Cycle counting and exceptions
Investigate stock differences and floor problems with controlled counts, corrections and approvals.
- CC-0442 · CYC-2041 1 EA
- CYC-3310 2 EA
- CYC-5107 0.8 KG
- CYC-5140 6 EA
Choose what to count
Configured ABC cadences select locations for recurring counts. Exceptions and shrinkage concerns can add targeted work, and Warehouse Manager can request a one-off count. This supports continuing stock checks without making a claim about replacing the organization’s required physical-count policy.
Inventory Controller coordinates the count and assigns tasks. Each task identifies its location and required item scope. The expected stock snapshot includes license plate, lot, serial, receipt provenance and order ownership, so a difference cannot be hidden by combining unlike positions.
YouStatusAssignedCountingRecount
Protect the comparison
A LocationLocks record freezes stock movements in the counted location while the snapshot, blind count, review and any correction are completed. Picks, put-away, replenishment, packing transfers or other movements touching that location must respect the lock. Other locations can continue working.
The count freezes the complete position and version set for its location. Correction checks that set, including missing or newly appearing identities, and the live lock before posting. Changes at unrelated locations do not invalidate an unchanged locked scope. If the lock expires or the comparison is invalidated, the task requires a recount; a timestamp and a labor log alone cannot make a moving target safe to adjust.
The counter scans the location, containers and tracked items and enters base quantities without seeing the expected amount first. CountResults preserves the original entry and subsequent recounts as separate sequences. Unexpected stock must be identified, not folded into a different lot or serial balance.
Approval conditions
Warehouse Manager: Approve independent Adjustments above threshold or requiring special review
PendingApproval
- ADJ-61413 LCT-140 590
- ADJ-89465 LCT-150 660
- ADJ-20719 LCT-110 90
- ADJ-36834 LCT-110 480
- ADJ-18419 LCT-140 250
ADJ-61413
- Location
- LCT-140
- Item
- ITM-6691
- LotNumber
- L26-7144
- QuantityBefore
- 590
Approval waits for the warehouse manager.
Review variances and recounts
WarehousePolicies defines quantity and percentage tolerances, recount requirements and approval thresholds. Both tolerance tests must pass. A result outside either goes to a different counter. The review compares the evidence and investigates any disagreement before accepting a quantity.
| Situation | Required treatment |
|---|---|
| Expected quantity is zero | Review the absolute difference; do not divide by zero or treat it as no variance |
| Lot, serial or provenance differs | Investigate the exact positions instead of netting them together |
| Count lock or inventory version is stale | Renew the protected comparison and recount |
| Unit cost is missing | Resolve the cost or use the required higher-authority route |
| Stock is found in another location | Use a controlled move where appropriate, rather than offsetting unexplained adjustments |
Inventory Controller confirms supported results and drafts linked adjustments. Policy explicitly permits a requester or counter to confirm their own eligible below-threshold existing-stock correction; that is controller confirmation, not independent approval. Above-threshold, discovered, identity-changing, reserved or order-owned stock and missing or stale cost require independent Warehouse Manager approval. A usable reviewed cost remains mandatory before posting.
Posting creates a signed stock event and retains the source result, reason and approval. The count closes only after its results and corrections are resolved and the location lock can be released. Delivery to the financial inventory system is retried separately from local posting, so one correction cannot become two quantity events.
StatusOpenRoutedInTriage
Raise a problem where it happens
Warehouse Operator, Packer or Receiving Lead can raise an exception with the affected task, receipt, location, plate, item, quantity, severity and useful photographic evidence. Type-based routing gives the issue an operational owner while preserving the original reporter.
Short picks require a recorded shortfall and controlled reservation replacement. Damage holds affected stock and can request a quantity adjustment or quality follow-up. Wrong-item and not-found reports can lead to a correction move or protected count. Overages go to dock review; blocked bins and equipment failures go to the responsible building or floor owner.
StatusOpenPendingApprovalReleasedInProgress
Resolve through controlled work
Shift Supervisor handles floor triage, Inventory Controller investigates stock, Receiving Lead owns dock issues and Warehouse Manager handles building restrictions and higher-authority decisions. Critical severity escalates to Warehouse Manager under the configured routing policy.
The fix remains a traceable count, move, adjustment, disposition or task correction. Closing an exception does not waive a count approval, clear a hold without authority or silently reduce an order’s requested quantity. Resolution records the actor, outcome and linked evidence.
My Cycle Count Tasks, Adjustments Pending Approval and Open Exceptions provide the work queues. Cycle Count Accuracy and Pick Accuracy support investigation. LaborTracking records actual task intervals and units, with operational timestamps suitable for cross-shift review; it complements stock evidence rather than replacing it.
on hand
| Item | Location | License Plate | Lot Number | Serial Number |
|---|---|---|---|---|
| ITM-4871 | LCT-120 | LP-86838 | L26-8833 | INV-45431 |
| ITM-4207 | LCT-120 | LP-43172 | L26-5968 | INV-74718 |
| ITM-7739 | LCT-110 | LP-75864 | L26-7286 | INV-30305 |
| ITM-4992 | LCT-140 | LP-23247 | L26-7236 | INV-18410 |
| ITM-7408 | LCT-150 | LP-56789 | L26-2838 | INV-60717 |
| ITM-5403 | LCT-110 | LP-92944 | L26-4521 | INV-99000 |
Modules
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Building and locations
Map your warehouse and configure the locations, handling rules and equipment that guide each task.
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Receiving
Reconcile deliveries, resolve discrepancies and move received goods into storage.
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Put-away and replenishment
Guide stock into suitable storage and replenish pick faces for upcoming work.
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Inventory and license plates
Locate stock, protect order commitments and trace each quantity through the warehouse.
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Picking
Release prepared waves and guide operators from the right stock into the right order tote.
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Packing
Verify each order's contents and prepare the right carton and carrier label.
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Shipping
Reconcile the staged load, close carrier manifests and record what leaves the warehouse.
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Cycle counting and exceptions
Investigate stock differences and floor problems with controlled counts, corrections and approvals.
Reports
All reportsCycle Count Accuracy
First-count results within both effective quantity and percent tolerance divided by eligible first-count positions, with discovered stock, serialized discrepancies, stale snapshots and no-data cases flagged separately. Show recount rate and signed/absolute variance by like item/BaseUOM; do not sum incompatible units as one quantity.
Roles and permissions
Owns release decisions, physical control policy, material corrections and unresolved operational holds.
Coordinates the shift and may release only the waves covered by a current Warehouse Manager delegation.
Owns dock evidence, receipt acceptance and the close sent to procurement or production.
Executes assigned scan tasks and records actual physical identity and quantity at its permitted warehouse.
Confirms assigned carton or pallet contents, verifies weight and applies the existing confirmed shipping document.
Owns physical-count evidence, eligible small-correction confirmation and investigation of held stock.
Reads permitted warehouse and fulfillment summaries without operational write authority.
Related processes
Dock to stock
Reconcile each delivery and move confirmed stock from the receiving dock into storage.
6 stages · 1 approval
Order to ship
Take an accepted order through reservation, wave release, picking and packing to carrier handover.
6 stages · 2 approvals
End of day manifest close
Match the staged load to carrier documents, close the manifest and confirm handover.
6 stages · 1 approval