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Case Study

Wall-to-Wall Inventory of 1.2M Sq Ft Distribution Center

Complete physical inventory of a major retail distribution center with 25,000+ SKUs across multiple product categories, executed during a 3-week operational window with zero disruption to daily operations.

1.2M
Square Feet
25K+
SKUs Counted
3 Weeks
Timeline
Zero
Disruption

Client Challenge

A major retail chain needed a comprehensive wall-to-wall physical inventory of their primary distribution center to reconcile system records and prepare for year-end financial reporting. The facility operates 24/7 with continuous inbound and outbound shipments serving 200+ retail locations.

The client required complete inventory verification across all storage locations, including:

  • High-density pallet racking (40+ feet high)
  • Floor storage and bulk areas
  • Pick modules and case flow racks
  • Returns and damaged goods areas
  • Staging and cross-dock zones

The inventory had to be completed within a 3-week window while maintaining normal operations and meeting strict reporting deadlines.

Project Scope

Facility Size
1.2 million square feet across multiple zones
Inventory Scope
25,000+ SKUs across apparel, home goods, electronics, and seasonal items
Timeline
3-week execution window with ongoing operations
Team Size
45-person counting team with specialized equipment

Our Approach

A comprehensive methodology combining advanced technology, experienced personnel, and meticulous planning to ensure complete inventory verification.

Pre-Count Planning

  • Detailed facility walkthrough and zone mapping
  • WMS data extraction and location validation
  • Coordination with operations for minimal disruption
  • Team assignments and equipment preparation

Count Execution

  • RF scanning with real-time data capture
  • Systematic zone-by-zone progression
  • Blind counts with independent verification
  • Immediate exception flagging and resolution

Reconciliation & Reporting

  • Variance analysis by category and location
  • Root cause identification for discrepancies
  • Comprehensive documentation and audit trail
  • Process improvement recommendations

Results Delivered

Successful completion of comprehensive inventory verification with complete documentation and actionable insights.

On-Time
Completed within 3-week window
Zero
Operational disruption
Complete
Documentation & audit trail
15+
Process improvements identified

Key Outcomes

Operational Excellence

  • All 25,000+ SKUs verified across entire facility
  • Normal shipping and receiving operations maintained throughout
  • No customer service disruptions or delayed shipments
  • Completed within scheduled 3-week timeframe

Business Value

  • Comprehensive variance analysis by product category
  • Detailed reporting for financial statement preparation
  • Identification of process improvement opportunities
  • Enhanced inventory control procedures recommended

Technology Deployed

RF Scanning Devices
Industrial-grade handheld scanners with real-time data transmission
Lift Equipment
Order pickers and reach trucks for high-bay racking access
Inventory Management System
Cloud-based platform for count coordination and variance tracking
Analytics Dashboard
Real-time progress monitoring and exception management

Quality Assurance

Blind Count Methodology
Counters work without system quantities to ensure unbiased results
Independent Verification
Secondary counts performed on high-value and exception items
Exception Management
Immediate flagging and resolution of variances during count
Audit Trail
Complete documentation of all counts, recounts, and adjustments

Need a Wall-to-Wall Inventory Count?

Our experienced team can execute comprehensive physical inventories of any size facility with minimal disruption to your operations.

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