Inventory Discrepancies: What They Really Cost You Each Year
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Inventory Discrepancies: What They Really Cost You Each Year

The gap between physical and book stock is not just a figure in a report — it is an unnecessary purchase, a late customer order and an inaccurate set of accounts. Here we work out the real cost.

A Variance Is Not Just a Number in a Report

When a stocktake report shows a 3% variance between physical and book stock, many managers are inclined to treat it as an acceptable figure. But in a warehouse holding SAR 10 million of inventory, that percentage means a gap of SAR 300,000 that nobody can account for.

Three Hidden Costs That Never Appear in the Report

1. Unnecessary Purchasing

When the system shows less stock than is actually held, a purchase order is raised for an item already sitting on the shelf. Capital is tied up, storage space is consumed, and the stock is exposed to obsolescence.

2. The Late or Cancelled Order

The reverse is more dangerous: the system says the item is available, so the customer is promised a delivery date — and then the shelf turns out to be empty. The cost here is not only financial; it is customer trust.

3. Inaccurate Financial Statements

Inventory is an asset line on the balance sheet. Any flaw in its valuation feeds straight through to the financial statements and to shareholder decisions — which puts the finance function in an awkward position in front of the auditors.

Why Does a WMS Not Solve the Problem on Its Own?

A system does not correct a faulty practice — it documents it more precisely. If goods are received without a proper match, or an issue is recorded hours after the stock has physically left, the system will record the error with complete fidelity.

Where Do You Start?

Start with an independent diagnostic count that establishes the size of the gap and its sources, then fix the procedures that produced it, and finally lock in the result with a cycle counting programme that stops variances building up again.

United Integrated Team

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