Bin Flow

What is Bin Flow?

Bin Flow is an advanced functionality that allows you to configure minimum and maximum levels (MinMax) for specific bins in your warehouse. These special bins, called “flow bins”, are automatically prioritized when ShipEdge processes orders, helping you maintain optimized inventory in strategic locations.

When a flow bin is below the configured minimum, you can use the refill function to automatically move inventory from other source bins to the flow bin, maintaining optimal levels without constant manual intervention.

Activation Requirement

Bin Flow is only available if it’s enabled in warehouse preferences (preferences_wh.bin_flow = 'true'). If you don’t see this functionality, contact the administrator to activate it.

---

Why Use Bin Flow?

Picking Optimization

Flow bins are automatically prioritized during order processing, reducing picking time and improving operational efficiency.

Inventory Level Control

Define minimum and maximum levels for each flow bin. The system alerts you when levels are low and need replenishment.

Automated Refill

Replenish flow bins automatically from recommended source bins. The system calculates the needed quantity and facilitates inventory movement.

Maximum Efficiency

When your inventory rotation is set to “Maximum Efficiency”, ShipEdge attempts to fill orders from flow bins first, optimizing workflow.

Complete Visibility

View all your flow bins in a complete table with account information, SKU, location, current quantities, and configured Min/Max levels.

Centralized Management

Manage all your flow bins from a single view. Add, edit, or delete MinMax configurations easily.

---

How to Access Bin Flow

1. Verify Bin Flow is enabled

   Bin Flow is only available if it’s enabled in warehouse preferences. If you don’t see the option, contact the administrator.

2. Navigate to Bin Flow

   Access /bin_flow.php directly or from the system menu. You can also find it in Warehouse Overview as “MinMax bins”.

3. Explore the view

   The page displays a table with all configured flow bins, including account information, SKU, location, bin, current quantities, and Min/Max levels.

---

How to Use Bin Flow

View the Flow Bins List

The page automatically displays all configured flow bins in a DataTable with the following columns:

• Account: Account associated with the bin
• Sku: Product SKU in the bin
• Description: Product description
• Location: Bin location
• BIN: Bin name
• Current Qty: Current quantity in the bin
• Qty-in-processing: Quantity reserved in orders being processed
• Min: Configured minimum level
• Max: Configured maximum level
• Actions: Buttons to edit or refill

You can filter, search, and sort the table using standard DataTables functions.

Add a New Flow Bin

1. Click the add button

   Look for the button to add a new flow bin (usually “Add” or ”+” in the interface).

2. Search for the bin

   A modal will open. In the “Search Bin” field, start typing the name of the bin you want to configure as a flow bin.

3. Select the bin

   The system will show suggestions as you type. Select the correct bin from the dropdown list.

4. Review the information

   Once selected, the modal will automatically display:

   • Account
   • SKU
   • Description
   • Bin (Bin name)
   • Bin Volume (Bin volume)
   • CurrentQty (Current quantity)

5. Configure Min/Max levels

   Enter the minimum and maximum values:

   • Min: Minimum inventory level (must be greater than 0)
   • Max: Maximum inventory level (must be greater than 0 and greater than or equal to minimum)

6. Save the configuration

   Click “Save” to save. The system will validate that:

   • Min is greater than 0
   • Max is greater than 0
   • Max is greater than or equal to Min

7. Confirm saving

   The modal will close and the table will automatically update showing the new flow bin.

Edit an Existing Flow Bin

1. Find the flow bin

   Search or filter the table to find the flow bin you want to edit.

2. Click edit

   Click the edit button (pencil icon) in the flow bin row.

3. Modify the values

   The modal will open with current information. Modify the Min and/or Max values as needed.

4. Save changes

   Click “Save” to save changes. The system will validate values before saving.

5. Verify the update

   The table will automatically update with the new values.

Delete a Flow Bin

1. Find the flow bin

   Search or filter the table to find the flow bin you want to delete.

2. Click delete

   Click the delete button (usually a trash icon or “X”) in the flow bin row.

3. Confirm deletion

   The system will ask for confirmation with a message “Are you sure?”. Confirm the deletion.

4. Verify deletion

   The flow bin will be deleted and the table will automatically update. The bin will still exist, but will no longer have MinMax configuration.

Refill a Flow Bin

1. Identify bins that need refill

   Look for flow bins where the current quantity is below the configured minimum. These are candidates for refill.

2. Click Refill

   Click the “Refill” button in the row of the flow bin you want to replenish.

3. Review refill information

   A modal will open showing:

   • Account
   • SKU
   • Lot#, Expir, UOM (if applicable)
   • Description
   • Loc / Bin (Current location and bin with quantity)
   • Refill (Calculated quantity needed to reach maximum)
   • Min / Max (Configured levels)
   • Source Loc/Bin (Recommended source bins to move inventory from)

4. Select the source bin

   In the “Source Loc/Bin” dropdown menu, select the bin from which you want to move inventory. The system shows recommended bins that have the same product, lot, UOM, and expiration date.

5. Enter the quantity to move

   In the “Qty Move” field, enter the quantity you want to move from the source bin to the flow bin. The system shows the suggested quantity (difference between maximum and current quantity).

6. Validate restrictions

   The system will validate that:

   • The quantity to move doesn’t exceed the available quantity in the source bin (minus quantity in processing)
   • The total quantity doesn’t exceed the flow bin maximum
   • The SKU is not serialized (cannot move if serialized)

7. Execute the movement

   Click the “Move” button (with exchange icon) to execute the movement.

