Warehousing & Distribution • Stabilization Playbook

Inventory Accuracy Recovery Checklist (Post Go-Live)

If inventory accuracy drops after WMS go-live, treat it like a control failure—not a counting problem. This checklist focuses on rapid containment, targeted cycle counting, root cause elimination, and long-term control discipline.

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First 72 Hours: Contain the Damage

Command center live (single intake, severity model, daily cadence).
Define "accuracy" measurement method (by location, by SKU, by value, by units).
Freeze risky transactions if needed (ad-hoc moves, blind adjustments, uncontrolled relabeling).
Identify the top variance drivers (receiving, putaway, replenishment, picking, returns).
Quarantine rules active (what inventory is blocked until verified).

Goal: Stop the bleeding first—then fix the underlying process and system behaviors causing record drift.

Guardrail KPIs (Inventory Integrity)

Inventory count accuracy
Adjustment volume and value (trend + by user)
Replenishment accuracy (forward pick outs, shorts)
Pick shorts / exception rate
Dock-to-stock cycle time (late putaway often drives errors downstream)
Returns discrepancy rate

Key Risk Callouts (Accuracy Recovery)

Risk: Counting without fixing causes

If you only correct records, accuracy will collapse again. Every variance needs a cause + corrective action loop.

Risk: Uncontrolled adjustments

Too many users with adjustment access masks problems and destroys trust. Tighten permissions and require audit notes.

Risk: Receiving/putaway discipline drift

If inbound isn't scanned/located correctly, you'll chase variances forever. Fix inbound controls early.

Hypercare Expectations (Vendor ↔ Org)

Daily war room cadence (accuracy KPIs first, then variances, then fixes).
Support tiers defined (process coaching + configuration + defect/performance escalation).
Fix validation rules defined (regression checks after config/process changes).
Exit criteria defined (accuracy stable + variance trend down for 5–10 business days).
Knowledge transfer completed (count playbook, cause codes, training assets, controls).

Long-Term Maintenance (Keep Accuracy High)

Cycle counting becomes permanent (frequency by SKU class and velocity).
Variance RCA program maintained (top causes reviewed monthly with corrective actions).
Adjustment controls enforced (permissions, approvals, thresholds, audit trail).
Receiving and putaway audits scheduled (spot checks + retraining triggers).
Quarterly inventory integrity review (accuracy, exceptions, process drift, training needs).

Inventory Accuracy Recovery Checklist (Post Go-Live)

First 72 Hours: Contain the Damage

Rapid Investigation Checklist

Cycle Count Strategy (Targeted, Not Random)