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Process file · Manufacturing Manufacturing

What’s inside: output checking · monitoring

Cycle counts: real shortages get the floor walk

The question this file answersWhy does every stock count end in a spreadsheet argument about which number is right?

Fits: plants where receipts, counts and invoices are reconciled by hand.

Typical day

What the desk looks like today

Typical pattern, not a measured desk; the manufacturing playbook has no published volume for cycle counts. A count sheet says one thing, the ERP book quantity another, the bin a third. Someone exports all three to Excel and rebuilds the story line by line before anyone walks the floor.

What changes

What Monday looks like after

After a count, the stores lead opens a list of the genuine breaks — not a spreadsheet of every line. The walk covers the locations that disagree, not the ones that did not.

Typical, not a measured client result. Every figure here comes from the playbook source named below.

Match

the same three-way build as invoice matching — no published figure for stock counts

Before: a count sheet, a book quantity and a bin disagree, and someone rebuilds the story in Excel. After: in-tolerance lines clear and the genuine breaks arrive with all three numbers; the true shortage still gets a floor walk. No percentage — the three-way figure is about invoices, on the parent file.

No published figure for this desk. The range lives on the parent file: Invoices hand-matched to POs already in the ERP →

How this file is built

No published benchmark covers cycle-count reconciliation. This file borrows the build, not the number, from AP three-way matching (Ardent Partners, 2023) — that figure is about invoices and we do not transfer it. Not a stock-accuracy claim.

What we install

What we put in front of the systems you already run

Your ERP stays — SAP S/4HANA, Dynamics, Infor or the one you run. This is the same three-way checking build as our AP invoice matching, aimed at stock:

  1. count results are read from the sheet or the scanner export
  2. each line is matched to the book quantity and the bin record in the ERP
  3. lines inside your tolerance are cleared; the rest appear on one screen with all three numbers and the gap — and that list is what the floor walk is for.
What stays human — and what this will not do

True shortages. Location chaos. The part that is on a trolley.

Not a stock-accuracy claim.

What can go wrong — and what we do about it

Bin locations that are wrong in the ERP produce "breaks" that are really data errors — the first counts will show more of those than true shortages. Parts on a trolley or in WIP are not in any bin; those lines stay a person's judgement.

What it costs to get there

The path: free 60-second estimate → free 20-minute review → paid audit of this one process (€1.5–3K, typically two weeks) → pilot with your people in the loop (€10–20K, weeks, not quarters). No transformation programme. Prices are public, on the services page →

Scoped in the audit — the playbook has no estimate for this exact desk.

This is about you if…
What does this mean in euros?

That depends on your volumes and wage costs — this page will not invent the number. The free 60-second estimate runs that calculation from your answers, with every multiplier sourced.

Get your free savings estimate 60 seconds · no sales call Or write first → Map a manufacturing process like this one — free, 60 seconds →

Not a named Aperanda client. Process file · Manufacturing.

Short process file. Same build as its parent file; the playbook has no separate volume or benchmark for this desk.

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