8. Confirm the result

   The system will process the movement and show a success message or errors if there are problems. The movement will be recorded as an inventory correction type “Move”.

Important about Refill

The refill process physically moves inventory between bins. To undo or make changes after refill, you’ll need to use the Inventory Control application or go to Inventory > Corrections and create a manual movement.

Print Flow Bins Roll

1. Select bins (optional)

   If you want to print only specific bins, you can filter the table. If you want all, leave it without filters.

2. Click print

   Look for the print button or “Print Roll” in the interface.

3. Review the report

   A window will open with the refill report showing bins that need replenishment and suggested quantities.

4. Print or save

   Use browser options to print or save the report as needed.

---

Functionality Details

Min/Max Value Validation

The system validates that:

• Min must be greater than 0
• Max must be greater than 0
• Max must be greater than or equal to Min

If any value doesn’t meet these requirements, you’ll see an error message and must correct it before saving.

Prioritization in Picking

When Bin Flow is enabled and your inventory rotation is set to “Maximum Efficiency”:

1. ShipEdge attempts to fill orders from flow bins first
2. If there’s not enough inventory in flow bins, it uses the rest of the warehouse
3. Flow bins have priority over regular bins during the selection process

This optimizes workflow ensuring the most efficient bins are used first.

Bin Categories

Flow bins have bincategory_id = 5. This special category identifies bins that are configured for Bin Flow and are prioritized during picking.

Refill Calculation

When you request a refill, the system automatically calculates:

Refill = Max - Current Qty

For example:

• If Max = 100 and Current Qty = 46
• Suggested Refill = 100 - 46 = 54 units

You can adjust this quantity according to your needs, but you cannot exceed the flow bin maximum.

Source Bins for Refill

The system searches for source bins that meet these criteria:

• Same ProductID (same product)
• Same lot
• Same UOM (Unit of Measure)
• Same expiration date (expir)
• Allowed bin category (bincategory_id in 2, 0, 4 - not in 1, 3)
• Available quantity greater than 0
• Not the same bin as the flow bin
• Not in the list of used bins (if applicable)

Refill Restrictions

You cannot refill if:

• The SKU is serialized (requires special handling)
• The quantity to move exceeds what’s available in the source bin (minus quantity in processing)
• The total quantity would exceed the flow bin maximum
• There are no available source bins that meet the criteria

---

💡 Best Practices

Configure Realistic Min/Max

Set minimum and maximum levels based on your actual sales volume. Values that are too high waste space; values that are too low require constant refill.

Monitor Flow Bins Regularly

Regularly review which flow bins are below minimum. Set up alerts or review daily to maintain optimal levels.

Use Refill Proactively

Don’t wait for bins to be completely empty. Refill when they’re near minimum to avoid picking interruptions.

Select Strategic Bins

Configure as flow bins those that are in easily accessible locations with high rotation. Optimize picking efficiency.

Coordinate with Inventory Rotation

If you use “Maximum Efficiency” in inventory rotation, Bin Flow works better. Make sure both configurations are aligned.

Document Important Changes

For significant changes in Min/Max levels, document the reason outside the system for future reference and trend analysis.

---

Troubleshooting

I don’t see the Bin Flow option

Problem: I can’t find the Bin Flow page or button.

Solutions:

1. Verify that Bin Flow is enabled in warehouse preferences (preferences_wh.bin_flow = 'true')
2. Contact the administrator to activate the functionality
3. Verify that you have the necessary permissions to access this functionality

I can’t save Min/Max values

Problem: When trying to save, a validation error appears.

Solutions:

1. Verify that Min is greater than 0
2. Verify that Max is greater than 0
3. Verify that Max is greater than or equal to Min
4. Make sure values are valid numbers (not text)
5. Review specific error messages in the modal

Refill doesn’t work

Problem: I can’t refill or an error appears.

Solutions:

1. Verify that there are source bins available with the same product, lot, UOM, and expiration date
2. Make sure the quantity to move doesn’t exceed what’s available in the source bin
3. Verify that the total quantity doesn’t exceed the flow bin maximum
4. If the SKU is serialized, you cannot use automatic refill - use Inventory Control manually
5. Review specific error messages in the refill modal

I don’t see source bins in the dropdown

Problem: The source bins menu is empty or doesn’t show options.

Solutions:

1. Verify that other bins exist with the same product
2. Make sure source bins have the same lot, UOM, and expiration date
3. Verify that source bins have available quantity (greater than 0)
4. Make sure source bins are in allowed categories (not blocked or in restricted categories)
5. Wait a few seconds - the system may take time to load options

Flow bins are not prioritized in picking

Problem: Orders are not using flow bins first.

Solutions:

1. Verify that Bin Flow is enabled in warehouse preferences
2. Verify that your inventory rotation is set to “Maximum Efficiency”
3. Make sure flow bins have available inventory
4. Verify that flow bins are in category 5 (flowbin)
5. Contact the administrator if the problem persists

The suggested refill quantity is incorrect

Problem: The refill calculation doesn’t seem correct.

Solutions:

1. The suggested refill is: Max - Current Qty
2. Verify that Min and Max values are configured correctly
3. Verify that the displayed current quantity is correct
4. You can manually adjust the quantity to move according to your needs

---

Related Links

Next Steps:

• Bin Lists - Manage bin volumes
• Bin Refill - Automated replenishment process
• Bin Overview - Complete bin inventory view
• Assign Bins - Assign and manage bins
• Warehouse Overview - Warehouse overview
• Inventory Control - General inventory control