Car Parts Cycle Count and Wall-to-Wall Count to Update Stock On-Hand File
Case Study
Read Full Case Study
Bin locations
12,000+
Units
467,000
Auditors
90
Customer
A Global Filtration Manufacturer
Sector
Historical
A global leader and expert in the field of filtration and developing innovative solutions for the health and mobility of people, with a wide range of products and services to meet the needs of customers and society, required the support of RGIS. The manufacturer have more than 22,000 employees worldwide at over 80 locations, and produce more than 170 million filter elements every year for the global market.
THE CHALLENGE
The customer required RGIS to provide the following:
- Both warehouses to be counted simultaneously
- Regular real time updates throughout both counts
- Identify variances
- All stock owned by the customer to be counted within the 3PL warehouses
Recent Case Studies
Why RGIS?
The filtration manufacturer needed a solution to provide simultaneous stock counts within two third party logistics (3PL) warehouses.
Our Solutions
The filtration manufacturer partnered with RGIS to complete the simultaneous 3PL warehouse count project, and provided the following:
Scheduled a team of 90 experienced RGIS auditors to count both 3PL warehouses over three days
The 3PL warehouse provider supplied RGIS with a full list of possible bin locations at each site
Bin locations were checked to ensure they were empty and not just missed
RGIS generated a SKU variance report which showed the expected quantity versus the RGIS count
Every two hours, RGIS Supervisors ensured all up-to-date data was processed and an upload file was produced. This was then emailed directly to the 3PL warehouse and to the customer
Results
The filtration manufacturer found by outsourcing the simultaneous 3PL warehouse count project to RGIS, the following results were achieved:
New South Wales 3PL warehouse: Counted 3,443 bin locations and 272,119 units
Victoria 3PL warehouse: Counted bin 9,292 locations and 195,062 units
Once variance checking was completed, upload data was provided to the 3PL warehouse provider and to the customer to load into the Warehouse Management System (WMS) immediately
The efficient process allowed the 3PL warehouse provider to resume picking straight away, with minimal business disruption
Conclusion
By partnering with RGIS to conduct simultaneous wall-to-wall counts across both 3PL warehouses, the filtration manufacturer gained immediate, accurate visibility of all customer-owned stock with minimal operational disruption. Real-time data uploads every two hours ensured continuous alignment between physical inventory and system records, while detailed SKU variance reporting enabled swift reconciliation and correction within the WMS. With over 467,000 units and 12,000+ bin locations verified across both sites, the project delivered full inventory integrity, supported uninterrupted warehouse operations, and strengthened control over third-party managed stock.
