Warehouse Staging

       

 Warehouse staging is an important part of logistics that helps make order processing faster, keeps inventory organized, and improves the warehouse's overall efficiency. 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. It temporarily moves items to a designated area (a staging bin) before they are officially shipped out or transferred. It acts as a holding step that helps warehouse staff organize and prepare goods in advance.

 Whether fulfilling a sales order or executing a transfer order, staging helps streamline operations by organizing items in advance, reducing picking time, and minimizing errors. Staging is commonly used in Sales Orders, where goods are prepared for customer shipment, and Transfer Orders, where items are moved between different warehouse locations.

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  Warehouse Staging Setup 

      1.3  Configure Location and Bins

      1.4  Create and Manage Warehouse Bins

      1.5  Set Up Warehouse Worksheet Template

     2. Create Shipment Staging

           2.1  Shipment Staging 

           2.2  Create Warehouse Staging Document

           2.3  Prepare Shipment for Staging

           2.4  Clear Staging Lines

           2.5  Print Staging Documents

           2.6  Register Staged Shipments

     3. Verify Stock Movement

     4. Undo a Registered Movement from Staging

           4.1 Undo movement for Selected Lines

           4.2 Undo movement for the whole Sales Order

     5. 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.

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 inventory control during shipment preparation.

 

1.2. Warehouse Staging Setup

1. Warehouse Staging Nos.

• This is where you define the numbering series for warehouse staging. A predefined sequence helps organize and track staging operations.

• Select the number series (e.g., Staging) from the dropdown menu to assign unique numbers to each warehouse staging record.

2. Warehouse Staging Archive

•  A toggle (switch) that enables or disables automatic archiving.

•  Enable this option by turning the switch ON. When enabled, when you create and register a warehouse staging, the system automatically saves those lines as archive entries.

•  It keeps a copy (archive) of what was done in the staging process, which is useful for tracking and auditing past actions.

3. Allow to Delete Sales Order

• A toggle to control if users can delete sales orders after staging.

• Enable if you want users to be able to delete sales orders from staging. Usually kept disabled (OFF) to prevent accidental deletion of sales orders.

4. Allow to Delete Transfer Order

• Similar to the previous option, it applies to transfer orders.

•  Enable if you want users to be able to delete transfer orders from staging. Otherwise, keep it disabled.

• Generally disabled (OFF) to protect data integrity unless there's a strong use case for deletion.

 

    1.3. Configure Location and Bins

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

• You can navigate to the Location where bin staging must be enabled.
• You can 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.

• Click here to know more about Create Bin.

 

1.4  Create and Manage Warehouse Bins

Staging Bin Configuration:

When configuring a staging bin, consider the following parameters:

     1.  Code

• Enter a unique Bin Code for the bin you are creating.

• Use a consistent naming format like STG001, where STG stands for Staging.

• A transparent and standardized code makes it easier for the warehouse team to identify and locate bins quickly. It also helps during system integration and avoids confusion.

      2.  Description

• Enter a Description that explains the purpose of the bin.

• Clear descriptions help all warehouse staff (especially new ones) understand what each bin is used for, reducing misplacement and errors.

     3. Enable Shipment Staging Bin 

• Set the Shipment Staging Bin to True (Yes) if this bin will be used to stage items for outbound shipment.

• Marking the bin for staging ensures that the system includes it in order fulfillment workflows and prioritizes it during shipment preparation.

    4. Decide if the Bin Should Be Excluded from Staging

• Turn on Exclude from Staging if the bin is not used for staging.

• This will exclude the bin from picking the stock from that bin during the staging process.

• This setting ensures that such bins aren’t mistakenly included when the system allocates stock for shipments. It keeps staging operations accurate and clean.

 

    1.5  Set Up Warehouse Worksheet Template

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

• Choose the  icon, and navigate to "Warehouse Worksheet Template".

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

 

Staging Configuration

1. Assign a Name to the Worksheet
   Enter a clear and descriptive name. This name helps users identify the worksheet's purpose and distinguishes it from others in the system.

2. Select the Location Code
   Choose the appropriate location code from the list to link the worksheet to a specific area in the warehouse. This ensures all staging activity is tied to the correct location.

3. Enable Shipment Staging
   Set the shipment staging field to True. This designates the worksheet for shipment-related operations like picking and transferring inventory for outbound orders.

4. Enter the Bin Code
   Input the bin code that will be used for staging, such as STG002. Ensure this code matches your warehouse's bin setup to avoid misplacing inventory.

