Rolling Replenishment helps you automatically generate picklists based on what your technicians used from their trucks. This makes it easy to restock trucks daily (or on a schedule) without manually tracking what was used.

What is Rolling Replenishment?

Rolling replenishment is an automation that creates a picklist for a truck based on materials that were deducted from that truck.

For example:

A tech uses 5 units of a material from their truck
That material is deducted from the truck inventory
Rolling Replenishment will generate a picklist to restock those 5 units.

This is designed to help you restock the truck consistently based on real usage.

Once you set it up, Ply automatically generates a pick list for each enrolled truck on your chosen schedule. The warehouse team sees the picklist, pulls the materials, and completes it; the truck stock is restored without anyone having to manually check what was used.

The difference from the Critical Items List

The Critical Items List requires you to check manually and take action. Rolling Replenishment does the checking for you and creates the picklist automatically; your team just needs to fulfill it.

Where to find Rolling Replenishment

Rolling Replenishment is configured from Settings → Automations → Rolling Replenishment

From there, you can:

Connect trucks to Rolling Replenishment
Choose where the truck is replenished from (Source Warehouse)
Set frequency (Daily/Weekly/Monthly/Custom)
Choose how the replenishment is calculated (usage vs. min settings) Usage: Replenishes the net amount used since the last update. It calculates the difference between materials consumed and those already restocked. Min Settings: Replenishes materials whenever their current stock level falls below the defined minimum threshold for this location.

Before you start (important requirements)

To ensure rolling replenishment works correctly:

✅ The technician must have materials in their truck (with stock available)

✅ The technician must be assigned to the truck

✅ Materials must actually be deducted from the truck (usage/transfer to job/etc.)

If the truck has no materials or nothing was deducted, Rolling Replenishment won’t generate anything.

Here are the 3 requirements for a Truck Inventory Log to be generated in Ply:

	🚛 Materials on the Truck	👤 Tech Assigned to the Truck	📦 Stock Actually Deducted
Requirement	The truck must have materials in its stock inventory	The technician must be assigned to the specific truck location in their Ply user profile	Materials must have been used or transferred from the truck
If not met	An empty truck has nothing to track	—	No deductions = no picklist generated

⚠️ Also required for Min Settings strategy

If you choose the min settings strategy, materials must have their minimum quantity configured in their stock location settings. Without a minimum, Ply has nothing to compare against.

Step 1: Add a truck to Rolling Replenishment

Go to Settings → Automations → Rolling Replenishment
Click Add Truck

3. Select the Source Warehouse

This is the warehouse that will replenish the truck

4. Select the Truck you want to connect

Step 2: Choose your settings

Here you will be able to choose between picklist or PO:

This means Ply will generate a picklist automatically for the truck based on the logic you choose.

Or, when you select Create Purchase Order instead of Pick List, Ply will automatically generate a draft PO sent directly to a supplier rather than an internal pick list for warehouse staff.

➡️ Strategy: Usage vs Min Settings

You’ll see two strategy options:

Usage

This generates replenishment picklists based on materials deducted/used from the truck.

Best for:

Daily restocking workflows
Companies that want trucks replenished based on actual usage
Usage: Replenishes the net amount used since the last update. It calculates the difference between materials consumed and those already restocked.
Min/max Settings

This generates replenishment picklists based on minimum stock thresholds.

Best for:

Keeping trucks above a minimum stock level at all times
Restocking “standard truck inventory” regularly
Min Settings: Replenishes materials whenever their current stock level falls below the defined minimum threshold for this location.

