Inventory accuracy 101: from 92% to 99.98% in 90 days

The leak we found

A client came to us at 92% inventory accuracy. Their oversells were averaging $13K/month, their understocks were averaging another $27K/month in lost orders. Total leak: ~$40K/month. They thought they had a 'theft problem'. They didn't — they had a process problem.

The fix

• Daily cycle counts on top 20% SKUs
• Mandatory scan-in on every receive
• Scan-pick on every order
• Auto-reconcile every 4 hours
• Weekly variance review with floor lead

90 days later: 99.98% accuracy. Leak closed. Same warehouse, same headcount, same software. Just different discipline.