Pick-Face Case Break Replenishment Calculator

Method, formula and assumptions

An empty-face refill accepts floor(capacity/case units) whole cases. After using starting units, round remaining wave demand up to refill-unit cycles. End units = start + replenished units - demand.

Input definitions and supported units

• Maximum units in pick face: Whole-number count, from 1 to 1000000; must be positive.
• Units in each replenishment case: Whole-number count, from 1 to 1000000; must be positive.
• Starting pick-face units: Whole-number count, from 0 to 1000000; zero is supported where the stated method permits it.
• Wave unit demand: Whole-number count, from 0 to 1000000000; zero is supported where the stated method permits it.

Worked example with answer

A 120-unit face with 24-unit cases refills five cases, or 120 units. Starting with 50 units for a 500-unit wave needs four refill cycles and finishes with 30 units.

How to use the results

Refill cycles occur when the face empties, not as simultaneous deposits. This plans case breaking and wave execution, not an inventory reorder trigger.

Results retain full precision internally and display up to four decimal places. Very small nonzero results use scientific notation rather than appearing as zero. Check the labels before comparing values across units.

Limitations and references

Assumes replenishment stock is available immediately and no partial-case top-ups. It does not estimate walking time, replenishment labor or stockout probability.

The method is a self-contained arithmetic, geometric or explicitly stated mathematical model. There are no imported tariffs, empirical presets or equipment specifications; measured values and allowances must come from your own process.

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