Rolling Replenishment Strategies

	📊 Usage Strategy	📐 Min Settings Strategy
How it works	Replenishes the net amount consumed since the last run. Calculates: starting qty − current qty = any already at the minimum level.	Replenishes materials whose current stock has fallen below their set minimum. Restocks back to the minimum level.
Example	Truck starts with 10 AC Filters. Tech uses 5 during the week. Rolling Replenishment creates a picklist for exactly 5 filters — restoring back to 10.	AC Filter minimum = 4. Truck currently has 2. Rolling Replenishment creates a picklist for 2 filters — just enough to bring it back to the minimum of 4.
Best for	Daily restocking after field work	Keeping trucks at a minimum standard load
	Trucks are always restored to their pre-use levels	Works even if no materials were formally "used" via a job
	Accurate to actual usage — no over-ordering	Requires minimum levels set per material at the truck location
	Works best with consistent daily or weekly runs	Good for standard truck loadouts that should never go below a threshold

Step 3: Set the schedule

In the Replenishment Schedule, choose how often Ply should generate the picklist:

Daily
Weekly
Monthly
Custom Frequency

Then select:

Time (when the automation should run)
Schedule Start Date

Once saved, picklists will be generated automatically based on the schedule.

Step 4: Confirm

Click Confirm to save the automation.

Once enabled, your truck will appear in the Rolling Replenishment list with:

Linked location
Frequency
Strategy
Rolling Repl toggle enabled

➡️ Managing existing trucks

Once a truck is connected, you can click the three dots (⋯) to:

➡️ Edit Replenishment Settings

Use this to change:

Schedule (daily/weekly/etc.)
Strategy (Usage/Min Settings)
Start date/time

➡️ Process Now

Once a truck is enrolled, you can trigger rolling replenishment immediately at any time without waiting for the next scheduled run. Open the truck in the Rolling Replenishment list → click the three dots (⋯) → select "Process Now." Confirm the prompt, and a picklist will be generated right away.

➡️ Delete

This removes rolling replenishment from that truck.

➡️ What does “Process Now” do?

When you click Process Now, Ply will immediately generate the rolling replenishment picklist for that truck right away, even if it’s not time for the scheduled run yet.

This is helpful if:

You want to test the setup
You want to generate the picklist early
You don’t want to wait until the scheduled time

You’ll see a confirmation modal like this:

“Are you sure you want to process the rolling replenishment for ‘[Truck Name]’?”

Then you can click:

Process now
Cancel

➡️ Where do the picklists show up?

Rolling replenishment picklists are created automatically in the Picklists tab.

Tip: The picklist name will include the truck/location name, so you can quickly identify where it came from.

➡️ Where do the PO shows up?

Once the schedule runs (or you trigger it manually with Process Now as explained above):

Ply calculates which materials need restocking based on your chosen strategy
A draft PO is automatically created
You can review and edit the PO before sending it to the supplier
Once approved, the PO is sent and the receiving flow begins

🔧So, Edit, Pause, or Remove a Truck

Click the three dots (⋯) next to any enrolled truck in the Rolling Replenishment list

Auto-generated picklists behave exactly like manually created ones; they go through Needs Refill, Ready to Assemble, Waiting for Pickup, and Completed. If the warehouse is out of stock, the picklist will show "Needs Refill," and someone needs to resolve the shortage before it can be fulfilled.

🛠️ Common Issues

❓ “I enabled Rolling Replenishment, but no picklist is being created.”

The most common reasons:

(1) No materials were deducted from the truck: if the tech didn't use or transfer any materials since the last run, there's nothing to replenish.

(2) Truck has no materials in stock: add materials to the truck first.

(3) Minimum settings are chosen, but no minimums are set: configure minimums for materials at the truck location. Use Process Now to test immediately without waiting for the next scheduled run.

❓ “Will I see the picklist immediately after a tech uses materials?”

Not immediately. Rolling replenishment runs on a schedule, so

If a tech uses materials today
The picklist will be created the next time the automation runs (usually the next day).

This is not retroactive.

Need help setting it up?

If you tell us:

which truck(s) you want to enable
what warehouse should replenish them
whether you want Usage or Min Settings
your preferred schedule (daily/weekly)

We can confirm the best setup for your workflow.

✅ Summary

Rolling Replenishment helps you automatically restock trucks by generating picklists on a schedule. You can configure it from: Settings → Automations → Rolling Replenishment

And you can manually trigger it anytime using Process Now.