Warehouse Wall-to-Wall Counts: How Much Can You Really Save?

Hey there,

When was the last time you conducted a wall-to-wall inventory count in your warehouse? For many brands, it’s an afterthought—but it shouldn’t be. A comprehensive count isn’t just about tallying up inventory; it’s about uncovering hidden opportunities to save money, optimize operations, and boost your bottom line.

In my experience with an apparel brand juggling multiple SKUs and sizes, we uncovered $10,000 worth of missing inventory during a count—money we were able to recover through refunds. These findings aren’t rare; they’re the kind of opportunities waiting to be discovered in your own warehouse.

Here’s how a wall-to-wall count can transform your operations:

1. Prevent Overstocks and Overstock Costs

Excess inventory sitting in your warehouse isn’t just a storage problem—it’s a cash flow killer. A wall-to-wall count gives you a clear picture of what’s on hand so you can adjust purchasing decisions.

Savings Potential:

• Reduced storage fees for unnecessary inventory.

• Frees up capital tied in overstock, which can be reinvested in new products or marketing.

Example:

An apparel brand I worked with discovered 5,000 units of a slow-moving SKU that were still being replenished automatically due to outdated system settings. After the count, they paused reordering and ran a clearance sale, saving $15,000 in storage fees and recouping $50,000 in cash flow.

2. Catch Stock Discrepancies Early

Stock variances happen more often than we’d like—damaged goods, misplaced inventory, or even theft can add up over time. Regular counts help identify these issues before they spiral into bigger problems.

Savings Potential:

• Avoid stockouts caused by inaccurate inventory records.

• Minimize loss by identifying missing or misplaced items early.

Example:

During a wall-to-wall count, a personal care brand found that 1,000 units of a top-selling item were misplaced in the wrong bins. Correcting the issue avoided a stockout during their peak season, preserving $25,000 in sales revenue.

3. Optimize Storage Space and Layout

An accurate count helps you understand how efficiently your warehouse is being used. You might find underutilized space or opportunities to reorganize for better flow.

Savings Potential:

• Reduced need for additional warehouse space.

• Increased picking and packing efficiency, saving labor costs.

Example:

A DTC brand discovered during their count that their warehouse was charging full pallet costs for items that didn’t fill an entire pallet and using extra bins unnecessarily. By switching warehouses, they saved $20,000 annually and streamlined operations.

4. Avoid Expired or Obsolete Inventory

If your products have expiration dates or seasonal demand, knowing what you have is critical to avoiding waste.

Savings Potential:

• Reduce write-offs for expired goods.

• Prevent deadstock from occupying valuable space.

Example:

A personal care brand found $10,000 worth of near-expiry inventory during a count. They quickly launched a promotion to sell the goods at a discount, turning potential losses into $8,000 in revenue.

5. Improve Vendor Relationships

A wall-to-wall count can identify vendor-related issues, like over- or under-shipments. Armed with this data, you can negotiate better terms or request replacements.

Savings Potential:

• Claim credits or refunds for vendor discrepancies.

• Strengthen supplier trust with accurate feedback.

Example:

After identifying consistent vendor shipment errors during counts, a home goods brand negotiated a 5% credit on future orders, saving $6,000 annually.

How to Make Your Wall-to-Wall Count Impactful

• Plan Ahead: Schedule counts during slower seasons to minimize disruption.

• Invest in Tools: Use barcode scanners or inventory software for faster, more accurate counts.

• Engage Your Team: Train staff on proper counting procedures to ensure consistency.

• Analyze the Results: Look beyond the numbers—identify patterns, inefficiencies, and opportunities for improvement.

Why It’s Worth the Effort

A wall-to-wall count isn’t just a box to check—it’s a critical tool for uncovering hidden savings and improving operations. Here’s what it can do for your business:

• Boost Margins: Cut unnecessary costs and reinvest in growth opportunities.

• Enhance Efficiency: Optimize warehouse space and streamline operations.

• Build Resilience: Address discrepancies and inefficiencies before they become costly problems.

Ready to Start Counting?

If it’s been a while since your last wall-to-wall count—or you’ve never done one—now’s the time. Need help getting started or figuring out how to analyze the results? Hit reply, and let’s chat.

Here’s to smarter inventory management and bigger savings,
Lara