How Hard Is It to Count Inventory Correctly? (Part 2: Process)

A broken process will break even the best technology. And nowhere is this more obvious than in inventory management.

Here’s the scenario we see far too often: a company implements a new WMS or ERP and expects process magic. Instead, inventory data becomes less reliable, users are confused about which system owns which function, and leadership starts blaming the tool.

Failure Example: One manufacturer tried implementing an inventory system and ERP simultaneously—with no defined handoff rules, unclear picking logic, and zero phased rollout. Systems clashed. Inventory accuracy dropped. Picking errors climbed. Operations were more manual than ever.

Success Example: A CPG firm used a phased rollout plan—starting with a single warehouse. They clearly defined handoffs between receiving, put-away, and order picking. Weekly feedback loops refined the process. By the time they rolled it out company-wide, they had an ironclad SOP and a fully trained team.

You can’t automate a process you haven’t tested manually. Process clarity is the blueprint for system success.

If you’re heading into peak season, process confusion is profit erosion. At Full Sail, we help you define workflows, build SOPs, and map implementation steps so your systems work with your people—not against them.