Warehouse Staging

Warehouse staging is a critical logistics process designed to enhance the efficiency of order fulfillment, inventory management, and overall warehouse operations. It involves temporarily relocating goods from their storage locations to designated staging areas. These areas act as buffer zones between storage and shipping, ensuring that goods are ready and consolidated for shipment. By streamlining this process, businesses can improve inventory control, reduce errors, and optimize their logistics workflows.

           This guide provides detailed, step-by-step instructions to configure warehouse staging effectively, ensuring seamless operations across all stages of order fulfillment and shipping.

    In this article

    1. Staging Setup

      1.1  Enable Bin Staging

      1.2  Configure Location and Bins

      1.3  Set Up Warehouse Worksheet Template

     2. Create Shipment Staging

     3. Verify Stock Movement

     4. Create Warehouse Shipment and Pick

    1. Staging Setup 

    1.1. Enable Bin Staging

        To begin, you must enable the bin staging feature within the warehouse setup.

         Follow these steps:

1. 1. Choose the icon and type "Warehouse Setup."  

   2. Navigate to the "Warehouse Setup" page.

   3. Locate the "Enable Bin Staging" option and ensure it is activated.

This feature allows the system to manage specific bins as staging areas, enabling better control over inventory during the shipment preparation process.

    1.2. Configure Location and Bins

• Choose the icon and search for "Locations" in the system.

• Navigate to the specific Location where bin staging has to be enabled.
• Select the location and Zones where you want to specify the Staging bins.

• Click on the "Bins" Action within the Zone list.

• Click "New" to create a new bin or select an existing one. To know more on Create Bin.

Staging Bin Configuration:

When configuring a staging bin, consider the following parameters:

• • Code: The bin code is a unique identifier assigned to each bin in the warehouse. It should be concise, easily recognizable, and consistent with your warehouse naming conventions. For instance, "STG002" could represent the second staging bin in your warehouse. Always ensure that the bin code is unique to avoid confusion or overlap with other bins in the system. The code also plays a crucial role in system integrations and helps warehouse staff quickly locate the bin during operations.

  • Zone Code: The zone code specifies the area of the warehouse where the bin is located. This helps organize bins into logical groups, such as staging zones, picking zones, or overflow areas. When creating a bin, choose a zone code that accurately reflects its purpose and location. Proper zoning ensures that staff can efficiently navigate the warehouse and access items without delays. It also supports optimized workflows and reduces the time spent searching for inventory.

  • Description: Providing a clear and detailed description of the staging bin enhances its usability. For example, "Staging bin for outbound sales orders" or "Temporary storage for high-priority shipments." This description can assist both new and existing warehouse staff in understanding the bin's purpose. Detailed descriptions also reduce errors and improve communication across the warehouse team.

  • Shipment Staging Bin: Marking a bin as "True" for shipment staging indicates its specific role in the order fulfillment process. This designation ensures that the system recognizes the bin as a key part of staging operations. It also helps streamline shipment workflows by prioritizing items stored in these bins for outbound processing.

  • Exclude from Staging: Enabling this option omits the bin from staging calculations, ensuring that its inventory is not included during shipment preparation. This is useful for bins used for other purposes, such as quarantine, damaged goods, or internal transfers. By excluding such bins, the system focuses on staging-specific bins, improving accuracy in inventory management and staging calculations.

    1.3. Set Up Warehouse Worksheet Template

    Warehouse worksheet templates allow for smooth movement and tracking of inventory during staging:

• Choose the  icon, Navigate to "Warehouse Worksheet Template".

• Select "Movement" , Click on "Names".

• Staging Configuration:

