. Below are the key benefits of AI in warehouse management.
A combination of AI technologies is shaping smarter warehouse systems to help revolutionize warehouse management.
ShipHero has taken AI integration to the next level with its AI Picking feature, designed to significantly improve warehouse efficiency. This feature automates the picking process, reducing the reliance on manual labor and enhancing productivity in ways that were once thought impossible.
Let’s dive deeper into how ShipHero’s AI Picking works and the advantages it offers.
AI Picking optimizes warehouse operations in two key ways:
The AI Picking feature delivers a wide range of benefits:
The transformative power of AI extends far beyond just picking. AI is also revolutionizing other aspects of warehouse management, driving improvements in operational efficiency, inventory management, and safety.
AI automates tasks, reducing errors and increasing speed. Automated sorting and real-time inventory tracking ensure accuracy, while real-time monitoring helps managers adapt and ensure timely deliveries.
AI plays a vital role in maintaining accurate inventory levels. By leveraging predictive analytics, AI can forecast demand and optimize stock levels, helping warehouses avoid both stockouts and overstock situations. This leads to better inventory management and fewer disruptions in supply chains.
AI-driven systems can monitor warehouse conditions to ensure safety and compliance with industry regulations. These systems can analyze warehouse data and predict potential hazards before they occur, proactively reducing risks and ensuring a safer working environment.
AI technologies are playing a transformative role in the supply chain and logistics sectors by improving efficiency, reducing costs, and enhancing decision-making.
These intelligent systems effortlessly manage supply chain processes by using data to optimize operations, predict trends, and automate routine tasks. This ultimately reshapes everything, from how goods are moved to stored and delivered.
The future of warehouse management looks promising with greater automation and efficiency, but future warehouse digitization brings challenges, such as high upfront costs and the need for skilled personnel.
AI-powered drones, autonomous robots, and IoT integration are smart warehouse technologies that are revolutionizing warehouse operations. Drones will deliver goods quickly, while robots automate sorting and transportation, thereby reducing the need for manual labor.
IoT and AI integration will enable real-time monitoring and optimization of operations. Smart technology in warehouses is leading to fully automated systems that are faster, scalable, and need minimal human input.
While AI offers immense benefits, businesses must also consider certain challenges. High initial investments in AI technology, data security concerns, and the need for skilled personnel are just a few of the hurdles that must be addressed.
However, with a strategic approach, companies can eliminate the challenges and embrace AI’s full potential to boost accuracy in picking and improve overall warehouse operations.
AI minimizes error by automating tasks like inventory tracking, order picking, and sorting, ensuring greater accuracy and efficiency.
Yes, AI-driven predictive analytics can predict demand, track inventory levels, and improve supply chain efficiency by forecasting needs with greater accuracy to help businesses stay ahead of trends and market fluctuations.
AI solutions are becoming more cost-effective thanks to cloud-based services and subscription pricing models. These options make AI technology more accessible to small businesses, allowing them to take advantage of its benefits without large upfront costs.
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