Last updated on 2024年9月4日

You're facing inventory discrepancies in a fast-paced warehouse. How will you ensure accurate stock counts?

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Managing inventory accurately is vital for the success of any fast-paced warehouse. When faced with discrepancies, it’s essential to implement strategies to ensure stock counts are precise. Inventory discrepancies can lead to significant losses, customer dissatisfaction, and operational inefficiencies. To tackle this challenge, you'll need to employ a combination of best practices, technology, and process improvements. It's about finding the right balance between efficiency and accuracy to keep your warehouse running smoothly.

本文章的要点总结

Cycle counting:

Regular small-scale inventory checks help identify discrepancies without halting operations. This method pinpoints errors quickly, ensuring stock levels are consistently accurate and reliable.
Drone technology:

Utilize automated drones for inventory counts to reduce errors and increase efficiency. They scan and process information quickly, making stocktaking faster and more accurate without closing the warehouse.

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1 Cycle Counting

Cycle counting is a proactive inventory management technique where a small subset of inventory, in specific locations, is counted on a specified day. Unlike traditional physical inventories that disrupt operations, cycle counting can be integrated into daily activities without shutting down the warehouse. By systematically auditing your inventory, you can quickly identify and correct discrepancies, thus maintaining an accurate stock level. Regular cycle counts also help in pinpointing the root causes of inventory errors, allowing you to implement targeted corrective actions.

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Raja Raju

Deputy General Manager @ OTIS Elevator Company Limited, Mumbai | "Strategic Supply Chain Leader | 30+ Years in Global Sourcing, Logistics & Warehouse Management | Expert in Cost Reduction, Vendor Management".
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In my experience, the following will help 1.Regular cycle count and reduce the discrepancies if any. Better accuracy will help to run the warehouse smoothly. 2.Review the Receiving process and barcode if the same is available. Also ensure one part one location for better accuracy. 3.Any value addition like kitting or prepacking will help a lot for easy identification. 4.Warranty returns of parts to be monitored properly and keep the records up-to-date. Ensure the returned parts are stored separately. Space for the returns to be earmarked separately to avoid mixing. 5.Conduct random audits like Bin audit, Put-away audit and also review the work instructions regularly. These will definitely help to improve the accuracy.

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2 Audit Trails

Maintaining a comprehensive audit trail is crucial for tracking inventory movements and identifying where discrepancies occur. This involves documenting every transaction that affects your inventory, from receiving and putaway to picking, packing, and shipping. By keeping detailed records, you can trace any inventory changes back to their source, making it easier to spot errors or inconsistencies. Moreover, an effective audit trail provides accountability, as every stock movement is associated with a user or automated system.

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3 Tech Integration

Leveraging technology, such as warehouse management systems (WMS) and barcode or radio-frequency identification (RFID) scanners, can significantly enhance stock count accuracy. These tools automate data capture and reduce the likelihood of human error during inventory transactions. For instance, using handheld scanners for real-time updates ensures that stock levels are immediately adjusted with each transaction. Integrating technology streamlines processes, providing you with up-to-the-minute inventory data for better decision-making.

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Wolfgang Lehmacher

Board Member @ Wolfgang Lehmacher | Supply Chain, Logistics, Transport
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Manual stocktaking and inventory controls are time-consuming, error-prone and costly. Another challenge is loss of revenue and profit caused by a temporary closure of the warehouse. Drone technology can help through automating warehouse counts. The drones are either remote controlled or fly preprogrammed through warehouse aisles without any human intervention. Sensors capture barcode labels and the data needed, while taking pictures for optimizing storage space and detecting damages and risks. The data is fed into the warehouse management system (WMS) where it is converted into information to detect discrepancies in the inventory as soon as the system reads the data. Drones make stocktaking faster, easier, more accurate, cheaper, and safer.

