Annual Physical Inventory Across 12 Production Facilities for Fortune 500 Aerospace Manufacturer
Coordinated comprehensive physical inventory count across 12 manufacturing facilities spanning 3 continents, managing plant shutdowns and counting raw materials, work-in-process, and finished goods inventory valued at over $850 million.
Complex Multi-Site Coordination with Minimal Production Disruption
The aerospace manufacturer faced the daunting task of conducting their annual physical inventory across 12 geographically dispersed facilities while minimizing production downtime and maintaining accuracy for financial reporting compliance.
Geographic Complexity
Facilities spread across North America, Europe, and Asia with different time zones, languages, and operational procedures requiring synchronized counting protocols.
Production Shutdown Constraints
Limited shutdown windows due to customer delivery commitments and production schedules, requiring precise timing and rapid execution to minimize revenue impact.
Diverse Inventory Categories
Complex mix of raw materials (titanium, composites, electronics), work-in-process at various production stages, and finished aircraft components requiring specialized counting procedures.
Regulatory Compliance
Strict SOX compliance requirements and audit trail documentation needed for SEC reporting, with zero tolerance for material misstatements in financial reporting.
Coordinated Multi-Site Inventory Execution
We deployed a comprehensive inventory management solution with synchronized counting protocols, advanced technology, and experienced teams across all facilities.
Pre-Count Planning
Developed detailed site-specific count plans with shutdown schedules, team assignments, and cutoff procedures. Conducted pre-count meetings and training sessions for all 180 team members across 12 locations.
Mobile Technology
Deployed handheld scanners with real-time data capture and validation. Integrated with client ERP systems for immediate discrepancy identification and resolution during the count process.
Experienced Teams
Deployed 180 trained inventory specialists with aerospace industry experience. Each team included supervisors, counters, and quality control personnel to ensure accuracy and efficiency.
Quality Control
Implemented multi-level verification with blind recounts on high-value items and statistical sampling. Real-time accuracy monitoring with immediate corrective action for any discrepancies identified.
24/7 Command Center
Established central coordination hub monitoring all 12 sites in real-time. Provided immediate support for issues, standardized procedures across time zones, and ensured consistent execution globally.
Compliance Documentation
Created comprehensive audit trails with timestamped records, variance explanations, and reconciliation documentation. Delivered SOX-compliant reporting package for external auditors and SEC filing.
Exceptional Accuracy with Minimal Disruption
The coordinated inventory count was completed on schedule across all 12 facilities with outstanding accuracy and minimal impact on production operations.
99.7% Accuracy Rate
Achieved exceptional accuracy across 385,000+ line items with variance of only 0.3%, well within acceptable tolerance levels and exceeding client expectations.
Completed 2 Days Early
Finished all counting and reconciliation activities ahead of schedule, allowing production to resume earlier than planned and minimizing revenue impact.
$12.4M in Discrepancies Identified
Discovered and documented inventory variances totaling $12.4 million, enabling proper financial statement adjustments and improved inventory management processes.
Clean Audit Opinion
External auditors provided unqualified opinion with no material weaknesses identified. Comprehensive documentation met all SOX compliance requirements for SEC reporting.
"The team's coordination across our global facilities was exceptional. They completed the most complex inventory count in our company's history with minimal disruption and outstanding accuracy. Their professionalism and expertise were evident throughout the entire process."
Project by the Numbers
Comprehensive inventory count across global operations
Need Expert Inventory Services for Your Manufacturing Operations?
Our experienced teams can handle complex multi-site inventory counts with precision and minimal disruption to your production schedule.
