Companion site to the book Inventory Accuracy: People, Processes, & Technology     
By David J. Piasecki     

A comprehensive treatment of  Inventory Accuracy and Cycle Counting in distribution, fulfillment, and manufacturing environments.

Inventory accuracy starts with an understanding of the conditions under which errors occur and ends with error-resistant processes, intelligent use of technology, a well-trained and highly motivated workforce, and an ongoing process of continuous improvement. In between, there’s cycle counting, root cause analysis, process evaluation, user interface design, procedures, employee training, accountability, control methods, process checks, audits, exception reporting, transaction techniques, measurement, counting methods, bar codes, RF systems, speech-based technology, light systems, and software.

Inventory Accuracy: People, Processes, & Technology covers all of these topics and more in a comprehensive treatment of the subject of inventory accuracy in distribution, fulfillment, and manufacturing environments. In addition to documenting the standard tools and techniques used to achieve accuracy, the author provides insights as to why many of the standard solutions don’t provide the best results and offers alternative methods. The focus on practical solutions that take into account the sometimes-conflicting priorities that affect accuracy, results in an approach that not only looks good on paper, but more importantly, works in the real world.

Topics Covered Include:

  • Physical inventories
  • Cycle counting
  • Training
  • Audits
  • Backflushing
  • Bar code scanners
  • Portable computers
  • Wearable systems
  • Blind counts
  • Checking methods
  • Confirmation transactions
  • Employee testing
  • Control methods
  • Event-triggered count methods
  • Cycle count options
  • Exception reporting
  • Counting scales
  • Voice-directed tasks
  • Pick-to-light
  • Reconciling count
  • Warehouse management systems
  • Locator systems
  • Negative inventory
  • Non-stock inventory
  • Unit-of-measure conversions
  • Multi-plant processing
  • 24/7 operations
  • Outsourcing
  • WIP tracking
  • Scrap reporting
  • 1D and 2D bar codes
  • Paperless systems
  • Task interleaving
  • ABC stratification
  • Accuracy measurements
  • RFID
  • Allocations
  • Error analysis
  • Advanced shipment notifications
  • Accuracybook01

     ISBN 0972763104

    Format:      Hardcover, 352 pages
Author:       David J. Piasecki
Publisher:  Ops Publishing (March 15, 2003)
ISBN:   0-9727631-0-4

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What you'll learn:

  • The various factors that contribute to making errors.
  • The importance of considering the overall objectives of the company when evaluating processes.
  • How focusing on process changes that make it easier for workers to be accurate can have a significant positive impact on inventory accuracy.
  • Various techniques for improving the human-machine interface.
  • How directed tasks and transaction-by-exception techniques can increase accuracy.
  • The importance of procedures, and what should and should not be included in them.
  • The importance of employee training and how technology can increase the effectiveness of training.
  • The value of process checks and under what circumstances they should be applied.
  • The importance of accountability and methods for communicating and monitoring performance.
  • The benefits of cycle counting.
  • The characteristics of a standard cycle count program.
  • Why a standard cycle program may not be the best method for your operation.
  • Alternatives to the standard cycle count program.
  • How to implement and run a cycle count program.
  • How to evaluate cycle count variances.
  • The pros and cons of blind counts.
  • How counting your inventory sometimes does more harm than good.
  • How to conduct a physical inventory.
  • A better method for conducting tag counts.
  • How to reconcile counts.
  • How to avoid the annual physical inventory.
  • Various methods for measuring accuracy and how to calculate them.
  • Why accuracy measurement is often misleading.
  • How to conduct an accuracy audit.
  • How exception reporting can help to identify errors and monitor processes.
  • How to prevent "lost" inventory from creating problems with planning systems.
  • How to properly utilize counting scales.
  • The benefits of using bar codes.
  • The basics of bar code printing technology.
  • How a programmable bar code scanner using a keyboard-wedge interface can provide a low-cost means of incorporating automated data capture (ADC) into your operation.
  • The pros and cons of hand-held portable computers.
  • The benefits of wearable systems.
  • How speech-based technology (voice-directed, speech recognition) can increase accuracy.
  • How light-directed systems (pick-to-light, put-to-light) can increase accuracy and where they are best applied.
  • What is RFID and how it can be utilized.
  • How to control the costs associated with implementing accuracy-related technologies.
  • What a locator system is and why you probably should be using one.
  • How a warehouse management system (WMS) can increase accuracy.
  • How to best utilize technology to accomplish business objectives.
  • Specific tips on receiving, putaway, returns, order picking, and shipping processes.
  • How to deal with negative inventory balances.
  • Problems associated with multi-plant processing and how to avoid them.
  • How to maintain accuracy when outsourcing manufacturing or distribution operations.
  • How to maintain accuracy and cycle count in a 24/7 environment.
  • How theft occurs and methods to reduce exposure.
  • What WIP (work-in-process) really is and how to maintain accuracy with it.

And much more.