SyteLine Cycle Counting Configuration and Setup Guide
Cycle counting in SyteLine replaces disruptive annual physical inventories with continuous counting programs that maintain inventory accuracy year-round. Proper configuration of ABC classification, count frequencies, variance thresholds, and approval workflows ensures your cycle count program delivers sustained accuracy improvements. This guide covers the complete setup from classification through count posting.
ABC Classification and Count Frequency
Cycle counting effectiveness starts with ABC classification on the Items form. The abc_code field on the item record assigns items to classes based on annual usage value. The Cycle Count Parameters form (accessible from Inventory Parameters) defines count frequency per ABC class. SyteLine uses the SLCycleCounts IDO to generate count schedules that spread counting workload evenly across the period.
- Assign abc_code values (A, B, C, D) on item records based on annual usage value or transaction frequency
- Configure count frequency per ABC class: A items monthly, B items quarterly, C items semi-annually
- Use the ABC Analysis utility to auto-calculate and assign ABC codes based on actual transaction history
- Set the cycle_count_interval field on item-warehouse records for item-specific frequency overrides
- Enable random count selection in Cycle Count Parameters to prevent predictable counting patterns
Count Generation and Execution
The Generate Cycle Counts utility creates count lists based on ABC schedules and item-warehouse settings. Count lists appear on the Cycle Count Entry form where warehouse staff enter physical counts. The SLCycleCountEntry IDO captures counted quantities by location and lot for lot-tracked items. Blind counting mode hides system on-hand quantities during entry to prevent bias.
- Run Generate Cycle Counts on a scheduled basis to create daily or weekly count work lists
- Enable blind counting by hiding on-hand quantities during count entry for unbiased results
- Cycle count entry supports barcode scanning integration for faster and more accurate count capture
- Multi-location counting walks the counter through all locations holding each item in sequence
- Recount triggers automatically fire when initial count variance exceeds the configured threshold
Variance Analysis and Posting
After count entry, the Cycle Count Variance Report compares counted versus system quantities. Variance thresholds configured in Inventory Parameters control which counts require supervisor approval before posting. The Post Cycle Counts utility adjusts inventory records and creates adjustment transactions in the matltran table with full audit documentation.
- Configure variance_tolerance_pct and variance_tolerance_qty in Inventory Parameters per ABC class
- Counts within tolerance post automatically; counts exceeding thresholds route for approval
- Variance analysis reports show count accuracy percentages by warehouse, location, and ABC class
- Posted adjustments create matltran records with reason codes for financial reconciliation
- Track inventory accuracy trending over time to measure cycle count program effectiveness
Improve your SyteLine inventory accuracy with a properly configured cycle count program—contact us for setup assistance.
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