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Cycle Counting and Inventory Accuracy--Online/Onsite

Five Weeks To Inventory Record Accuracy

Cycle Counting - Physical Inventories - Error Prevention - Transaction Reduction

Accurate inventory records are attainable. This seminar not only explains how, it guides your team through the design of an inventory accuracy program for your facility. Your team will decide how to:

  • Reduce the cost and frustration of Physical Inventories. 

  • Setup and operate Cycle Counting to eventually replace physical inventories. 

  • Find and eliminate the Root Causes of record errors.

  • Reduce transaction volume to cut cost and reduce new errors.

Program Summary

Format Onsite Kaizen Event Online Who Should Attend?
Time 1-Day 1-2 wks Materials Managers
Warehouse Stockers
Inventory Trackers
Cycle Counters
Cost $3600 (Includes Travel) $2600
Participants 5-40 5-20
Next Step Call us at 816-931-1414

Participants Will Learn...

  • Reducing The Pain With Cycle Counting

  • What Cycle Counting is and why it works

  • The fundamental statistical principles that underlie cycle counting.

  • How to organize, staff and direct your cycle counters.

  • To determine procedures for cycle counting and fixing errors.

  • How to determine the number of cycle counts per day and how many people to assign.

  • How to cope in a 24-7 environment.

  • To measure progress and adjust your program as required.

  • Three ways to measure inventory accuracy and which to use for your situation

  • How To Eliminate Root Causes

  • Why finding the cause of an error is more important than the error.

  • How to find and fix the Root Causes of errors.

  • Is bar-coding right for you?.

  • Easy and Accurate Physical Inventories

  • How to set up an efficient and effective procedure for the physical inventory

  • How to prepare for a physical inventory

  • How to motivate your counters and workers

  • About using count teams for speed and accuracy

  • The advantages and disadvantages of hiring an outside inventory firm

Program Outline



Team Tasks



►Organize Kaizen Team

►Read Chapters 1 & 2

►Preliminary Information


1.0 Inventory Accuracy

What It Is and Why It Matters

How To Measure Accuracy

2.0 Cycle Counting

Introduction To Cycle Counting

Why Cycle Counting works

Designing The Program

Selection Methods

Improving Effectiveness

►Gather Information

►Estimate Error Creation Rate

►Investigate Software Capabilities

►Setup ABC Classes

►Establish Count Tolerances


2.0 Cycle Counting (Continued)

Estimating Resources

Timing And Interference

Cycle Counting Implementation

►Scenarios w/Strategos Estimator

►Estimate Resources

►Design Program


3.0 Process Improvement

Prevention Versus Correction

Root Causes of Inventory Errors

Process Improvement Example

►Identify An Error Source

►Determine Root Causes/Solutions


4.0 Reducing Transaction Volume

Drivers of High Volume

Techniques For Reduction

Transaction Reduction Example

►Prepare Product Process Chart

►ID Transaction Reduction Opportunities


5.0 Physical Inventories

The Annual Inventory

Conducting A Successful Audit

Cards, Count Sheets, Barcodes

Staffing For The Inventory

6.0 Inventory Accuracy Strategies

Combining PI & Cycle Counting

Error Prevention

Organizing The Implementation

►Develop Accuracy Strategy

►Plan Implementation

Theoretic Results

Actual Results

Statistical Sampling

■ ■ ■ ■ ■ ■ ■

Value Stream & Process Mapping

The Strategos Guide To Value Stream and Process Mapping goes  beyond symbols and arrows. In over 163 pages it tells the reader how to do it and what to do with it.

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PUB FEB 2016