5. Add a Description
   Write a short description explaining the worksheet's purpose, such as "Staging Area for Sales Orders." This helps users quickly understand what the worksheet is used for.

 

    2. Create Shipment Staging

   2.1 Shipment Staging

• Navigate to "Shipment Staging"

• Click on the "New" action.

 

2.2 Create Warehouse Staging Document

The Warehouse Staging Document page manages staging operations such as preparing and registering outbound sales or transfer orders. Below is a guide to each field and its purpose.

• No. 

  • The warehouse staging number will be automatically assigned based on the number series defined in the Warehouse Staging Setup.
  • Each staging entry receives a unique and sequential number without manual selection.
  • It ensures each staging record is tracked separately in the system.

• Batch Name

  • In the Batch Name field, click the dropdown and select a batch from the list.

  • Choose the batch from the dropdown where the staging should take place.

  • This determines the staging area.

• Shipment Date

  • Select the date when the items are scheduled to be shipped based on sales orders.

  • This helps filter and group orders based on the planned shipment day.

• Location Code

  • The Location Code is automatically filled based on the value assigned to the selected batch name in the worksheet setup.
  • For instance, if STAGING1 is associated with the location WINDFERN, this value is immediately applied to the staging record, ensuring the staging activity is correctly tied to the relevant warehouse location.

• Description 

  • The Description field is also auto-filled based on the description defined for the selected batch name. 

  • This provides clarity about the purpose or type of staging being performed. For example, choosing STAGING1 will populate the Description field with "Staging 1 Template", as specified in the worksheet configuration.

• To Bin Code

  • The To Bin Code is assigned automatically to indicate the destination STAGING area within the warehouse where items should be moved or staged.
  • This value is pre-configured in the system for the selected batch 
• Transaction Type
  • • Select the Transaction type: Sales Order or Transfer Order

      When the transaction type is Sales Order:

      
      
      • Customer No.: Select the customer associated with the order.
      • Sales Order No. Choose the specific sales order you want to stage.
      • Load Type Code: Choose from one of the three options:
        • Truck Load (TL)
        • Less Than a Truck Load (LTL)
        • Parcel
        • Hold Shift + Right Click to select multiple load types (e.g., TL and Parcel together).
      • Shipping Agent Code: You can select the shipping agent responsible for handling the shipment. The system filters relevant sales orders according to the load type chosen and shipping agent.
      • Enter the Sales Order No.
      • If a sales order is selected, the staging module will pick that sales order to move stock. Hence, fields like Customer No. and Sales Order No. Is editable.
      • When Sales Order is selected and Prepare is clicked, the system generates all required pick lines from the sales order and directs them to the staging bin for outbound shipping. This ensures accurate fulfillment and smooth shipment flow.
•  

  • • When the transaction type is Transfer Order: 

    • If a Transfer Order is selected, the staging module will pick Transfer Orders for moving stock; hence, only the Transfer Order Number will be relevant.

    • Transfer Order No. This field is used only when the transaction type is Transfer Order.

    • Customer No. and Sales Order No. are non-editable. These fields remain blank or disabled since they are not relevant to transferring orders.

    • By selecting the Transaction Type as Transfer Order and clicking Prepare, the system automatically filters and stages only the required items based on the setup. This helps streamline the transfer process between warehouse locations while ensuring accurate tracking and handling of goods.

• Create Whse. Shipment / Create Whse. Pick: Enable these toggles if you want the system to automatically create warehouse shipments or pick documents based on the staged orders when the Staging is registered.
• Remarks (optional): Add any additional notes or special handling instructions.
• Error Message: This field displays validation or processing errors, if any occur.

2.3  Prepare Shipment for Staging

After you click Prepare, the system pulls in line items matching your selected criteria (e.g., date, transaction Type, load type, shipping agent). Here’s what happens:

• • You’ll see each item's description, quantities, bin locations, sales order or transfer order numbers, and more.

  • You can also click “Show Source Document” to view the origin of the data (From Sales Order or Transfer Order)

  • When you click Prepare, the system pulls and displays data based on the selected Transaction Type. It filters the information accordingly, so only the records related to that transaction type are shown.

  • It filters and presents the relevant information according to that selection.

Understanding the Staging Lines

After preparation, you’ll see the staging lines populated below. These lines include:

Field	Description
Action Type	Shows what action needs to be performed
Source Document	Indicates the source, like the transfer order
Item No. and Item Description	Details of the item to be transferred
Location Code	The warehouse location
Zone Code	Specific zone within the warehouse
From Bin Code	The current bin where the item is stored
To Bin Code	The staging bin where items should be moved
Quantity	Number of units to be staged
Lot No.	Lot number for tracking

 

2.4  Clear Staging Lines

• This operation clears out the records (lines) of goods temporarily placed in the staging area before they are moved to their next destination, such as storage, shipment, or production.
• What “Clear Staging Lines” does:

1. 1. Deletes or resets staged item records
      It removes the entries of items staged (temporarily placed) in the system.

