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Inventory Accuracy
Continual
improvement
By: ____________________
No of Number % with
items with Outside signficant Missing Scale Wrong
Date counted variance Tolerence error Location docs eroor Lagtime identity Other
3-Mar 120 20 10 8.33% 2 1 3 1 2 1
4-Mar 110 12 6 5.45% 1 2 1 2
5-Mar 115 30 4 3.48% 1 2 1
6-Mar 125 21 12 9.60% 2 1 8 1
7-Mar 120 15 6 5.00% 1 2 1 1 1
Totals 590 98 38 6 7 12 5 6 2
% 17% 6% 16% 18% 32% 13% 16% 5%
Common Causes for Errors
• counting procedure/equipment
• untrained personnel
• carelessness
• poor forms design
• poor document control
• inventory adjustments
• lack of transaction discipline
• midnight requisitions
Deciding What to Count
• ABC analysis
• Location counting
• Negative on-hand items
• When order placed
• When order received
• Today’s problems
• Control Group
Deciding How Often to Count
• ABC
• After specified number of
transactions
• What’s possible with staffing level
Oracle Cycle Counting Set Up
Continual
improvement
Research
error
Identify cause
of error
Step 1 – Controlled Test
1. Pick 100 representative parts
2. Divide into 25/day – Mon thru Thur
3. Friday for clean up
4. Begin with accurate count
5. Note and investigate variances
each day
6. Keep track of daily accuracy
percentage (spreadsheet)
Step 1 – Controlled Test
6. Cycle Counter uses checklist to
investigate possible root causes
7. Oracle Transaction Summaries
report will show transactions in
system (go back one week)
8. After finding root cause, correct
inventory record (spreadsheet)
Step 1 – Controlled Test
9. Record of cause, who will fix and
when
10. Keep checking until you’ve
attained 100% accuracy for two or
three weeks (Predictable results)
11. If time available, also check
negative on-hand items
Results of Step 1
• You have begun to establish the
discipline necessary to maintain an
accurate inventory
• You have identified and corrected
most of the errors that are causing
inaccurate inventories
Step 2 – An Expanded Test
1. Expand to a larger number of items
(600 to 700?)
2. Use ABC categories
– A – count bimonthly
– B – count monthly
– C – count quarterly
3. Keep inventory accuracy and cause
records (spreadsheets)
Step 2 – An Expanded Test
4. Example formula for counts
– Counting 4 days/week
– A’s – every 2 weeks (once every 8 days)
• 100 A items = 100/8 = 13 items/day
– B’s – monthly (once every 16 days)
• 200 B items = 200/16 = 13 items/day
– C’s – quarterly (once every 52 days)
• 400 C Items = 400/52 = 8 items day
Step 2 – An Expanded Test
All 600 items can be divided into 34
items/day
In a quarter, all A items will have been
counted 6 times, B items 3 times, C
items once.
5. Continue until you’ve attained 100%
accuracy for two or three weeks
(Predictable results)
Step 3 – Full Cycle Counts
• Once the root causes are identified
and are being dealt with for the
items in the Expanded Test, and the
Cycle Counting procedures have
been reviewed and are in place, the
Cycle Counting program should be
expanded to include all of the
inventory items.
97% + Accuracy
• You can achieve 97%+ accuracy
• If accuracy level maintained long
enough – you may be able to
eliminate periodic physical inventory
counts
Questions?