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Inventory Accuracy Improvement

$65 Million Industrial Distributor

Improvement Opportunity

  • Company was experiencing unacceptable inventory accuracy levels (> 75%).
  • Cycle counting was labor intensive and ineffective in identifying error causes.
  • Customer service levels were being impacted due to inaccuracies in inventory.

Approach

  • Assess the cycle counting process for effectiveness.
  • Assess operations for sources of error in material, WIP and finished product inventories.
  • Sources of error were identified and systematically addressed to eliminate or minimize impact on inventory accuracy.

Results

  • Many sources of small, but additive errors were identified and eliminated.
  • Inventory accuracy was increased to an acceptable level (<98%).
  • Cycle counting accuracy was improved requiring less time & labor and provided value in error elimination.