• Name:  Assigning a name to the worksheet is a crucial first step, as it serves as the primary identifier for the configuration. For instance, using a name like "Staging2" can indicate that this is the second staging configuration in your warehouse operations. Ensure the name is both descriptive and unique to avoid confusion, especially in warehouses with multiple worksheets. The name should clearly denote the purpose of the worksheet, such as "Staging2 - Outbound Orders" for clarity. This makes it easier for staff and system users to understand its role during operations. Additionally, a well-chosen name simplifies reporting and troubleshooting, as it provides immediate context.
• Location Code:  The location code is essential to link the worksheet to a specific physical or logical area within your warehouse. Choosing the relevant location code ensures that the worksheet aligns with the staging configuration applied to that location. This helps in maintaining accurate inventory tracking and movement across the warehouse. Verify that the location code matches the intended staging area to avoid operational errors. Use your system’s search functionality to identify and select the appropriate location ID. Proper configuration of the location code ensures smooth coordination between storage, staging, and shipping operations.
• Shipment Staging: Marking the shipment staging option as "True" is critical to designating the worksheet for staging-related processes. This setting enables the system to apply the worksheet specifically to shipment staging operations. When this option is activated, the worksheet will prioritize tasks associated with preparing shipments, such as picking and transferring inventory. This ensures that staging processes are integrated seamlessly into your warehouse’s broader logistics workflows. Configuring this option helps the system differentiate staging bins from regular storage bins, streamlining operations. It also reduces manual interventions, as the system automatically includes or excludes bins based on this setting.
• Bin Code:  The bin code uniquely identifies the bin used for staging within the warehouse. Specifying the correct bin code ensures that the system associates inventory movements with the intended staging area. For example, a code like "STG002" could represent the second staging bin in your warehouse. Align the bin code with your existing bin configuration to prevent mismatches and errors during operations. Clear and logical bin coding simplifies inventory tracking and improves warehouse efficiency. 
• Description: Providing a detailed description for the worksheet clarifies its role and scope, making it easier for users to understand its purpose. For example, a description like "Staging Area for Sales Orders" immediately conveys that the worksheet supports outbound sales operations. Descriptions are particularly useful in complex warehouse environments where multiple worksheets are in use. They aid in training new staff and in troubleshooting, ensuring that everyone is aligned on the worksheet’s function. 

• This configuration ensures that the system can automatically assign items to the appropriate staging bins based on bin content.

• It will get the sales order item based on Bin Content and load it on the staging list

    2. Create Shipment Staging

• Navigate to "Shipment Staging"

• Click on the "New" action.

Fill in the required fields:

• Select "Batch Name", "Shipment Date", "To bin Code", add "Notes" if needed.
• Batch Name: The Batch Name is a unique identifier, This will show the Batches you created in the step 1.3  Set Up Warehouse Worksheet Template  
• Shipment Date: The Shipment Date is a mandatory field that specifies when the shipment is scheduled to leave the warehouse. Accurately entering this date ensures that all downstream processes, such as picking and staging, are aligned with the delivery timeline. 
• To Bin Code: The To Bin Code represents the destination staging bin where items will be moved during shipment preparation. The To Bin Code will automatically field in based on selection of Batch Name. The "To Bin Code" is vital for tracking inventory movement and ensuring that items are ready for dispatch. Always verify the bin code during setup to avoid errors that could disrupt the shipment workflow. 
• Notes:  The Notes field is an optional yet valuable space to record additional information relevant to the shipment batch. Use it to communicate special instructions, such as handling fragile items or coordinating with specific shipping agents. 

• Filter sales orders based on criteria such as:

  • Sales Order No.: Filter by specific sales orders.

  • Customer No.: Filter by specific customers.

  • Shipment Agent Code: Filter by specific agents.

• Shipment Date is Mandatory Field.

• Click "Prepare" action.to generate a list of filtered sales orders. These orders will be displayed with detailed line-level information.
• The system will filter Sales Orders based on specified criteria (Shipment Date, Sales Order, Customer No., Shipping Agent). The filtered sales orders will be displayed at the line level providing detailed information and it will suggest you to move stock "From Bin Code" to "To Bin Code" Which is Staging and based on the availability of stock in FIFO it will pick the stock from the Warehouse BIN.

• Click on the "Print" action. The system will generate a Staging Picklist detailing Items to pick, Bin locations for picking, Quantity to pick.

• Click on "Register". 

• The Register function will transfer stock from the "From Bin Code" bin to the Staging Bin and update inventory levels accordingly. 

• 

     3. Verify Stock Movement

• Navigate to "Registered Warehouse Movement List."

• Review the registered movement sheet to confirm that inventory has been moved from the source bin to the staging bin.

• Click on the "Lines Action" to trace the movement’s source document.

• Opening the source document will provide details about the sales order for which the movement was executed.

   4. Create Warehouse Shipment and Pick

• Create Warehouse Shipment

1. Open the sales order details page.

2. Select the desired sales order.

3. Click on "Create Warehouse Shipment."

• Create Warehouse Pick

1. After creating the shipment, click "Create Warehouse Pick."

2. The system will automatically populate two fields:

   • Staging Bin: Indicates the designated staging area.

   • Recommended Staging Bin: Suggests the most suitable bin based on prior shipments.

• The stock will be picked from the Staging Bin, as the stock was moved with Warehouse Staging functionality. 
• From here, you can print the pick and register.
• Once it gets registered you can post the shipment and Invoice.

• By following these steps, the warehouse operations team can ensure that inventory is efficiently prepared and dispatched, minimizing delays and maximizing accuracy in logistics operations.