Accuracy CountsSophisticated inventory management software is designed to minimize the risks of tallying inaccurate quantities, but that risk reduction may not happen if the system does not enable manufacturing inventory accuracy. Incorrect inventory quantities can lead to delays in order fulfillment and upset customers. If the data do not match the physical inventory in the warehouse, then it is time to take corrective action.

Achieve Manufacturing Inventory Accuracy

Although there is rarely a quick fix for inaccurate inventory quantities, a multipronged solution may help. Here are five tips to achieve a more accurate count:

1. Document the current workflow process. Work with employees to gain a comprehensive understanding of all steps impacting inventory. Be sure to record the current operations on paper.

2. Develop a strategic workflow process. Define how the processes should work down to the individual task level for each step of the process: purchasing, receiving, stocking, order processing, fulfillment, and shipping. This process should include completing and processing paperwork, entering data through automated scanning techniques (or manually at workstations), and performing any required monitoring checks for inventory.

3. Ensure all employees are properly trained. Set-up customized, periodic training sessions for all employees to review inventory processes and individual responsibilities. By tailoring employee training, new employees can receive more extensive training while more experienced employees receive refreshers as processes change. Test employees on their knowledge and ability to perform expected tasks, and be sure to provide them with constructive feedback.

4. Set realistic goals for inventory accuracy. Identify and report inventory inaccuracies (e.g. improper counting, data entry errors, or lost goods) on a regular basis. Determine the mistakes and calculate the lost profits they cause.

5. Focus on continuous improvement. Regularly review operations to pinpoint weak process areas and identify solutions for reducing errors. Identifying these areas of development will allow for enhancements or new processes as business needs change.

Implement Cycle Counting

Cycle counting involves taking a physical count of a portion of the inventory in the warehouse on a regular basis. Companies can meet their inventory accuracy goals by comparing counts against the inventory levels shown in the inventory management system. By pinpointing inventory discrepancies through cycle counting, firms can determine the cause of accuracy problems and quickly implement the right solutions. There are two types of cycle counting that manufacturers and distributors need to employ in combination:

1. Control group cycle counting.This kind of counting involves selecting a control group made up of a cross-section sample of inventory (including parts and materials), counting the items in the control group, and comparing the total to the inventory management system data. Companies rotate their control groups on a set schedule so that it counts all inventory in the warehouse at least annually. Control group cycle counting should be a weekly process so that companies can more efficiently identify the roots of any problems.

2. Random cycle counting. After fully implementing the control group cycle counting process, businesses should then perform a random cycle counting process. Random cycle counting involves taking a random sample of the inventory to assess conformance to inventory accuracy expectations. The organization then makes an inference of the accuracy of the entire stock.

Does Your Manufacturing Inventory Accuracy Add Up?

If inaccurate inventory quantities are a problem for your manufacturing company, then take corrective steps as soon as possible. Failing to take proactive measures can result in lost customers and sales. CRI’s manufacturing CPAs can help remedy inventory inaccuracies and make sure that your numbers add up.