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

Cycle Counting:

The Ultimate Cycle Count Resource

How to Cycle Count

Cycle counting can be an important tool in achieving inventory accuracy. Developing the best cycle count strategy for your operation requires a thorough understanding of the characteristics of your operation as well as an understanding of various cycle counting strategies and the inner workings of cycle count programs. Inventory Accuracy: People, Processes, and Technology not only covers the "standard cycle count program" but also introduces alternative methods that may prove to be far more effective in a given environment.

In addition, the book details how the actual computer programs used to perform cycle counts work (or should work) and provides tips on improving the cycle count process. It also covers in detail how to conduct a cycle count, with special considerations given to maintaining productivity and accuracy while cycle counting.

Cycle Counting Topics Covered:

  • The objectives of a cycle count program.
  • Determining a cycle count strategy.
  • Pros and cons of using ABC stratifications for determining cycle count frequency.
  • Other methods for setting cycle count frequency.
  • Combining methods to develop a custom cycle counting strategy.
  • Understanding how quantities are handled in a cycle count program.
  • The importance of transactional control.
  • The reasons for counting a control group.
  • The pros and cons of conducting Blind Counts.
  • Process for conducting recounts.
  • Process for reconciling variances.
  • Understanding the effects of adjustments.
  • How to handle "lost inventory" in a cycle count program.
  • How to cycle count without special programming.
  • How to cycle count in a 24/7 operation.
  • Why you may need to supplement your cycle count process with other verification methods.
  • How to incorporate task interleaving into a cycle count strategy.
  • Various means of measuring accuracy based on the output of your cycle count process.

And More:

Inventory Accuracy: People, Processes, and Technology doesn't stop with the cycle counting process. Though important, cycle counting is only one piece of the accuracy puzzle. Understanding the characteristics of the work environment and the sources of error, developing processes that make accuracy easy, and creating an environment that is conducive to accuracy, are all covered in the book. In addition, detailed descriptions of technologies used and tips on specific processes round out this comprehensive treatment of inventory accuracy in distribution, fulfillment, and manufacturing operations.