Rant: My inventory count was off by 237 units last quarter

I run a small parts distribution out of my warehouse in Austin, and last quarter our physical count showed 237 more widgets than the system said we had. Turns out, our receiving clerk was double entering inbound shipments and nobody caught it for months. We had to redo the whole count and adjust the ledgers, which cost us around 40 extra man hours. Now I have to set up a new check in process with a simple paper log. Has anyone else dealt with phantom inventory that made you redo your whole ops flow?

2 comments

2 Comments

bettykim1mo ago

Yeah it's wild how one little double step can snowball into a whole nightmare.

casey_ward511mo ago

Always thought it was just clumsy before, but yeah this changed my mind completely.