FlexSim Warehouse Simulation – Inventory Replenishment Logic for Order Picking (Part 3)

In this video, we complete our warehouse order picking exercise in FlexSim by implementing inventory replenishment logic for rack storage. This is Part 3 of the Order Picking Process series, where we focus on ensuring that SKUs are automatically replenished when inventory levels reach a predefined threshold. If you are new to this series, we recommend watching Part 1 and Part 2 first, where we covered warehouse layout creation, order generation, and detailed process flow logic for picking operations. In this session, you will learn how to monitor SKU inventory levels using lists and partition IDs, trigger replenishment using a Create Token activity, and model inbound replenishment flows using totes, operators, and task sequences. We also demonstrate how to locate rack slots dynamically, project slot positions into global coordinates, and move bulk replenishment items back into the rack with realistic operator movement and delays. By the end of this video, you will have a complete and practical understanding of how to model a realistic warehouse order picking system in FlexSim, including automatic inventory control and replenishment logic. This exercise is ideal for beginners and intermediate users who want hands-on experience with warehouse simulation, process flows, and real-world modeling techniques in FlexSim. 👉 Explore our self-paced FlexSim courses: https://ccsstrategy.com/course/ 📩 Get free simulation ideas and case studies by joining our newsletter: https://commercial-consultancy-services.aweb.page/p/3b19c9cc-8b39-4a53-8526-1fc78f17c577 Thanks for watching! Don’t forget to like, share, and subscribe for more FlexSim tutorials. Happy Simulating! 🎉 #flexsim #warehouse #warehouseSimulation #inventorymanagement #inventory #orderprocessing #processflow #materialhandling #supplychain #digitaltwin #warehouseoperations #discreteeventsimulation #flexsimtips #SimulationModeling #WarehouseAutomation #FlexSimTraining