Inventory Accuracy & Warehouse Lean Kit — records you can trust, stock you can find
A complete inventory accuracy and warehouse Lean system for warehouse managers, materials managers, and Lean leaders. Build a cycle counting program on ABC analysis instead of the annual wall-to-wall count, track inventory record accuracy until the system can be trusted, size kanbans from real demand and lead time instead of guesswork, and audit warehouse 5S and slotting so the stock you do have is in the right place. The worked examples running through the kit classify 20 SKUs covering $1,328,887 of annual spend.
One-time price — no subscription
Excel · PDF
Built by a practitioner — Brian Sheard, 25 years in manufacturing
20SKUs classified in the worked ABC analysis
$1,328,887annual spend covered by the worked example
8parts sized in the kanban calculator example
4files in one download
What's inside
Four working files that take you from "the system says we have it, the shelf says we don't" to a counted, classified, right-sized inventory the floor can run on.
Workbook · Excel
Cycle Count Program Workbook
The core of the kit: an ABC-driven cycle counting program that replaces the annual shutdown count with a schedule the warehouse can actually keep.
- ABC classification by annual spend — worked end to end on 20 SKUs covering $1,328,887, so A items get counted most often and C items least
- Count schedule by class: how many counts per day, week, and year, spread across the calendar
- Inventory record accuracy tracked by formula — counted vs. correct, overall and by class
- Root-cause space on every miss, because a count that only fixes the number fixes nothing
Workbook · Excel
Kanban Sizing Calculator
Pull replenishment sized from numbers instead of habit: enter demand, lead time, and container quantity and get the kanban quantity and number of containers in the loop.
- Daily demand, replenishment lead time, container size, and safety factor drive every calculation
- Eight fully worked parts, each one checked against a hand calculation
- Re-size when demand or lead time changes — the formula is the standard, not the first guess
Workbook · Excel
Warehouse 5S & Slotting Audit Forms
The audit side of the system: score the warehouse the way it actually runs — aisles, racking, staging, and dock — and check that stock sits where the pickers need it.
- 5S audit scoring written for warehouse areas, not office space
- Slotting review: fast movers in the golden zone, slow and dead stock flagged for a decision
- Findings-to-action table, so every audit produces fixes with owners instead of a score on a wall
Guide · PDF
Inventory & Warehouse Lean Implementation Guide
The how-to that sequences the kit: what to set up first, how to start counting without shutting the warehouse down, and how to keep accuracy from sliding back.
- The rollout sequence — classify first, then the count program, then kanban sizing on the A items
- How to run the first cycle counts alongside normal receiving and picking
- The failure modes that kill accuracy programs — counting without root cause, kanban sized once and never revisited — and the counter for each
Pricing — one-time, both licences get the whole kit
Same files either way. The only difference is how many plants you can run it in. Pay once, keep it, and reuse it on the next product family or the next warehouse.
Single plant
Single-Plant Licence
For one plant or site — every department and shift in it.
- All 4 files: 3 Excel workbooks and the implementation guide PDF
- Use across the whole site, all shifts
- Re-run it as often as you like
$249one-time
Or split it with Cash App: 3 weekly payments of $83 — no interest, no fees.
Send payment 1 — $83 (how it works, below)
Company-wide
Company Licence
For every plant you run — roll the same system out site by site.
- Everything in the Single-Plant Licence
- Use at all your company's plants and sites
- Share with your operations and Lean team company-wide
$599one-time
Or split it with Cash App: 4 weekly payments — $150, $150, $150, then $149 — no interest, no fees.
Send payment 1 — $150 (how it works, below)
One-time payment — no subscription, no renewal, no per-user fees.
Paying with Cash App? Put the product name and your email in the payment note — your download is emailed to you after payment.
How split payments work: send payment 1 from the licence card above, then send the rest weekly to $bms0842 in the amounts shown on the card. Put the kit name, your email, and the payment number (for example "payment 2 of 4") in each payment note. No interest and no fees, ever. The full kit is emailed to you as soon as the final payment lands. Need to skip a week? Email [email protected] — everything you have paid stays credited toward your kit.