Manual Inventory – Challenges and Costs
Manual stock counting, writing results on paper, and re-entering them into the system is still a daily reality for many companies, especially in the SME sector. As a result:
- inventory can take several days or even weeks, leading to operational downtime,
- errors occur due to human factors: miscounts, illegible notes, or mistakes during data entry,
- some warehouse processes must be paused — receiving, shipping, and picking are suspended during the count,
- employees are pulled away from their daily tasks, impacting the overall efficiency of the company,
- final reports are only available after the entire process is completed, making it difficult to quickly react to discrepancies,
- inconsistency and outdated data in the ERP system can lead to poor purchasing or logistics decisions,
- difficulty in conducting inventory across multiple locations simultaneously,
- high stress and workload for teams, often working outside standard hours.
The cost of such operations is high — both directly (overtime, downtime) and indirectly, through lost opportunities, stock discrepancies, customer complaints, and delayed order fulfillment.
Step-by-Step Guide to Digital Inventory
Implementing digital inventory is a process that should be well thought out and carefully planned. The key components of an effective solution include:
The Right Software
The foundation of digital inventory is a well-designed tool that enables real-time data capture, progress tracking, discrepancy detection, and report generation. At MANUCO, we create custom applications tailored to specific processes and needs — lightweight, intuitive, and ready for deployment in just a few days.
Integration with Business Systems
Inventory cannot function in isolation from the rest of the IT ecosystem. It’s essential that inventory solutions integrate with WMS, ERP, accounting, and quality control systems. This ensures data consistency and makes results immediately actionable in operational and strategic processes.
The Right Equipment
Professional devices such as Zebra MC2200 and TC22 data collectors or mobile terminals from the Zebra TC5x series offer speed, accuracy, and convenience. High-quality scanners, durability, and offline capabilities make them indispensable in demanding warehouse environments.
Planning and Preparation
Technology alone isn't enough. Careful planning is key — dividing the warehouse, scheduling tasks, assigning responsibilities, preparing labels, and training employees. Inventory should be part of a broader quality and stock control system.
Combining all these elements allows inventory to be completed quickly, efficiently, and stress-free — even within a single day.
Fixed Asset Inventory
When it comes to fixed asset inventory — such as office equipment, furniture, electronics, or production assets — RFID technology is a perfect fit. It enables lightning-fast scanning of multiple items at once without manually reading barcodes.
For such tasks, the Zebra EM45 device is ideal — lightweight, ergonomic, and equipped with an RFID reader, it's perfect for office or administrative environments. Thanks to integration with dedicated software, assets can be quickly located, confirmed, and reported — all from a single application.
This solution not only speeds up the process but also minimizes errors and provides full control over company assets.
Complete Solutions from MANUCO
At MANUCO, we deliver comprehensive inventory solutions — from Zebra Technologies hardware and both ready-made and custom software, to implementation and team training. We also develop mobile apps that support counting, quality control, and ERP integration.
Whether you're planning annual, quarterly, or daily cycle counts — we can help simplify and automate your inventory process.
Get in touch with us to find out how you can carry out inventory faster, easier, and error-free.
Schedule a free consultation