Stock does not match
Understand why ERP, stores and physical stock stop agreeing.
01 · What is usually happening?
The system says 400 kg. Stores finds 250. Nobody knows where the rest went, and the next purchase decision is based on the wrong number.
Mismatches build up slowly from small gaps: an issue not entered, a rejection not moved, a receipt booked twice.
The question people usually ask“Who made the mistake?”
The more useful question“Which entries are missing, and how do we stop them going missing?”
02 · Common causes
- 01Issues to production entered late or not at all
- 02Rejected material still counted as usable
- 03Receipts entered before inspection
- 04Wrong unit of measure between purchase and issue
- 05Scrap and process loss never recorded
- 06Material moved between locations without an entry
03 · What to check now0 of 7 checked
04 · What good looks like
- 01Every movement has a slip and an entry on the same day.
- 02Rejected and hold stock is kept and booked apart.
- 03Small weekly counts replace one big yearly count.
- 04Differences are investigated, not just adjusted.
- 05One person owns stock accuracy.
05 · Where this connects
This rarely stays in one department
What it can lead to: Wrong purchase decisions and surprise shortages.
Start from a problem
Work flows left to right, top to bottomKEYMost important for manufacturing
These support every part of the business
Problem
Stock does not match
Usually connected to
How it spreads
- Receipt
- Inventory
- Issue to production
- Books
What it can lead to: Wrong orders, surprise shortages and stock you have paid for but cannot find.
lamplamp can compare entries across systems and show where they stop agreeing.
08 · lamp
lamp could keep this moving
lamp is not available yet. These are things it is being built to do.
- lamp could compare receipts, issues and stock entries.
- lamp could point out where the numbers stop agreeing.
- lamp could remind stores of pending entries.
Does your business handle this differently?Tell us what we have missed: a cause, a check, or a better way of handling it.
Suggest an addition