Roger B. Brooks & Larry W. Wilson 
Inventory Record Accuracy 
Unleashing the Power of Cycle Counting

Praise for INVENTORY RECORD ACCURACY

‘This updated version of Inventory Record Accuracy preserves its
humorous and easy-to-read style. Supply chain practitioners, in
traditional or lean manufacturing, will find it a helpful guide.
Cleverly outlined, the rigorous yet simple process for both on-hand
and on-order inventory provides accuracy levels required for
real-time data systems.’

-Maria Teodorovic, Quality Systems Manager Weyerhaeuser
Corporation

‘Inventory Record Accuracy is truly a practitioner’s guide. The
book’s collection of anecdotes provides real-life insight into the
potential challenges of achieving IRA, and the combination of an
easy-to-read text and simple drawings makes this book an easy road
map to follow on the proven path to higher inventory record
accuracy.’

-John Dietz, Director, Manufacturing Resource Planning Lockheed
Martin Space Systems

‘Brooks and Wilson are the experts on inventory record accuracy.
Inventory Record Accuracy goes right to the core of the issues
without a lot of soft-soaping. Every materials manager, stockroom
manager, and cycle counting supervisor should have a copy within
arm’s reach.’

-Adrian R. Barrett, 6 Sigma Master Black Belt Caterpillar,
Inc.

‘Excellent coverage of a fundamentally important topic. By far, the
best book on the subject I’ve ever read. The three-phase approach
to inventory record accuracy should be required reading for all
manufacturing managers.’

-Edward W. Davis, Professor of Business Administration The Darden
School, University of Virginia

Table of Content

Acknowledgments xiii

Introduction xv

Chapter 1 The Company Bank 1

Chapter 2 Tolerances and Measures of Accuracy 9

Chapter 3 The Three-Phase Approach to Inventory Record Accuracy 29

Chapter 4 Phase I–Design and Preparation: Getting the System Right 35

Chapter 5 Phase I–Design and Preparation: The Physical Stockroom 61

Chapter 6 Phase II: Establishing Initial Balances 93

Chapter 7 Phase III: Cycle Counting 109

Chapter 8 Inventory Record Accuracy in a Lean Environment 143

Chapter 9 Accountability 163

Chapter 10 Looking Back and Looking Forward 171

Glossary 175

Index 179

About the author

ROGER B. BROOKS is a Principal of Oliver Wight Americas who consults with companies on planning and control, strategic planning, and continuous improvement. He is a popular speaker at seminars and symposia.

LARRY W. WILSON is a Principal of Oliver Wight Americas who consults to businesses on customer service, inventory reduction, and efficient inventory management. He also is a popular speaker at seminars and symposia.

For more information, please visit www.oliverwight.com