Why replenishment failures cost more than brands realise

Your stock is moving. But is the supply keeping up?

01

Replenishment driven by habit, not data.

Distributors reorder based on rep visits or gut feel, not real stock positions and demand signals. Fast movers run out. Slow movers accumulate. The brand carries the cost of both.

02

The PO-to-stock cycle is slow and manual.

Purchase orders created manually, ASNs shared over email, GRNs confirmed on paper. Each step adds days and error. By the time stock lands, the market window has closed.

03

No visibility until stock runs out.

Brands and distributors discover a replenishment failure at the point of stockout, when the damage is already done. No early warning, no automated trigger, no closed loop between secondary demand and primary supply.

What Lighthouse Replenishment delivers

Automated supply planning, from demand signal to stock put-away

Six capabilities that close the loop between secondary demand and primary supply. Replacing manual PO creation, email-based ASN tracking, and reactive restocking with rule-driven automation, real-time pipeline visibility, and AI-powered demand sensing.

Automated PO Generation

Replenishment rules trigger purchase orders automatically based on reorder points, days of stock cover, and sales velocity. No manual calculation, no missed reorders.

Demand-Seeded Planning

Primary replenishment is seeded by real secondary demand: orders, sell-out velocity, and projected consumption from the field. The plan reflects what the market is actually doing.

ASN and GRN Automation

Advance shipment notices generated and sent electronically. GRN confirmed digitally on arrival with discrepancy handling built in. No paper, no reconciliation lag.

Full P2P Cycle Visibility

Every stage of the purchase-to-pay cycle is visible in one view: PO created, sent, confirmed, in transit, received, put away. Brands and distributors see the same real-time status.

Inventory Put-Away Control

Goods received against ASN with QC check, bin location assignment, and automatic FIFO allocation. Batch tracking, expiry management, and stock adjustment handled without manual ledger entries.

AI Stockout Prediction

ML models monitor sell-out velocity and project stockout risk days in advance. Alerts surface to the supply chain team before the gap hits the shelf, with auto-PO recommendations ready for approval.

Platform Capabilities

One automated engine. Every replenishment workflow.

From Market Signal to Purchase Order, Automatically

Rule-driven replenishment that triggers POs based on real stock positions and actual demand, not a fixed calendar or a distributor's phone call.

Replenishment Planner — Live

Live

Active Replenishment Rules

Min Cover: 7 days

All SKUs, all DTs

Active

Velocity Trigger: 120%

Fast movers, auto-PO

Active

Promo Buffer: +30%

Pre-activation stock build

Pending

Auto-POs This Week

DTSKUsStatus

Mehta Agencies6 SKUsSent

Al Falah Dist.3 SKUsPending

Sri Ram Traders4 SKUsDraft

AI Insight

SKU-A12 trending +42% above velocity baseline. Recommend increasing reorder quantity by 25%.

Configurable rules by SKU, DT, territory, and season: minimum cover days, reorder points, and velocity multipliers

POs auto-created and routed for approval based on rules, with manual override available at every step

Secondary demand seeding: actual sell-out data and field order velocity feed directly into replenishment calculations

Promotional buffer rules activated pre-campaign to ensure stock cover through peak demand windows

PO to Stock Put-Away, No Manual Steps

The full primary procurement cycle from purchase order to inventory put-away, automated and visible at every stage for both brand and distributor.

P2P Pipeline — PO #841 · Al Falah Dist.

Live

PO Created — Auto-generated by rules engine

09:14

Approved & Sent to Plant — Supply chain sign-off

11:02

ASN Received — 840 units confirmed, 3 SKUs

14:30

In Transit — ETA tomorrow 10:00

Now

GRN — Pending arrival

—

Put-Away — Pending GRN

—

POs sent electronically to plant or depot with approval workflow and real-time status tracking end to end

ASNs received digitally in DMS with automatic matching against the originating PO and quantity confirmation

GRN process handles saleable, damaged, and discrepancy goods receipts with full audit trail and finance posting

AP, purchase, and STS ledgers updated automatically on GRN confirmation, no manual posting required

Real-Time Stock Across Every Node and Bin

From primary receipt to van load-out, every unit is tracked in real time with full batch, expiry, and location visibility across every distributor depot.

