Cycle counting
Count fewer products, but count them more often.
Cycle counting spreads physical checks over time. Instead of stopping work to count the entire catalogue, the team verifies a small selection regularly. The method works particularly well when products do not all carry the same risk or move at the same speed.
01
Choose what to count
Start with references where an error has consequences: products that can block activity, fast movers, long supplier lead times or high value. Very stable references can tolerate a lower frequency without degrading everyday purchasing decisions.
A simple classification is often enough. Group A for critical or fast products, B for intermediate references and C for the rest. The classification should change when suppliers, prices or activity change rather than becoming another permanent spreadsheet ritual.
02
Create a small routine
A cycle count needs to be short enough to survive the real calendar. Five minutes each week on one area or category is more useful than a perfect procedure nobody launches after the second month.
Software can suggest products based on the last check and configured frequency. The user enters the physical quantity, then the system records only the correction required against theoretical stock.
03
Read the discrepancies
The objective is not merely to restore the correct number. A recurring discrepancy shows where the process is generating poor data. Ambiguous pack units, shared locations or a consumption action that takes too long are common causes.
Keeping corrections in history makes these patterns visible. A product that is always wrong may need a different workflow, while a stable product can be checked less often and release time for more important work.
04
Connect to replenishment
A physical check creates a reliable base immediately before a purchasing decision. Once quantity is confirmed, threshold, coverage and target stock mean more, especially for products whose last recorded movement is several days old.
Cycle counting therefore complements perpetual inventory. It does not replace daily movements, and movements do not replace physical verification. The two mechanisms check each other, which is healthier than asking the file what it feels like believing today.