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Warehouse audit found 38 pallets of stuff nobody ordered

Last month we did a full inventory at our distribution center in Columbus and found 38 pallets sitting in the back corner that had been there for over a year. Turns out a temp worker in receiving typed in the wrong SKU on a bulk order and nobody caught it until the vendor asked why we never requested a return. We paid storage on that stuff for 14 months, plus the insurance cost. What bothered me more is we had no system flagging a receiving discrepancy that big, it just sat there because the floor was full and someone kept pushing it further back. I asked the ops manager how many other ghost pallets we might have and he said he honestly didn't know. We're now doing a weekly spot check on anything that sits in receiving for more than 48 hours. Has anyone else found mystery inventory that somehow survived two cycle counts?

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christopher_flores4615d ago

Tagged every pallet with a color-coded sticker and scanned them weekly, caught 12 more ghosts within a month.