Coordinated multi-site inventory execution delivering 99.7% accuracy across 4.2 million SKUs in 72 hours with zero operational disruption
A leading third-party logistics provider operating 18 distribution centers across the United States, managing inventory for over 200 retail and e-commerce clients. The company handles high-velocity consumer goods, seasonal merchandise, and omnichannel fulfillment operations.
With annual throughput exceeding $2.8 billion in inventory value, the client required simultaneous physical inventory counts across all facilities to meet year-end financial reporting deadlines while maintaining continuous operations for critical clients.
All 18 facilities required synchronized counting to provide a single point-in-time snapshot for consolidated financial reporting, with strict deadline adherence for SEC filing requirements.
Critical clients required uninterrupted fulfillment operations during the count period, necessitating sophisticated zone-based counting methodologies and real-time inventory freezes.
Multiple warehouse management systems across facilities with varying data structures, requiring custom integration protocols and real-time variance reporting capabilities.
SOX compliance mandated comprehensive documentation, segregation of duties, independent verification protocols, and complete audit trail for all count activities and adjustments.
Developed comprehensive project plan with site-specific execution strategies, resource allocation models, and contingency protocols. Conducted pre-count site assessments at all 18 locations to identify operational constraints, high-risk areas, and critical client requirements.
Implemented enterprise-grade mobile counting platform with real-time synchronization, automated variance detection, and integrated WMS connectivity. Custom API integrations enabled seamless data exchange with multiple warehouse management systems.
Implemented sophisticated zone control system allowing continuous operations in non-count areas while maintaining inventory integrity. Dynamic zone scheduling optimized resource utilization and minimized operational impact.
Executed multi-tiered quality control process with independent verification, statistical sampling, and comprehensive audit trail documentation. All procedures designed to meet SOX compliance requirements and external audit standards.
Exceeded industry benchmark of 98.5% with only 12,600 variance items across 4.2M SKUs counted
Identified and documented inventory variances totaling $8.4M, with $6.2M in overages and $2.2M in shortages
All 18 facilities completed within planned 72-hour window, meeting critical financial reporting deadline
Maintained 100% on-time fulfillment for critical clients throughout entire count period
Complete audit trail documentation with no findings during external audit review
Perfect coordination across all facilities providing accurate point-in-time inventory snapshot
"The complexity of coordinating simultaneous inventory counts across 18 facilities while maintaining operations was daunting. The team's meticulous planning, advanced technology, and flawless execution delivered results that exceeded our expectations. The 99.7% accuracy rate and zero operational disruptions were critical to meeting our financial reporting deadlines and maintaining client trust."
Our team specializes in complex, simultaneous inventory projects across multiple locations with zero operational disruption.
