"If it takes you a month to do inventory, and you don't have $50 million dollars in inventory, then something is wrong with your system. We were running about $5 million in inventory, and our crew could inventory the entire place in a single weekend...including running down variances in the counts...and that was with each bin being counted TWICE by separate teams. Inventory was done by two-person teams, with one person counting and the other person writing down the quantity next to the part number that printed out on the bin sheets. Parts that didn't come up on the bin sheets but that were physically in that bin were added to "write-in" sheets. Any part location errors were usually found by running a multiple bin location report".
I agree that if it takes a month to do a small inventory, it is a bad system. In this case it was way beyond bad. I also agree that doing it with groups of 2 people is the fastest way. You'd do one item on a shelf in the warehouse, the next item on the list was in the showroom, the next one was upstairs, the next one was on a different shelf in the warehouse but the number listed was higher so you had to check if there were any in the showroom or hiding somewhere else. Someone stuff just wasn't there but the list showed there was some, so you had to hunt around for 15 minutes looking for it. Then when the boss came back from a sales call, he remembers that he doesn't them it anymore because he gave some samples out a year earlier and never took them off the inventory list.
Could you imagine doing inventory with 5 million in parts, having to run around all over the place 1 item at a time on the inventory list because the list isn't in sync with the parts bins/shelves and you've got over 150 pages of inventory? That's what I had to deal with on a smaller scale and having a couple hundred coffee cans with the lids crammed together on the shelves made it even worse. I'm not exaggerating about how bad his inventory system was and his computer system wasn't much better. He expected you to learn the computer with about 15 minutes of training on and off when he had a couple minutes at a time to show you. His dad even said it was too complicated and he did the books. I think he knows that no one else would want to work under those conditions and that's why he called me. His one employee is going away for 2 weeks and the boss doesn't look into getting some help until 2 days before the guy leaves? That's not too smart if you ask me but that's how he does most things. No advance planning or forward thinking at all. Dave
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