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Successful Cycle Counting While Items Are on Open Whse Picks

  • 1.  Successful Cycle Counting While Items Are on Open Whse Picks

    TOP CONTRIBUTOR
    Posted Sep 09, 2019 11:34 AM
    Hello,

    I wanted to find out how anyone may be handling cycle counting when items being counted may be on an open pick that was physically picked but not yet registered.  We have some time gaps between the time a picker picks an item and the time that the pick gets registered.  We're currently implementing warehouse scanning, so we believe that we will shorten that time gap, but still are interested to hear how others handle this situation other than maybe looking at bin contents or creating an items on open picks report.




    ------------------------------
    Lewis Rosenberg
    IT Manager
    Mars Fishcare
    Chalfont PA
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  • 2.  RE: Successful Cycle Counting While Items Are on Open Whse Picks

    Posted Sep 09, 2019 02:17 PM
    Lewis

    I don't like the fact that I can't "lock" a bin location during a physical inventory, that being said, the only work around I found was using human intervention and telling the pickers that a certain range of bins are off limits and cannot be picked. Granted, reports are run in advance to make sure there aren't any picks are yet to be registered. We do use RF handheld devices specifically for physical inventories. We use tethered readers for shipping. Hopefully another member has a different approach.

    Good Luck!

    ------------------------------
    Alfredo Zelaya
    Sr. Systems Analyst
    Megadyne Americas LLC
    Fairfield NJ
    ------------------------------

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  • 3.  RE: Successful Cycle Counting While Items Are on Open Whse Picks

    TOP CONTRIBUTOR
    Posted Sep 10, 2019 08:53 AM
    Lewis,

    Generally , accounting controls during cycle counting or any real stock inventory taking , requires that you process all open transactions on an item, area, plant or whatever the relevant cycle counting selection is before physically counting it and freezing actual transactions until the cycle count is recorded.

    That's my old school philosophy anyway.

    ------------------------------
    Michael Carr
    VP , Finance
    Philadelphia Scientific LLC
    Montgomeryville PA
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  • 4.  RE: Successful Cycle Counting While Items Are on Open Whse Picks

    TOP CONTRIBUTOR
    Posted Sep 10, 2019 09:10 AM
    The problem is that things are moving too quickly.  If we "freeze" anything we'll either back order someone or we'll be late on a shipment.

    ------------------------------
    Lewis Rosenberg
    IT Manager
    Mars Fishcare
    Chalfont PA
    ------------------------------------------------------------------------
    BCUG/NAVUG All-Star
    BCUG/NAVUG Board of Advisors, Chairperson
    BCUG/NAVUG Programming Committee

    Twitter: @RosenbergL
    LinkedIn: https://www.linkedin.com/in/rosenbergl
    ------------------------------------------------------------------------

    NAVUG/BCUG Summit (navugsummit.com)
    Orlando, FL - October 15-18, 2019

    Come hear me speak:
    GET50 - All About NAV/BC Security
    Friday, October 18, 2019
    9:45 AM - 10:45 AM
    ------------------------------

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  • 5.  RE: Successful Cycle Counting While Items Are on Open Whse Picks

    TOP CONTRIBUTOR
    Posted Sep 10, 2019 03:00 PM
    Lewis, even if you chose and cycle items thst have no open orders for today , this hour or you segregate any that are shipping today and move to another location?

    What's your turnaround time , in days , hours , minutes?

    ------------------------------
    Michael Carr
    VP , Finance
    Philadelphia Scientific LLC
    Montgomeryville PA
    ------------------------------

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  • 6.  RE: Successful Cycle Counting While Items Are on Open Whse Picks

    SILVER CONTRIBUTOR
    Posted Sep 10, 2019 09:46 AM
    We had the same problem.  Our solution was to do our cycle counts first thing in the morning before we start processing picks and moving inventory.  We have a small team and not too many bins to count, so it works out well enough.  If you can't make a time window, maybe specific bin selection instead of random can help.  Choosing bins w/o picks should get most bins over time except for the A item bins where you will need to do the bin contents reconciliation math.

    ------------------------------
    Eric Moe
    Global Supply Chain Manager
    Industrial Revolution
    Tukwila WA
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  • 7.  RE: Successful Cycle Counting While Items Are on Open Whse Picks

    Posted 30 days ago
    Lewis,

    This is a great question and I am interested in the responses.  The options I see are:

    1) Cycle count before picks are generated.

    2) If picks are in flight, identify the bins that happen to have no picks against them via custom report and cycle count those before picks take the inventory.

    3) Another option might be to identify two zones within the warehouse:  Zone A, Zone B.  Pick from Zone A while counting Zone B and vice versa.

    4) Ideally one could cycle count bins with picks in flight against those bins.  We used to have this option prior to NAV when we ran an advanced WMS system which managed this quite elegantly.  With NAV we have a vertical's handheld solution and making inventory adjustments via cycle counting can reduce inventory to the point where the pick can no longer be satisfied.  That's a problem.

    5)  I wonder if the "Block Movement" or "Blocked" settings in Bin Configuration could be leveraged to prevent picks from considering certain bins while they are being cycle counted mid-day?  This presumes one could "catch it" right when the bin does not have picks against it and change the setting to prevent future picks temporarily.

    There are probably other options I'm not thinking about at the moment.

    ------------------------------
    Alex Scheler
    Carma Laboratories, Inc.
    Franklin WI
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  • 8.  RE: Successful Cycle Counting While Items Are on Open Whse Picks

    TOP CONTRIBUTOR
    Posted 30 days ago
    Yes @Alex Scheler.  Our challenge is that we cannot back order an item because it happens to come up in a cycle count.  So that rules out freezing bins.

    We are very close to going live with hand-held scanners. We believe that will help us to be more accurate and much closer to real-time in our transactions.  Hopefully this will be a big enough improvement where we can find a window of time where cycle counting will work.

    Today, with all transactions being manual, an order will be picked and there will be a delay before the pick is entered and registered in NAV.  We also have delays in replenishment moves in the warehouse where inventory will be moved from higher putaway bins to floor-level putpick bins.  (Those higher putaway bins are really putpick bins now, but we cannot physically pick from them until the pickers get someone in the "big" forklift to move the inventory down.  - All kinds of challenges!)

    ------------------------------
    Lewis Rosenberg
    IT Manager
    Mars Fishcare
    Chalfont PA
    ------------------------------------------------------------------------
    BCUG/NAVUG All-Star
    BCUG/NAVUG Board of Advisors, Chairperson
    BCUG/NAVUG Programming Committee

    Twitter: @RosenbergL
    LinkedIn: https://www.linkedin.com/in/rosenbergl
    ------------------------------------------------------------------------

    NAVUG/BCUG Summit (navugsummit.com)
    Orlando, FL - October 15-18, 2019

    Come hear me speak:
    GET50 - All About NAV/BC Security
    Friday, October 18, 2019
    9:45 AM - 10:45 AM
    ------------------------------

    Conference-BCNAVUG_200x200


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