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Luiz Felipe Batista de Almeida

Gerente de Projetos, Opera??es, Delivery & PMO. Melhoria Contínua | CX | CS | Logística | WMS | TMS | SAP SD & TM | Tecnologia & Transforma??o | Implanta??o de Sistemas, CSC & BPO | Gest?o & Desenvolvimento de Pessoas.
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As tecnologias de integra??o logística, s?o cruciais, as principais aliadas em acuracidade, e velocidade da opera??o. Bons sistemas logísticos sempre suprem toda uma opera??o. Mas, ao mesmo tempo podem ser um problema sem fim caso o sistema seja administrado de forma incorreta, imputs errados de informa??es causam um acúmulo grande e significativo de fretes e informa??es de armazenagem incorretos, e para corrigir demandam tempo é muito servi?o manual. Eu, sempre sugiro bons sistemas WMS e TMS, e existem para todos os tipos de opera??es com investimento que cobre no bolso, o retorno sempre é positivo. E para ter ainda mais acertividade, o ideal é sempre ter um bom keyuser na implanta??o…

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4 Staff Training

Adequate staff training is paramount to maintaining accurate inventory counts. Your team should be well-versed in best practices for handling stock and using any inventory management systems in place. Regular training sessions can help reinforce proper procedures and introduce new techniques or technologies. Ensuring that your staff is knowledgeable and skilled not only minimizes errors but also boosts overall efficiency and productivity within your warehouse operations.

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Alex Markovic

I help your company's spot freight and expedite workflow become more efficient, controlled and insightful ?? with our proprietary platform, Violet Space ?? President of Purple Logistics Inc
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Managing inventory is very process driven. "If this happens then this must happen". Your organization can limit errors in inventory reporting by training your staff closely in best practices and standard operating procedures in relation to inventory. Deciding who to train should not be depended solely on their title. The decision should be based on their involvement in inventory transactions. For example, a machine operator in a manufacturing environment who is the final operator in a process and must test the product for quality determines if it passes or not. But, they also determine how the inventory transaction is handled based on the quality analysis.

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Luiz Felipe Batista de Almeida

Gerente de Projetos, Opera??es, Delivery & PMO. Melhoria Contínua | CX | CS | Logística | WMS | TMS | SAP SD & TM | Tecnologia & Transforma??o | Implanta??o de Sistemas, CSC & BPO | Gest?o & Desenvolvimento de Pessoas.
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A capacita??o é a etapa mais importante de todo o bom processo de uso de uma ferramenta e para ter acertividade no estoque, uma movimenta??o incorreta gera muito retrabalho e divergência de informa??es. O treinamento envolve muita gest?o da mudan?a e comunica??o acertiva, sempre é muito importante ter um ponto focal de conhe?a todo o sistema e controle do armazenamento, essa pessoal precisa ser um usuário chave do sistema WMS e precisa ser bem aberta ao acesso e comunica??o, para que a opera??o o procure sem receios. Tendo isso, é uma boa garantia de que as informa??es do armazém estar?o seguras e sem furos,

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5 Process Review

Conducting regular reviews of your inventory management processes is essential to identify any inefficiencies or areas prone to errors. This might involve reassessing how goods are received, stored, picked, and shipped. By continuously evaluating and refining these processes, you can implement improvements that enhance accuracy and reduce the potential for stock variances. Process optimization is an ongoing task that can lead to significant gains in inventory control and warehouse performance.

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6 Data Analysis

Data analysis plays a critical role in understanding and resolving inventory discrepancies. By analyzing your inventory data, you can uncover patterns and trends that may indicate underlying issues. For example, frequent discrepancies in a particular area might suggest problems with labeling or storage practices. Data-driven insights allow you to make informed decisions about where to focus your efforts for improving stock accuracy and optimizing warehouse operations.

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You're facing inventory discrepancies in a fast-paced warehouse. How will you ensure accurate stock counts?

1

2

3

4

5

6

1 Cycle Counting

2 Audit Trails

3 Tech Integration

4 Staff Training

5 Process Review

6 Data Analysis

Logistics Management

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You're facing inventory discrepancies in a fast-paced warehouse. How will you ensure accurate stock counts?

1

2

3

4

5

6

1 Cycle Counting

2 Audit Trails

3 Tech Integration

4 Staff Training

5 Process Review

6 Data Analysis

Logistics Management

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感谢您的反馈

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