   2. Frees up space in the staging area
      Useful if the staged items were canceled, returned, or incorrectly placed.

   3. Allows reprocessing
      Once cleared, the same goods can be re-staged correctly with updated info.

• When it is used:

  • Wrong items were staged by mistake.

  • An order was canceled or changed.

 

2.5   Print Staging Documents

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

 

2.6  Register Staged Shipments

• Click on "Register". 

• The Register function transfers stock from the "From Bin Code" bin to the Staging Bin and updates inventory levels accordingly. 

     

3. Verify Stock Movement

• Navigate to "Registered Warehouse Movement List."

• Please 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. Undo a Registered Movement from Staging

The "Undo Movement" function in warehouse staging allows users to reverse a previously registered inventory movement, especially when an error occurs, such as moving the wrong quantity or item. In a typical scenario, an item is moved from a bin to a staging bin as part of internal logistics. Once this movement is registered, it is usually locked from further editing.

However, using the "Undo Movement" feature, the system takes the item back from the staging bin to its original bin, effectively reversing the action. This makes it possible to reopen the movement, correct the quantity or other details, and then register the correct movement again. This process is crucial in warehouse operations because it helps maintain inventory accuracy, reduces manual errors, and allows adjustments without impacting the overall stock integrity.

Note: If a pick has been registered, the system will not allow the stock to be moved from the staging area back to the bin. A Registered pick indicates the stock has already been moved from staging to shipment. Therefore, the system will not permit undoing the staging process if the pick is already registered.

 

4.1 Undo movement for Selected Lines

• Go to Staging.
• Then, Go to Registered Staging Movement.
• In the Registered Movement screen, go to the Actions tab.
• Click on Undo Registered Movement.

 System Prompt

• A confirmation message appears:

  "Do you want to delete the warehouse shipment and pick documents, if they exist, and undo the registered movement WM_000001?"

  This indicates that the system will:

  • Delete the warehouse shipment and pick records (if they exist).

  • Reverse the registered movement.

• Click Yes to proceed.

 

System Behavior

• The lines related to the movement will now appear in red, as seen.

• The system will reverse the action sequence:

  • Originally: Take ➝ Place

  • After undo: Place ➝ Take

  This means the stock is virtually "returned" from the staging bin to its original bin.

Updating the Sales Order

Once the movement has been reversed:

Reopen the Sales Order

• Go to the Sales Order linked to the shipment.

• Click Reopen to make changes.

Edit Quantity or Details

• Modify the quantity or any other necessary field.

Release the Order

• After making the changes, click Release to make it available again for picking and staging.

Note:

• You cannot undo staging if the pick is registered.

• You cannot move the stock back to the bin if the shipment has already been registered.

Re-staging After Undoing a Registered Movement

After Undoing the Movement:

• Once the registered movement is undone, the system returns the inventory to its original bin. You can create a new staging document and reprocess the same items.
• Click here for the steps to create staging, Create Shipment Staging.

 

4.2 Undo movement for the whole Sales Order

Note: Undoing the movement for an entire sales order means reversing the movement for all lines associated with that order. Once undone, you must repeat the staging process for the entire sales order from the beginning.

• Go to Staging
• Then, Go to Registered Staging Movement.
• In the Registered Movement screen, go to the Actions tab.
• Click on Undo All Registered Movement.

• A confirmation message appears.

• Click Yes to proceed.

• When you perform "Undo All Registered Movement" and see that everything is marked in red, it typically indicates that the movements have been reversed in the system and will reverse every registered line.
• If you perform "Undo All Registered Movement", the system will reprocess the quantity for all lines. This means the entire quantity from every registered movement will be returned to the original bin locations, as if the movements never happened.
• After this, the user must repeat the entire staging process again.

 

5. Create Warehouse Shipment and Pick

Note: If the Create Warehouse Shipment and Create Warehouse Pick toggles are turned on, you do not need to follow the manual steps outlined below—the system will automatically create Warehouse Shipment and Warehouse Pick documents.

• Create Warehouse Shipment

  • Open the sales order details page.

  • Select the desired sales order.

  • Click on "Create Warehouse Shipment."     

• Create Warehouse Pick

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

  • 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.