Let me pose an example.
As 1 counter is spending 5 minutes in location A with a theoretical N-1 reaching infinity locations to count, there are simultaneous interactions happening in real time to gauge the inventory at that moment. There are over 2000 parts at DBG, which truly each part is unique and identifiable but classified into categories such as steel coil, pre-formed, post-formed, pre-stamped, post-stamped, GP12 certified — the list goes on. We attempt to sort the count by relevancy to the desired statistic. Accuracy in $ for valuation of material used and thus turned into value for customers. This gives the part relevancy, and it’s value changes at each point of development. We want to count the parts when they are still, because then they can be located if an audit is performed by a second counter, often an outside party after there has been a discrepancy such as a controller or analyst from an arbitrator or reconciliation party.
The counter knows that when he counts, if he spends 5 minutes recording the data from his current perspective, he must keep the zone he is working in stable – there must be no interruptions to the inventory or there is a disconnection in the accuracy of parts – they are now considered valued higher or lower because labour was used to transport parts and the counts accuracy thus becomes more inaccurate. There is a threshold of inaccuracy that makes the count worthless. As the counter is progressing, time elapses and more parts within the desired snapshot are counted.
A few times, I have adjusted the count to reflect movement, but this disrupts the timing accuracy. Time and labour is spent in rework for a count that is not completed.
I attempt to finish certain counts within an 8 hour workday. This means I take maybe 1 hour, 4 hours, time recorded, and dedicate every resource I have to focusing on accuracy, timing, and completion. The more the process is misaligned, the wider the time span of the snapshot, and the greater the variance within the particular count due to aforementioned reasons.
Clear & Precise Resumes 