Is your inventory only accurate once a year, and at what cost?

Imagine a warehouse where your inventory data is always accurate, no surprises, no costly shutdowns, and no endless manual counting. Many companies believe there’s a trade-off between effort and precision: either count everything once a year with enormous resources or accept errors creeping in over time. However, with the proper process and technology, this trade-off can be eliminated.

By redesigning how inventory is handled and monitored, accuracy can become an automated, continuous outcome rather than a manual task. This article explores how to shift from periodic counting to process-driven inventory accuracy with Konecranes Agilon.

The inventory accuracy challenge

Many companies invest significant time and resources in counting, yet still fall short. Others maintain high inventory accuracy without heavy counting efforts. What sets them apart? They don’t prioritise counting; they design processes that prevent discrepancies from occurring in the first place.

This mindset shift is fundamental. When you build your operations with high reliability and traceability in mind, manual counting becomes the exception rather than the rule.

Inventory counting method comparison

Where do discrepancies come from?

Discrepancies typically stem from three leading causes:

1. Shrinkage loss due to theft, damage, or administrative error
2. Misplaced items in the wrong bin
3. Scanning errors: wrong items or quantities scanned

Most companies focus on detecting these issues after the fact. Top performers address the causes directly.

Inventory accuracy is a process outcome, not a counting activity.

To improve accuracy, focus on eliminating root causes, rather than just counting errors

This shift requires commitment, but it pays off with reduced labor, real-time data, and confident supply chain decisions.

To improve accuracy, focus on eliminating the root causes of errors, rather than simply counting them after the fact. This shift requires commitment, but it pays off with reduced labour, real-time data, and confident supply chain decisions.

 

Target process: your inventory accuracy checklist

To consistently achieve high accuracy, implement these essential practices:

1. Standardise all labels
2. Enable machine-readable identification (barcodes, QR codes, RFID)
3. Go entirely paperless
4. Use one SKU per bin
5. Scan bin locations during movements
6. Apply zero-stock and low-stock checks
7. Implement continuous plus cycle counting
8. Run a fully integrated WMS

Here is how Konecranes Agilon helps you

Agilon warehouse automation delivers high availability and reliability in demanding environments. It:

• Continuously monitors stock movements with 100% traceability
• Uses machine-readable ID and bin logic to prevent mix-ups
• Offers continuous cycle counting and zero-stock checks
• Provides accurate data for both operations and accounting needs

Ready to move from manual counts to process-driven accuracy?

Let Agilon show you how 100% inventory accuracy can be your everyday reality.