Standardized locations
A → 12 → 03
DeliverableLocation hierarchy, label specification and bin master.
On the floorGive every movement an unambiguous source and destination.
← Warehouse Design & Optimization
Inventory Accuracy & Control
Align physical stock, location records and warehouse transactions with daily operating discipline.
Stock is difficult to locate, physical quantities disagree with records, or replenishment repeatedly fails. We agree the operating requirements, input data and decision criteria before developing recommendations.
On site in Hyderabad, across Telangana and India. All our services in Hyderabad →
- Location standards & barcode workflows
- Cycle counting & variance investigation
- Receipt, transfer, pick & return controls
- ERP/WMS alignment & replenishment rules
| SKU / select | Description | ERP qty | Physical | Variance | Location | Status |
|---|---|---|---|---|---|---|
| Gear Housing | 120 | 87 | -33 | A-01-01 | Short | |
| Control Module | 56 | 56 | 0 | A-02-01 | Match | |
| Filter Assembly | 230 | 198 | -32 | A-03-01 | Short | |
| Hydraulic Seal | 75 | 76 | +1 | A-04-01 | Over | |
| Mounting Plate | 310 | 265 | -45 | A-05-01 | Short | |
| Sensor Cable | 90 | — | — | A-06-01 | Not counted | |
| Valve body | 58 | 58 | 0 | A-07-01 | Match | |
| Drive coupling | 61 | 56 | -5 | A-08-01 | Short | |
| Bearing kit | 64 | 64 | 0 | A-09-01 | Match | |
| Fastener box | 67 | — | — | A-10-01 | Not counted | |
| Valve body | 70 | 70 | 0 | A-01-02 | Match | |
| Drive coupling | 73 | 73 | 0 | A-02-02 | Match | |
| Bearing kit | 76 | 76 | 0 | A-03-02 | Match | |
| Fastener box | 79 | 79 | 0 | A-04-02 | Match | |
| Valve body | 82 | 77 | -5 | A-05-02 | Short | |
| Drive coupling | 85 | 85 | 0 | A-06-02 | Match | |
| Bearing kit | 88 | 88 | 0 | A-07-02 | Match | |
| Fastener box | 91 | 91 | 0 | A-08-02 | Match | |
| Valve body | 94 | — | — | A-09-02 | Not counted | |
| Drive coupling | 97 | 97 | 0 | A-10-02 | Match | |
| Bearing kit | 100 | 100 | 0 | A-01-03 | Match | |
| Fastener box | 103 | 98 | -5 | A-02-03 | Short | |
| Valve body | 106 | 106 | 0 | A-03-03 | Match | |
| Drive coupling | 109 | 109 | 0 | A-04-03 | Match | |
| Bearing kit | 112 | 112 | 0 | A-05-03 | Match | |
| Fastener box | 115 | 115 | 0 | A-06-03 | Match | |
| Valve body | 118 | 118 | 0 | A-07-03 | Match | |
| Drive coupling | 121 | — | — | A-08-03 | Not counted | |
| Bearing kit | 124 | 119 | -5 | A-09-03 | Short | |
| Fastener box | 127 | 127 | 0 | A-10-03 | Match | |
| Valve body | 130 | 130 | 0 | A-01-04 | Match | |
| Drive coupling | 133 | 133 | 0 | A-02-04 | Match | |
| Bearing kit | 136 | 136 | 0 | A-03-04 | Match | |
| Fastener box | 139 | 139 | 0 | A-04-04 | Match | |
| Valve body | 142 | 142 | 0 | A-05-04 | Match | |
| Drive coupling | 145 | 140 | -5 | A-06-04 | Short | |
| Bearing kit | 148 | — | — | A-07-04 | Not counted | |
| Fastener box | 151 | 151 | 0 | A-08-04 | Match | |
| Valve body | 154 | 154 | 0 | A-09-04 | Match | |
| Drive coupling | 157 | 157 | 0 | A-10-04 | Match |
Quantity matchShortOverNot counted
A-01-01 · BR-4587 · Count 87 · Short
Illustrative static dataset · no ERP connection · not counted ≠ verified match · filtered-out bins are dimmed
Possible cause · Receiving
Incorrect receipt quantity or an incomplete receipt reversal.
