Cycle counts verify that physical inventory matches system records, but manual counting, transcription, and variance investigation consume significant warehouse time and delay discrepancy resolution.
Automation validates count submissions in real time, compares physical to system counts instantly, and investigates variances by cross-referencing transaction logs and damage reports. The result is faster cycle completion, same-day variance resolution, and higher inventory accuracy.
The full workflow, from trigger to completion.
Automation is triggered on the scheduled cycle count date or when variance threshold is breached. The system retrieves the list of SKUs and locations to count.
Automation creates a structured count task list with SKU, location, and expected quantity. The list is formatted for mobile or handheld device input.
Automation sends a notification to the warehouse team with the count zones, expected timeline, and a link to the mobile count form.
Monitors count submissions from staff or mobile form, validates entries against expected ranges, and flags suspicious counts for manual review.
Automation pulls current balances and compares physical counts to system records, calculating variance percentage for each SKU.
Automation sends a alert to the manager with all items exceeding variance threshold, sorted by impact. High-variance items are flagged for immediate investigation.
Automation generates adjustment entries for approved variances, with variance reason and timestamp. Manager reviews and approves before posting.
Automation sends a final count summary and email with total items counted, variance summary, and next steps. Report includes audit trail and timestamp.
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