Thirty years of warehouse records, reduced to usable methods. No theory. Only what I have counted, corrected, and repeated.
Most inventory failures trace to one of three gaps: unknown velocity classes, skipped cycle counts, or missing audit trails. The sheets that follow close those gaps with numbers I have actually used.
This site is built in the same spirit as Abel Hall's field-guide — raw structure, no decoration. When a method holds for 30 years, it earns its own brutalist treatment.
| Record | Frequency | Trigger |
|---|---|---|
| SKU velocity class | Quarterly | Any SKU crossing 20 % YoY change |
| Physical cycle count | Daily A-items, weekly B, monthly C | Discrepancy > 1 % triggers recount |
| Bin location audit | Monthly | Any pick error logged |