Mobile Inventory Counting and Cycle Counts in SyteLine
Mobile inventory counting transforms SyteLine's cycle count and physical inventory processes from clipboard-based manual counts to real-time, scan-driven workflows on handheld devices. Operators scan location barcodes, scan item barcodes, enter counted quantities, and the mobile app submits counts directly to SyteLine's Physical Inventory module through IDO API calls. Real-time variance calculations display immediately on the device, enabling operators to recount suspicious discrepancies before leaving the location. This approach improves count accuracy to 99%+ while reducing counting time by 40-60%.
Cycle Count Configuration and Scheduling
Configure cycle counting in SyteLine's Physical Inventory module to generate count lists based on ABC velocity classification, value thresholds, or location zones. A-class items (top 20% by value or transaction volume) cycle count monthly, B-class quarterly, and C-class annually. SyteLine generates the cycle count list by selecting items due for counting and assigns them to specific counters. The mobile app retrieves the assigned count list for each operator through the SLPhyInv IDO, presenting locations in an optimized walking sequence that minimizes travel time through the warehouse.
- ABC classification: configure item ABC codes in SyteLine Items form based on annual usage value or transaction frequency
- Count frequency: SyteLine Physical Inventory > Count Frequency Setup: A=monthly, B=quarterly, C=annually
- Count list generation: run SLPhyInv.GenerateCountListSp to create count assignments for items due in the current period
- Walking sequence: sort count locations by aisle-rack-level to minimize operator travel distance between counts
- Blind count mode: configure mobile app to hide expected quantities so operators count without bias
Mobile Counting Workflow and Variance Handling
The mobile counting workflow guides operators through a structured count sequence. First, scan the location barcode to confirm the operator is at the correct location. The app displays the items expected at that location (or hides them in blind count mode). The operator scans each item barcode and enters the counted quantity. For lot-tracked items, the app prompts for lot identification. After counting all items in a location, the app calculates variances against the SyteLine on-hand quantity and highlights discrepancies exceeding the configured tolerance. The operator can initiate a recount for flagged items or submit the count for supervisor review.
- Location scan: scan location barcode to start counting; app validates location exists in SLLoc IDO
- Item counting: scan item barcode > enter quantity > scan next item; app tracks counted vs expected items
- Lot counting: for lot-tracked items, scan lot barcode or select from displayed lots at the location
- Variance display: show count vs system quantity and percentage variance after each item count submission
- Recount trigger: automatically prompt recount when variance exceeds threshold (e.g., >5% or >$500 value)
Count Posting and Inventory Adjustment
After operators submit their counts, the supervisor reviews variances in SyteLine's Physical Inventory Variance Report before approving adjustments. The mobile app posts counts through the SLPhyInv.CountEntrySp IDO method, recording the counter's identity, timestamp, and counted quantities. For variances within the auto-approval threshold, SyteLine can automatically generate inventory adjustment transactions. For variances exceeding the threshold, the system routes the count to a supervisor approval queue. After approval, SyteLine posts adjustment transactions through the SLMatlTrans IDO, updating on-hand quantities and generating the accounting entries for inventory valuation changes.
- Count submission: SLPhyInv.CountEntrySp(Whse, Loc, Item, Lot, CountQty, CounterId, CountDate) posts the count record
- Auto-approval: configure variance threshold (e.g., <2% or <$100) for automatic inventory adjustment posting
- Supervisor review: variances above threshold queue in SyteLine Physical Inventory > Variance Approval form
- Adjustment posting: approved counts generate adjustment transactions via SLMatlTrans posting to GL accounts
- Audit trail: all counts, approvals, and adjustments are logged with user ID, timestamp, and before/after quantities
Netray AI agents optimize your SyteLine inventory counting processes with intelligent cycle count scheduling, mobile workflow configuration, and variance analysis. Achieve 99%+ inventory accuracy.
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