Performing a Physical Inventory

Objective

After completing this lesson, you will be able to perform a physical inventory.

Physical Inventory Procedures

You carry out a physical inventory of your products in the warehouse for stock control and balance sheet purposes.

A stock supervisor carrying out a physical Inventory.

To perform a physical inventory, you can choose between various inventory procedures such as:

  • Periodic Physical Inventory (Storage-Bin Specific and Product Specific)

  • Continuous Physical Inventory Procedures

    • Ad-hoc Physical Inventory (Storage Bin Specific and Product Specific)

    • Putaway Physical Inventory

    • Low Stock/Zero Stock Physical Inventory

    • Low Stock/Zero Stock Check

    • Storage Bin Check

  • Cycle Counting

  • External Physical Inventory

    Which includes:

    Which includes the following: Sample-Based Physical Inventory

Periodic Physical Inventory

SAP EWM supports an annual physical inventory (storage bin-specific and product-specific). In an annual physical inventory, you record all stocks on a certain day (or within a short time-period). This is usually done at the end of the fiscal year. During this time, you can prohibit stock movements. You can also use this procedure to take a physical inventory for storage bins and quants that are subject to continuous inventory, but have not had any stock movements in the current fiscal year. A product-specific periodic or annual inventory is also possible.

Continuous Physical Storage Inventory Procedures

Ad-Hoc Physical Inventory (Storage-Bin Specific and Product Specific): For storage bin-specific ad-hoc physical inventory, you take inventory for certain storage bins. You can do this at any time of the fiscal year. This physical inventory procedure is manually controlled. The product-specific ad-hoc physical inventory is similar to storage bin-specific procedure, except that you perform it on products.

Putaway Physical Inventory: When stock if first placed on an empty bin in the fiscal year, the inventory process is triggered. The warehouse employee confirms the warehouse task of putaway and as a result, performs the physical inventory.

Low Stock/Zero Stock Physical Inventory: As a prerequisite in this case, you must define (in Customizing) a quantity threshold of physical inventory area-specific settings. If picking causes levels to fall below the threshold, the low stock physical inventory is triggered. The warehouse employee confirms the picking warehouse task and the system creates the physical inventory document in the background. For a zero stock physical inventory, the threshold value is zero.

Low Stock/Zero Stock Check: The low stock / zero stock check is a variant of the low stock physical inventory, where no physical inventory document is created. This check can be done in addition to a low stock / zero stock physical inventory and in can be done multiple times (while a physical inventory document is only created once in a fiscal period).

Storage Bin Check: In this procedure, the system checks if a product is on the correct storage bin. This procedure can be triggered manually (at any chosen time). This check is recommended if a product is damaged. This check does not create a physical inventory document.

Product-Specific Cycle Counting

SAP EWM supports cycle counting, which means that you carry out a physical inventory of your stocks at regular intervals during a fiscal year. By allocating products to different classes (for example, A, B, and C), you specify the intervals or cycles when you take a physical inventory of those products. This allows you to take inventory of fast-moving products in your warehouse more frequently than inventory of slow-moving products, for example.

Prerequisites for Physical Inventory Procedures

In addition to the customizing settings for physical inventory, it is necessary to create physical inventory areas and then assign them to activity areas.

For each physical inventory area, you can define the related procedure of physical inventory. Also, you maintain Tolerance Groups to clear differences and to use the Difference Analyzer.

The process of physical inventory begins with the creation of a physical inventory document. This can be created manually or automatically. This document is used to do the following:

  • Plan and perform the physical inventory

  • Record the count data

  • Post any differences revealed by the count

Physical Inventory Document

The physical inventory document can be printed using Post Processing Framework (PPF) and this printed document can be used during the count, or counting can be performed using radio frequency (RF) as in mobile data entry.

When creating the document, you can decide if the storage bin is locked during the physical inventory. If you perform the physical inventory by RF, it is not necessary to lock the storage bin.

Two workers carrying out a physical Inventory: one with a mobile device in a warehouse and one with paper in a shop.

The physical inventory document can be automatically active. You can activate it manually when you create the document or you can create it in an inactive state and activate it in a later step.

After the physical count is complete, the results of the count are entered in the system. Any differences can be checked using the Difference Analyzer tool and those differences must be posted to the ERP system, that is, when the quantity on a storage location level in ERP is updated.

Physical Inventory with an External System

It is also possible to perform the physical inventory with an external system. This can mean that the physical inventory documents are created and counted in an external system, but it is also used for sample-based physical inventory, where only the determination of bins to be counted, are determined in an external system.

SAP EWM offers transactions to upload and download storage bins and to count data. Use the following menu path and transactions: Physical InventoryPeriodic ProcessingUpload / Download Storage Bins and Count Data.

Stock Comparison

Under Periodic Processing, there is a transaction to compare the stock situation between SAP ERP and SAP EWM (SCWM/ERP_STOCKCHECK). This transaction is useful if there are differences between the stock quantities in ERP and SAP EWM.

On the ERP side, the displayed stock is cumulative at the storage location level. This transaction assumes that the stock in SAP EWM is the correct stock quantity and it adjusts the quantity on SAP ERP side.