// Industrial distributors · Vendor-managed bins
Bin counts and scans from the plants you stock, drafted as replenishment orders for your rep.
Your rep walks a plant's storeroom or crib, counts or scans the bins that are low, and someone at the branch turns that into a replenishment order at the plant's contract price. Some plants send their usage instead. In a free AI proof of concept, AI drafts those orders again from copies of 20 to 30 counts and scans your team already filled, with the working behind every quantity shown and any min or max that looks wrong marked for your rep. Your reviewer, the person on your team who knows these programs best, compares each draft with the order that shipped.
- Replenishments tested
- 20 to 30, already shipped
- Orders placed or levels changed
- None
- Plant visits by us
- None
// The one job
From a storeroom walk to an order your rep can approve
The input is rarely tidy: a handheld scan file, a count sheet from the weekly walk, an email from the crib attendant, or a usage export from the plant's maintenance system. Someone at your branch ties each bin to your item and the plant's part number, works out how many to send from its levels and pack size, prices it from the contract and puts it on the right PO or release.
For the test, AI reads copies of those inputs beside the orders your team built and drafts each replenishment: bin, item, quantity with its working, price source and PO reference. A bin whose min or max doesn't fit its usage gets a note for your rep with the numbers behind it. Nothing is ordered, and no level changes.
bin by bin
// The hard parts
Why a bin order is more than a count
The plant's system may be doing the same sum. In SAP, reorder point planning can use the lot-sizing rule SAP calls replenishment up to maximum stock level, the HB indicator in the Lot size field with a figure in the Maximum stock level field: once stock falls below the reorder point, the system proposes enough to reach the max. IBM's Maximo runs a reorder process that creates requisitions or purchase orders for storeroom stock from the reorder point, the economic order quantity, the current balance less reserved and expired stock, and what is on order. Your reviewer should know whether the plant's own reorder still runs on bins you manage. The draft works from your program file's levels and, when you send the plant's records, lists bins where the two disagree.
Counted in one unit, ordered in another. Maximo keeps an item's current balance in its issue unit, and an IBM support note says the reorder process skips an item that has no conversion set between its order unit and its issue unit. Storeroom bins behave the same way: the shelf is counted in eaches or pairs, and the order goes out in boxes, rolls or cases. The draft shows the count unit, the order unit and the conversion it used on every line, and a bin whose count can't be converted goes back to your rep instead of being rounded.
Owned and consigned bins bill differently. Infor's customer consignment guide for Distribution A+ shows the distributor's side: a logical consignment warehouse stands for the customers' sites, tracked by customer and ship-to; stock moves there on a no-charge stock transfer order, which can be generated from minimum and maximum quantities per item; and the customer is billed later on a Customer Consignment Invoice Only order, priced as of the transfer or the invoice. Infor LN's documentation describes both ends: the customer runs the VMI warehouse as a regular warehouse, while the supplier mirrors it as an administrative warehouse because it owns the goods; consumption is recorded by hand or from the customer's call-off message, and the customer may self-bill. The draft keeps owned and consigned bins apart and prices consigned usage on the date your program sets.
Some plants send the data themselves. In X12 EDI, the 852 Product Activity Data transaction lets a trading partner report inventory, sales and other activity so the receiver can plan and ship, or propose, replenishment quantities. Its header has a segment for preassigned purchase order numbers, so a plant can hand out the PO numbers your refills must carry before any order exists. Whatever the format, the draft puts each order on the PO, release or preassigned number your program file names, and holds any order that has none.
What your reviewer watches. Usually the VMI or storeroom program manager, or the rep for the largest plant: each bin mapped to the right item and part number, quantities that follow the levels and pack size, units that convert, contract prices, and consigned bins kept consigned. They also judge the flags, such as a bin that ran to zero between visits, one that hasn't moved in months, or a max smaller than one pack.
// What you send
Copies from your VMI program
20 to 30 shipped replenishments
Each count sheet, scan file or usage export as it reached you, with the order your team built from it. Include a bin that stocked out and one whose level you later changed.