Inventory Overview — Mehta Agencies

Live

Stock by Location

Warehouse A

3,240 units, 18 SKUs

Healthy

Van 07 (Rajesh)

440 units, 3 SKUs loaded

In Market

Bin B-12 (SKU-A12)

Fast mover, FIFO active

Reorder

Batch and Expiry

BatchExpiryQty

B-2024-11Mar 2026840

B-2024-09Jan 2026210

B-2024-07Nov 202560

AI Insight

Bin B-12 hits reorder point in 3 days. Auto-PO scheduled for tomorrow.

Real-time inventory across van, warehouse, and bin locations updated on every transaction

Batch management with FIFO enforcement, expiry tracking, and near-expiry alerts to prevent write-offs

Physical stock count, stock adjustment, damage management, and stock destruction workflows

Market and primary returns handled with full inventory and accounts receivable reconciliation

From Replenishment Data to Supply Chain Decisions

Pre-built supply analytics covering stockout risk, fill rates, cycle times, and demand forecasting, with AI/ML accelerators built in.

Supply Analytics — This Month

Live

Fill Rate Trend, 6 Months

Fill Rate

Key Supply KPIs

Fill Rate

97.4%

Stockout Rate

0.8%

Avg Cycle Time

2.1d

AI Insight

North Zone DTs show 34% shorter cycles after rule automation. South Zone still at 4.8d avg.

Supply KPI dashboard: fill rate, stockout rate, cycle time, days of stock cover, and PO lead time by DT and territory

AI/ML demand forecasting: sell-out velocity, seasonal patterns, and promotional uplift modelled per SKU and DT

Stockout risk scoring: predictive alerts surfaced 3–7 days before projected stockout with auto-PO recommendation

Integrated with XnappBI: replenishment data alongside sell-in, sell-out, and field execution for end-to-end commercial visibility

Enterprise Integration

Replenishment built into the supply chain you already run

Lighthouse Replenishment connects natively to your ERP, DMS, and SFA. The demand signal flows from the field, the PO is triggered automatically, and the stock lands at the right DT without a single manual intervention.

Native DMS Integration

Replenishment rules are driven by live DMS inventory data. Stock positions, sell-out velocity, and warehouse levels feed directly into the planning engine with no data transfer required.

ERP Connectivity

Pre-built connectors for SAP, Oracle, D365, Navision, and BPICS. POs, ASNs, GRNs, and ledger updates sync bidirectionally. No manual posting, no reconciliation gap.

SFA Demand Seeding

Secondary sell-out data from Lighthouse SFA flows directly into replenishment calculations. The plan is always based on what is actually happening at the outlet, not last month's forecast.

What our customers say

Trusted by the world's leading CPG brands

“

Lighthouse 3.0 is technologically robust, enriched with feature enhancements to meet the evolving needs of our sales teams and distribution partners. Its future-ready architecture positions us to respond with agility to emerging market challenges.

Yoginder Grewal, CIO at HCCB

Seamless rollout across 2,200 distributors · Nationwide · Zero disruption

Ready to see it in action?

See the replenishment cycle run automatically from demand signal to stock put-away

Every supply chain is different in structure, lead times, and DT mix. Our team will walk you through a live demo configured around your replenishment rules and market setup.

Request a Demo →

Eliminate Stockouts and Reduce Carrying Cost with Automated Primary Replenishment Planning

Your stock is moving. But is the supply keeping up?

Automated supply planning, from demand signal to stock put-away

One automated engine. Every replenishment workflow.

Replenishment built into the supply chain you already run

Trusted by the world's leading CPG brands

See the replenishment cycle run automatically from demand signal to stock put-away

Solutions

Company

Ground Transport
Solutions

Offices

Eliminate Stockouts and Reduce Carrying Cost with Automated Primary Replenishment Planning

Your stock is moving. But is the supply keeping up?

Automated supply planning, from demand signal to stock put-away

One automated engine. Every replenishment workflow.

Replenishment built into the supply chain you already run

Trusted by the world's leading CPG brands

See the replenishment cycle run automatically from demand signal to stock put-away

Solutions

Company

Ground Transport Solutions

Offices

Ground Transport
Solutions