Common Challenges in Manufacturing Stocktaking

1. Multiple Inventory Categories

Manufacturers often manage raw materials, in-process inventory (WIP), and finished goods simultaneously. Each of these requires different tracking methods, units of measure, and timing. This complexity increases the risk of miscounts or overlooking items altogether.

How to overcome it:
The COSYS stocktaking software allows businesses to create structured stocktake areas and assign specific inventory categories to each zone. Clear separation of WIP, raw materials, and finished goods simplifies the count and improves focus.

[*] High Inventory Turnover and Ongoing Production

In many manufacturing environments, production continues during the stocktake, leading to discrepancies caused by material consumption or movement while counting is in progress.

How to overcome it:
With real-time tracking and mobile data capture, COSYS ensures that inventory movements during the stocktake are recorded immediately, minimizing errors. The software also supports freezing inventory locations selectively, so that ongoing operations aren’t disrupted.

[*] Decentralized Storage and Complex Layouts

Manufacturing facilities often store parts and materials across several buildings, workstations, or temporary storage locations. These fragmented storage points are difficult to track using manual methods.

How to overcome it:
COSYS enables users to define custom stocktake areas and track the status of each location through a central dashboard. This improves visibility and ensures that no area is missed during the count.

[*] Manual Errors and Time-Consuming Processes

Traditional pen-and-paper stocktakes or outdated systems increase the likelihood of data entry errors, lost count sheets, and miscommunication between teams.

How to overcome it:
COSYS replaces manual methods with barcode scanning and mobile data entry, reducing input errors and speeding up the entire process. The intuitive interface ensures even temporary or less experienced staff can complete tasks with minimal training.

[*] Lack of Real-Time Insights

Without a clear view of current progress, management teams can’t identify delays, bottlenecks, or discrepancies until the count is complete—too late to take corrective action during the stocktake.

How to overcome it:
The COSYS WebDesk dashboard provides real-time analytics, showing how many items have been counted, by whom, and in which areas. This enables proactive intervention, better coordination, and faster resolution of issues during the count.

Conclusion

Stocktaking in the manufacturing sector comes with distinct complexities—but with the right tools and approach, these challenges can be turned into opportunities for improvement. From handling multiple inventory types to navigating decentralized storage and ongoing production, manufacturers need a stocktaking solution that is both flexible and powerful.

The COSYS stocktaking software offers exactly that: a digital, data-driven platform designed to meet the demands of modern manufacturing environments. With features like mobile barcode scanning, real-time progress tracking, and structured area management, COSYS helps ensure that every count is fast, accurate, and actionable.

By replacing outdated manual processes with intelligent automation and clear insights, manufacturers can reduce downtime, eliminate costly errors, and gain full control over their inventory. In short, COSYS turns stocktaking from a logistical headache into a streamlined, strategic asset.