Your program file
For the plants in the sample: each bin's location, your item, the plant's part number, min, max, pack and order units, and whether the stock is owned or consigned.
Contracts and PO rules
The plant's contract prices, the blanket PO, release or preassigned numbers your orders go on, and how consigned usage is billed.
An NDA, and your reps stay on site
The NDA is signed before any file moves. We never sign in to a handheld, your ERP or a plant's maintenance system, and no one from our side visits a plant. Plant names can be masked.
// Before it starts
Settled before the first scan file moves
Levels drive every order a plant will get, so the owner settles who may change them before anything is read.
- Your reviewer
- Named by the owner, often the VMI program manager or the rep for your largest plant
- Level changes
- Who on your team, and who at the plant, approves a new min or max
- Consigned bins
- Which bins are consigned, and which date prices their usage
- Success criteria
- Written and agreed: item match, quantity, units, price, PO and flags
- Sample
- Chosen by your reviewer, with a stockout, a slow bin and a consigned plant in it
- Price
- A range for running replenishment live
- NDA
- Signed before counts, contracts or price files are shared
// How it's judged
Each draft beside the order that shipped
| On the same 20 to 30 replenishments | The order your team shipped | The AI draft |
|---|---|---|
| Bin tied to your item and the plant's part number | Scored on your bins | Scored on your bins |
| Quantity worked out from min, max and pack size | Scored on your bins | Scored on your bins |
| Count unit converted to order unit | Scored on your bins | Scored on your bins |
| Contract price and PO, release or preassigned number | Scored on your bins | Scored on your bins |
| Owned and consigned bins kept apart | Scored on your bins | Scored on your bins |
| Mins and maxes flagged, with the usage behind each | Scored on your bins | Scored on your bins |
| Bins left for your rep, and why | Scored on your bins | Scored on your bins |
// After a yes
About 30 days on new counts and scans
When your reviewer says yes against the success criteria, the job drafts replenishments from new counts, scans and usage files for about 30 days.
Your rep or coordinator approves every order before it is entered or shipped, and every flagged level goes to the person your owner named and to the plant, never straight into a program file.
That month is priced as a fixed figure before you sign; a job after it is decided and priced on its own.
// What could come next
Possible next jobs, ranked
- 01Next
Usage reports for each plant
Monthly usage by bin, with stockouts and slow movers, drafted for your rep to review before the plant's buyer sees it.
- 02Then
Certs with the order
Material certs and certificates of conformance matched to each fastener or fitting line a plant requires them on, before the order leaves your dock.
- 03Also open
Cross-reference quotes
A part a plant wants added to its storeroom matched to an item you carry and drafted as a quote, before it gets a bin.
// One hard limit
It never places an order, changes a min or max, or goes on site.
Drafts land on a review sheet and stay there. Nothing is entered in your ERP, sent to a plant or put on a PO, and no level is changed in your program file or in the plant's system. Counts and scans stay with your reps and the plant's people; no one from our side walks a storeroom. In a live run, a person on your team approves every order and every level change.
Vendor-managed bins are priced as a job of their own: a range up front, then a fixed figure before you sign.
What sets the range: how many plants and bins you manage, how often each is counted or scanned, and how many come in as files rather than count sheets.
// Questions
Questions from VMI program managers
Will it change our mins and maxes?
Our reps scan with handhelds. Do you connect to them?
Some plants are on consignment. Does that change the test?
Does anyone from your side go into the plant?
Who should our reviewer be?

Rob Eason, founder
// Book a call with Rob
Bring one plant's last month of scans.
A 30-minute call with Rob about three things: your company and role, the job you'd test, and roughly how many plants and bins your team refills each month. Keep counts, contracts and price files back until the NDA is signed.
- Co-owned a 60-employee financial services firm and sold his share to his partner.
- Ran GOSO Technologies, a Boston solar company rated 5/5 across 24 Google reviews.
- 5/5 across 83 reviews in HighLevel's Certified Admin Directory.
- 4.3/5 from 6 Google reviews of Massmarket AI.
- Every directory and Google review, critical ones included, is shown word for word at massmarket.ai/reviews.
- Takes every proof-of-concept call himself.