Verification required
Compare the signed delivery note, receipt quantity and receiving count.
Confirmed findings
None. Source transactions have not been verified in this demonstration.
Illustrative evidence ledger · BR-4587 / A-01-01
| Reference | Observation / transaction | Quantity | Evidence status | Interpretation |
|---|---|---|---|---|
| BR-4587-OPEN | Opening snapshot | 120 | System record | ERP on-hand at the demo snapshot; not a movement. |
| BR-4587-COUNT | Independent physical count | 87 | Count observation | Observed units at this bin in the illustrative dataset. |
| BR-4587-REVIEW | Transaction trace | — | Review pending | Receipt, transfer, pick and issue documents must be checked. No cause has been confirmed. |
Pick face not replenished
34 of 100 shortages · 34% of the total · 34% cumulative · vital few
Countermeasure
Replenish against consumption, triggered before the face runs empty.
Illustrative Pareto · synthetic shortage records · not client data
Cycle counting & location control
Count smarter.
Improve accuracy.
Prioritize count effort by risk, inventory value or movement frequency.
Exact quantity match / counted records74.3%26 / 35; zero tolerance
Count completion35 / 40All 40 demo bins are planned for counting.
Quantity discrepancies9Counted records with non-zero variance.
Quantity matchShortOverNot counted
Select a labeled bin to inspect its count record.
Location accuracy: 34/35 inspected bins contain the expected SKU; separate from quantity accuracy.
Selected location
A-01-01
- SKU
- BR-4587
- Description
- Gear Housing
- ERP quantity
- 120
- Physical count
- 87
- Variance
- -33
- Status
- Short
- Observed SKU
- BR-4587
- Last count
- 2026-10-10
Count prioritization
Descending illustrative risk score / 100
Illustrative metrics calculated from 40 synthetic item-location records · no client results or target claims
From correction to control
Build processes that hold.
Engineer the standards, transaction points and daily checks that prevent the same failure from returning.
Barcode transactions
SCAN → VALIDATE → POST
DeliverableReceipt, putaway, pick and movement scan workflows.
On the floorCapture the physical action at the point of work, including exceptions.
Cycle counting & resolution
COUNT → TRACE → VERIFY
DeliverableRisk-based count plan, recount rules and discrepancy workflow.
On the floorResolve the difference and verify closure before updating records.
ERP / physical alignment
ACTION ⇄ TRANSACTION
DeliverableTransaction maps, confirmation points and ownership matrix.
On the floorAlign the timing and location of ERP postings with actual movement.
SOPs & monitoring
STANDARD → CHECK → ACT
DeliverableFloor-tested standard work, training and control dashboard.
On the floorMake reliable transactions part of daily work and review recurring failures.
Full service scope
Inventory segmentation: Group items by usage, value and criticality to set appropriate storage, counting and replenishment priorities.
Replenishment modeling: Evaluate reorder points, minimum and maximum quantities, and buffers against demand variability and lead times.
Location & transaction control: Design location labeling, barcode workflows and controls for receipts, transfers, picks and returns.
Cycle counting & visibility: Build count routines, investigate recurring discrepancies and define availability reports for daily decisions.
Service overview
Control stock at every handover.
The aim is a repeatable control process for receipts, put-away, transfers, picks, replenishment and returns. We define functional requirements with your warehouse and systems teams, trial changes in a selected area and verify the records against physical movements before wider rollout.
We investigate why physical stock and system records diverge, then design controls at the points where material changes location, quantity or status. The work connects location labeling, operator responsibilities, transaction timing and count routines.
B3 / Scope of work
Activities and controls included.
We agree the areas, data requirements and deliverables during scoping. The activities below define the service’s technical focus.
Item & location standards
Review SKU identifiers, units of measure, location addresses and storage rules. Define labels and barcode checks that operators can apply at the actual handover.
Cycle-count design
Segment items by value, activity and operational risk. Define count frequency, blind-count rules, recount triggers and approval for adjustments.
Discrepancy investigation
Separate quantity, location, SKU and status errors. Review movement evidence and recurring causes before deciding the corrective action.
Replenishment parameters
Review lead times, consumption, minimum and maximum quantities and pick-face buffers. Define normal replenishment triggers and exception handling.
