What is a good inventory accuracy rate for a manufacturer?

Most supply chain benchmarks target 95% or higher inventory accuracy for manufacturers. Rates below 90% typically generate measurable costs through excess stock, emergency purchasing, and production line stoppages. A 74% accuracy rate, for example, indicates systemic cycle count process failures rather than isolated data entry errors.

Do manufacturers need a new ERP to improve inventory accuracy?

In most cases, no. Inventory accuracy problems in manufacturing are more often caused by flawed cycle count processes, poor warehouse slotting, and inconsistent discrepancy resolution procedures than by the ERP system itself. Yuneva works inside existing systems to fix the counting methodology and operational habits that drive inaccuracy — without requiring an ERP replacement.

How much does low inventory accuracy cost a manufacturer?

A commonly used benchmark is $0.25 in annual carrying cost per dollar of inventory held. A manufacturer holding $4 million in inventory therefore carries approximately $1 million per year in carrying costs — before accounting for emergency purchases to cover stockouts, write-offs of obsolete material, and production downtime caused by phantom inventory.

What does Yuneva do to fix inventory accuracy?

Yuneva audits how a manufacturer's team conducts cycle counts — examining which locations are counted, how frequently, by whom, and what happens when a discrepancy is found. They redesign the cycle count process, implement slotting discipline, and introduce procedural changes built around the client's actual warehouse floor. Their mobile counting tool, CountIt, integrates with existing ERP and WMS platforms.

What is CountIt and how does it work?

CountIt is a mobile inventory counting tool developed by Yuneva. It is designed to sit on top of an existing ERP or warehouse management system without requiring replacement or major integration work. CountIt guides warehouse teams through structured cycle counts, captures discrepancy data, and helps managers identify accuracy trends by location, product class, and time period. More information is available at www.count-inventory.com.

Inventory Accuracy for Manufacturers: Start in the Warehouse

Yuneva Stock Count
Jul 30
2 min read

Manufacturing warehouse improving inventory accuracy through optimized processes and cycle counting.

A plant manager I spoke with last year had the same story I've heard a dozen times. Inventory accuracy sitting around 74%. Excess stock piling up in rack locations nobody was reviewing. Production line stoppages because the system said a component was on hand and it wasn't. His IT team was pushing for a new ERP. His CFO was pushing back. Meanwhile, the warehouse kept running the same broken cycle count process it had been running for three years.

The problem wasn't the software. It was that nobody had looked hard at how counts were actually being done — which locations were getting counted, how often, by whom, and what happened when a discrepancy showed up. That's where Yuneva comes in.

Yuneva is an inventory management consulting company that works specifically with manufacturers. Not retailers, not 3PLs, not distribution centers trying to hit same-day ship times. Manufacturers, where the pain looks different: raw materials mismatched against production orders, finished goods miscounted because the end-of-month push moved pallets before anyone scanned them, and WIP that nobody can reconcile because the process was designed around a system from 2009.

What they do is audit how your team counts, where your accuracy breaks down, and what's causing your excess stock to accumulate. Then they fix it — through better cycle count design, slotting discipline, and the kind of procedural changes that actually stick because they're built around your floor, not a generic best-practice deck. CountIt, their mobile counting tool, sits on top of your existing system. No replacement required.

A 74% accuracy rate costs real money. At roughly $0.25 per dollar of carrying cost, a manufacturer holding $4M in inventory is burning $1M a year just to store it — and that's before you count the write-offs, the emergency purchases, and the line stoppages.

If your inventory problems feel like a people problem or a process problem more than a technology problem, you're probably right. Find out more at www.yuneva.com or see what CountIt does at www.count-inventory.com.

#Yuneva #InventoryManagement #Manufacturing #WarehouseOperations #SupplyChain

Inventory Accuracy for Manufacturers: Start in the Warehouse

Recent Posts

Comments