1. PHYSICAL CYCLE COUNTS Standard Work Instruction: Physical Cycle Counts
Original Date: January 25, 2017
Version number: v1.0
Revision Date:
PHYSICAL CYCLE COUNTS
The purpose of this standard work document is to assist warehouse workers
in performing Physical Cycle Counts.
A Physical Cycle Count is a task generated by the Manager of Inventory Control. Physical Counts are done at least once per year. Any Distribution Center that has a Variance over 2% will be required to perform a Mid-Year Physical Inventory in an effort to reconcile inventory discrepancies and to minimize absolute variance.
Sign into the handheld by entering a username and password.
If prompted, enter the DC’s three digit code. For example, Lubbock’s Organization Code is 601.
At the main menu screen, scroll down using the arrow keys to Option 8: “Count”.
Press Enter.
From the “Count” sub-menu, select Option 1: “Cycle Tasks”.
A “Choose Eqp/Sub” screen will display. No information is required to be entered. The user can press enter four times to advance to the “Count” screen.
The “Count” screen will display the first bin and item combination that the user needs to count.
This information can be found at the “Loc” line item of the current task.
Ensure that the top line, “Name” reads as “Physical Count”.
If it does not, the user will need to request that management verify tasks have been assigned accordingly.
Note: Management assigns a user his or her own aisle to count to prevent overlap and expedite counting as all warehouse workers and drivers are on-hand for Physical Inventory. Management will assign all bins in said aisle to the user for counting.
Once the user has arrived at the bin, scan the Sub-inventory bar code, “Stock”, located in the top left-hand corner of the bin’s sticker.
Scan the Locator bar code in the bottom right-hand corner of the bin’s sticker. Example: C.
Check the handheld for the item number that needs to be counted – this can be found at the “Item” line item of the current task.
Locate the corresponding item in the bin and scan its barcode label.
Count how many of that item are present in the bin. Look at the entire contents of the bin before entering the quantity.
Enter the quantity counted into the “Qty” line on the handheld device.
Make an indication (sticker or chalk) on the top-most unit in the front stack that was counted to indicate that the stack has been counted.
Note: If there are multiple stacks of the same item in the bin, make an indication (sticker or chalk) on each stack to indicate to any one recounting, that the stacks have been counted

2. PHYSICAL CYCLE COUNTS Standard Work Instruction: Physical Cycle Counts
Original Date: January 25, 2017
Version number: v1.0
Revision Date:
PHYSICAL CYCLE COUNTS
The purpose of this standard work document is to assist warehouse workers
in performing Physical Cycle Counts.
If an item in a bin is found that was not scheduled for count after completing the last task for the bin, it will need to be cycled into inventory:
Return to the “Count” sub-menu by pressing the Blue button in the bottom left-hand corner of the handheld, followed by the number 2.
From the “Count” sub-menu, press Enter on Option 2: “Cycle”.
A “Cycle Counting” screen will display with a single line item “Name”.
Press the Ctrl button on the left of the handheld’s screen, followed by the Gray and “L” buttons to bring up a prompt list.
Using the arrow keys, scroll down to the second line, “Physical Count” and press Enter.
Scan the Sub-inventory.
Scan the Locator.
Scan the Item.
Enter the quantity present in the bin.
Select “Save/Next Item”.
Make an indication (sticker or chalk) on the top-most unit in the front stack that was counted to indicate that the stack has been counted.
Blue + 2 out.
Repeat steps 3-7
Repeat steps 13-21, and sub-steps a-k (if necessary) until no more tasks remain.
Drive the Order Picker to the Bullpen or near the manager’s office to advise that counts have been completed and to be assigned additional tasks, if necessary.
If there are no additional tasks, logout of the handheld device and return it to its charging dock in the WMS Handheld station or cabinet.