ERP/WMS functional alignment
Compare floor procedures with system configuration, access and transaction sequencing. Document functional changes, visibility requirements and responsibility for verification.
OPS-01 / Technical explanation
Transaction control
Trace receipts, put-away, transfers, picks and returns. Set the required record, confirmation point and accountable role for each movement.
Technical approach
From inputs to an operating decision.
Floor observation and operating data establish the basis; review and verification close the loop.
- 01
Trace records to the floor
Sample item-location records and follow the associated material movements and transaction evidence.
- 02
Design control standards
Agree location rules, count methods, transaction ownership and replenishment parameters.
- 03
Pilot in one area
Train operators, trial the controls and check count results and system confirmations on live shifts.
- 04
Roll out & review
Extend the agreed controls, investigate repeat errors and review accuracy and availability measures.
Applications
When this work is useful.
Typical operating situations; these are not client case studies.
- People search for stock the system says is there.
- Physical counts and system records regularly disagree.
- Replenishment fails and shortages appear without warning.
- Slow-moving and obsolete stock is taking up space nobody tracks.
Engineering outputs
What you receive.
Inventory accuracy assessment
Count protocol, tolerance definitions and a segmented discrepancy register.
Location control & labeling plan
Location hierarchy, label placement and source/destination confirmation standards.
Cycle-count strategy
Count scope, frequency, blind recounts and escalation thresholds.
Process & transaction controls
Receipt-to-issue flow, ERP events and ownership at each handover.
Discrepancy resolution framework
Evidence requirements, cause review, approval and independent verification.
Phased implementation plan
Pilot scope, training, rollout dependencies and stabilization checks.
How we track results
Verification measures.
Key measures are defined around the warehouse and the change being tested.
Inventory record accuracy
Exact item-location quantity matches among counted records.
Measurement method
Counted records within agreed quantity tolerance ÷ counted records. This demo uses zero tolerance; uncounted records are excluded.
Location accuracy
Whether the observed SKU belongs at the recorded location.
Measurement method
Counted locations with the expected SKU ÷ locations inspected. Quantity agreement is measured separately.
Count completion
How much of the planned counting scope has been completed.
Measurement method
Completed eligible location counts ÷ planned eligible location counts, for the agreed period.
Variance frequency
How often counted item-location records differ.
Measurement method
Counted records outside tolerance ÷ counted records; segment by process, item and location.
Discrepancy resolution time
Elapsed time from logged discrepancy to verified closure.
Measurement method
Record detection, investigation and verified closure timestamps. Report median and aged open cases.
Record-error shortage incidents
Shortages attributable to confirmed inventory-record errors.
Measurement method
Count incidents only after cause verification; distinguish total supply shortages and replenishment delays.
Scope, measurement methods and improvement targets are agreed during assessment. Demo outputs are not measured client results.
[ Questions buyers ask ]
Common questions
Why doesn't our system stock match the physical stock?
Common causes are moves that are never recorded, receipts posted before put-away, unlabeled locations, picks from the wrong location, and adjustments made without a reason. We trace your discrepancies back through the transactions to find which ones are causing yours.
How do we improve inventory accuracy?
Fix the causes, then hold the gain: controlled receiving and put-away, a label on every location, a scan at each move, cycle counting on a schedule, and a reason code and named approver for every adjustment. We set these up with your team and keep measuring until the accuracy holds.
Do we need a new WMS to fix inventory accuracy?
Usually not first. Most accuracy problems are process problems that a new system would inherit. We assess your current WMS or ERP functionally and, only if it genuinely can't support the process, write the functional requirements for a replacement.
What is cycle counting, and how often should we count?
Cycle counting checks a portion of locations on a schedule instead of stopping for a full annual count. Fast movers and high-value items are counted more often than slow ones, and we design the routine around your stock profile and the staff time you have.
Can you help with slow-moving and stagnant inventory?
Yes. Before TvastrOps, Roshan automated the analysis of $110M in stagnant inventory at Lowe's, supporting an improvement in inventory turns from 3.7 to 4.0. We bring the same visibility to your slow and inactive stock so it can be acted on.
Start here
Make your inventory dependable.
Tell us where records and reality diverge. We’ll help identify where control is breaking down and what needs to change.