Prepare and Freeze Inventory for Counting
Start preparation on the Physical Inventory Setup form (PhysInvSetup IDO) under Inventory > Physical Inventory. Select the warehouses and locations to include in the count scope. Run the Physical Inventory Freeze utility to snapshot current system quantities, this creates the baseline for variance calculation.
The freeze captures on-hand quantities at each item-warehouse-location and stores them in the PhysInvFreeze IDO. During the freeze period, block all inventory transactions by setting the Warehouse Status to Frozen on the Warehouses form. Generate and print count tags from the Physical Inventory Tag Print form.
- Configure count scope on Physical Inventory Setup form by warehouse and location range
- Run Physical Inventory Freeze utility to snapshot current system on-hand quantities
- Set Warehouse Status to Frozen on Warehouses form to prevent transactions during count
- Print count tags from Physical Inventory Tag Print form for distribution to count teams
Conduct Counts and Enter Results
Distribute printed count tags to counting teams organized by warehouse zones. Each tag includes the location, item description, and unit of measure but not the system quantity to prevent bias. Enter actual counts on the Physical Inventory Count Entry form (PhysInvCount IDO).
SyteLine supports blind counting (system quantity hidden) or open counting based on your Inventory Parameters configuration. For discrepancies, initiate recount procedures, the system tracks first count, recount, and final count quantities. Mobile scanning through Shop Floor Mobility accelerates data entry and reduces transcription errors.
- Distribute count tags to teams organized by warehouse zone for parallel counting
- Enter actual counts on Physical Inventory Count Entry form with blind or open mode
- Initiate recounts for items with significant first-count variances
- Use mobile barcode scanning for faster, more accurate count data entry
Resolve Variances and Post Adjustments
After all counts are entered, review variances on the Physical Inventory Variance Report (PhysInvVariance). The report compares frozen system quantities against counted quantities, calculating both unit and dollar variances. Filter by variance threshold to focus on significant discrepancies first.
Items within tolerance can be auto-approved; items outside tolerance require investigation and supervisor sign-off. Post approved adjustments using the Physical Inventory Posting form, which updates on-hand quantities and generates GL entries to the Inventory Adjustment account. Unfreeze warehouses after posting to resume normal operations.
- Review all variances on Physical Inventory Variance Report sorted by dollar impact
- Configure auto-approval for variances within tolerance thresholds
- Investigate and document root causes for significant variances before approval
- Post approved adjustments and unfreeze warehouses to resume normal operations
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SyteLine Cycle Count Variance Worksheet
An editable cycle count sheet that computes variance quantity, variance value and record accuracy per line and overall.
Frequently asked questions
How long does a physical inventory typically take in SyteLine?
The duration depends on warehouse size and item count. A typical manufacturing warehouse with 5,000-15,000 SKUs requires 2-3 days for counting plus 1-2 days for variance resolution. The freeze period should be minimized to reduce operational disruption. Many organizations count Friday through Sunday and resolve variances Monday-Tuesday. Preparation activities like tag printing and team organization should begin 2-3 weeks before the count date.
Can I do a partial physical inventory covering only certain warehouses?
Yes, the Physical Inventory Setup form allows you to select specific warehouses, location ranges, or product codes for counting. You can freeze and count one warehouse while others continue normal operations. This staged approach is useful for organizations with 3-8 warehouses that cannot shut down all locations simultaneously. Each partial physical inventory generates its own variance report and posting batch for independent review and approval.
What happens to open transactions during the physical inventory freeze?
When a warehouse is frozen, SyteLine blocks new inventory transactions including receipts, shipments, issues, and transfers for that warehouse. Open production jobs should be completed or suspended before freezing. Outstanding purchase order receipts should be processed or deferred. WIP materials on the shop floor should be excluded from the count scope or counted separately. Most organizations allow 1-2 days of transaction wind-down before initiating the freeze to minimize 15-25 blocked transactions.
Planning your annual physical inventory in SyteLine? Netray can help streamline the process with proven procedures, mobile counting tools, and variance analysis workflows.