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Job 03 · VMI and storeroom programs

// 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.

Book a proof-of-concept call30 minutes with Rob
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 scansHandheld, sheet or file
Plant and storeroom
Scan date
Scanned by
Program
Bin labelOn handMin and max
Made-up example scan file
Worked out
bin by bin
Draft replenishmentFor your rep
PO or release no.
Contract
Owned or consigned
Bins flagged
Your item no.Order qtyHow it was worked
Made-up example order

// 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

Copies and exports
No handheld, ERP or plant login
01

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.

02

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.

03

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.

04

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.

Vendor-managed bin test termsOwner signs off
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

Bin by bin
Every quantity worked out
On the same 20 to 30 replenishmentsThe order your team shippedThe AI draft
Bin tied to your item and the plant's part numberScored on your binsScored on your bins
Quantity worked out from min, max and pack sizeScored on your binsScored on your bins
Count unit converted to order unitScored on your binsScored on your bins
Contract price and PO, release or preassigned numberScored on your binsScored on your bins
Owned and consigned bins kept apartScored on your binsScored on your bins
Mins and maxes flagged, with the usage behind eachScored on your binsScored on your bins
Bins left for your rep, and whyScored on your binsScored on your bins
No marks yet. Cells stay empty until replenishments from your own plants have been run.Your reviewer scores every row and decides the result.

// 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

Ideas to talk through
Each priced alone
  1. 01

    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.

    Next
  2. 02

    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.

    Then
  3. 03

    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.

    Also open

// 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?
No. It marks a level that doesn't fit the usage in the copies you sent and shows the numbers behind the mark. Your rep and the plant decide whether anything changes, and only your team edits the program file.
Our reps scan with handhelds. Do you connect to them?
No. Send the scan files or exports your system already produces. The test never signs in to a scanner, your ERP or the plant's maintenance system.
Some plants are on consignment. Does that change the test?
Those bins are kept apart. A consigned bin's refill is drafted as a transfer of your own stock and its usage as the billing, priced on the date your program states, while an owned bin's refill is drafted as a sale.
Does anyone from your side go into the plant?
No. Counting, scanning and every storeroom visit stay with your reps and the plant's people. The test sees only the copies you send.
Who should our reviewer be?
The person who runs your storeroom programs, or the rep who knows the biggest plant's bins best. The owner names one, and that reviewer's call settles the test.
Rob Eason

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.

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