Moved physically. Never moved in the system Your system says you have 48 units of a SKU. Your picker walks to the slot and finds 11. Or a empty bay. Or someone else's product shoved in there from a messy put-away two weeks ago. The order is late, the customer is calling, and your inventory accuracy report from last Tuesday still says 98.6%. That number is the problem. Not because it's lying exactly, but because it's a snapshot of what your last count found, not a reflection o

Counting more often won't help if discrepancies aren't fixed We doubled our cycle count frequency one quarter and our accuracy got worse. Not a little worse. Meaningfully worse. It took a few weeks of digging to understand what had actually happened, and I think about it every time I hear someone say "we just need to count more often." The problem wasn't the counting. It was that we were counting fast, under pressure, in the same slots where our pick errors were highest, with