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Inventory · INV-02

Cycle counting without disrupting stock

Find stock errors early while keeping an auditable trail of count, variance and correction.

Download editable checklist

01 / prepare

Before you start

  • Select locations by risk, ABC class or recent discrepancy; publish the count scope.
  • Pause or timestamp movements for selected locations using the WMS count method.
  • Give counters a blind count sheet where practical.

02 / execute

Procedure

  1. 01

    Confirm location

    Check location ID, stock status and all handling units before counting.

  2. 02

    Count physically

    Count actual units using the correct unit of measure, batch and condition; do not copy the system balance.

  3. 03

    Record first count

    Capture count, counter and timestamp before viewing expected quantity.

  4. 04

    Recount variances

    Use a second person or independent method for differences beyond the site threshold.

  5. 05

    Investigate

    Check pending movements, nearby bins, damaged stock and conversion errors.

  6. 06

    Close

    Approve adjustments where justified, release the location and trend causes by process or item.

03 / exception control

Stop and escalate when

  • Uncontrolled stock movement during count: restart or reconcile to a known cut-off.
  • High-value or repeated variance: escalate before adjustment.
  • Never erase the first count result.

04 / verify

Ready-to-use checklist

Mark each item Pass, Fail or N/A in the downloaded CSV. Record evidence and assign a corrective action for every failure.

  • Scope and movement cut-off set
  • Location and unit of measure checked
  • Blind first count recorded
  • Batch/serial and condition verified
  • Independent recount performed if required
  • Transactions and nearby bins reviewed
  • Adjustment approved and posted once
  • Trend and corrective action logged
Site / shift: ____________________Date: __________Checked by: ____________________Approved by: ____________________

05 / evidence

Keep these records

Count scope, first count, recount, variance investigation, adjustment ID and trend log.

Basis and further reading

  • Based on warehouse process controls and the site-specific approval workflow; adapt to your WMS, products and risk assessment.

This is a working template, not a certification or legal opinion. Local law, site risk assessment, manufacturer instructions and approved procedures take priority. For India-specific licences, start with the warehouse licences guide.