Inventory accuracy is the backbone of any high-performing supply chain. When it slips, the impact is immediate. For growing businesses, understanding how to correct inventory errors and delays is essential, especially when working with a 3PL provider. Even minor discrepancies can disrupt fulfilment, increase costs, and erode customer trust, making a solid inventory management process critical to long-term growth.
Whether you’re dealing with stockouts, overselling, or delays, the key isn’t eliminating every error. It’s having the right systems, communication, and logistics partner to manage and prevent them.
Why Inventory Errors Happen
Inventory errors are rarely the result of one big mistake. More often, they come from a combination of small oversights, gaps in process, or system limitations. Understanding the root causes makes it easier to prevent them.
- Human error during receiving, picking, or replenishment
Even in highly automated warehouses, people remain a central part of the operation, and manual tasks create opportunities for miscounts or mis-picks. For example, a picker may scan the wrong barcode or place an item in the wrong tote. Without strong checks and scanning procedures, these minor errors can quickly distort stock accuracy.
- Poor warehouse layout or inventory organisation
When SKUs are stored too closely together, locations aren’t clearly labelled or fast-moving items aren’t placed strategically. As a result, staff are more likely to pick the wrong item or store goods incorrectly. Congested zones or inefficient layouts also increase handling time. A warehouse that isn’t optimised for product type, pick frequency, or volume naturally invites errors.
- Inaccurate or incomplete inbound data
Inventory accuracy starts long before stock reaches the shelves. If suppliers deliver short-packed cartons, mislabelled pallets, or mismatched paperwork, the 3PL is forced to reconcile inconsistencies manually. Missing product codes, incorrect manifests, or vague packing lists make it harder to verify quantities during receiving, and these often show up later as discrepancies, stockouts, or overages.
- System integration issues and delayed data syncs
When your sales platform, ERP, or order management system doesn’t sync in real time with your 3PL’s WMS, stock levels may appear correct on-screen while the physical warehouse tells a different story. Even a short delay in data transfer during high-volume periods can allow orders to process against stock that is already allocated or unavailable.
- High-volume spikes and peak-season pressure
When order volumes surge, even well-run operations face pressure. Staff may be onboarding quickly, temporary workers may be less familiar with processes, and the overall pace increases. Without robust peak planning, additional training, and reinforced QA, accuracy often slips during these critical periods.
- Lack of clear SOPs or inconsistent process adherence
Even if procedures exist, they may not be followed consistently. If different team members interpret tasks differently or shortcuts become common practice, discrepancies multiply. When SOPs are missing, unclear, or outdated, inventory accuracy becomes much harder to maintain.
The Impact: How Errors and Delays Affect Your Business
Not all errors look dramatic, but their effects are. A few examples include:
- Stockouts that could have been avoided
- Overselling, especially on eCommerce platforms
- Missed SLAs, leading to unhappy customers
- Inefficient replenishment due to inaccurate data
- Increased returns because customers receive the wrong item
- Production pauses for manufacturers waiting on parts
- Higher operational costs due to rework, double-handling, or emergency shipments
The good news is that with the right structure, collaboration, and controls, these issues can be managed and dramatically reduced.
Correcting Inventory Errors and Delays: A Practical, Repeatable Process
Inventory issues aren’t solved by guesswork. They’re solved by systems. Here’s how to correct inventory errors with your 3PL provider.
- Establish full visibility with real-time data
You can’t fix what you can’t see. An integrated WMS gives you live insight into stock levels, adjustments, orders, and discrepancies.
Look for:
- Item-level tracking
- Time-stamped stock movements
- Automated discrepancy alerts
- Full audit trail
Connect, our warehouse management system at Denholm Good Logistics, integrates directly with customer platforms to give real-time accuracy. Every stock movement is recorded, time-stamped, and fully traceable, reducing the risk of errors and making root-cause analysis straightforward.
- Use regular cycle counts
Annual counts alone aren’t enough. Regular cycle counts catch problems early and prevent issues from snowballing.
Effective cycle count programmes include:
- Daily, weekly, or monthly checks (depending on SKU volume)
- ABC categorisation (high-value or fast-moving items checked more often)
- Random location audits
- Post-error verification
Our team at Denholm Good Logistics runs structured cycle count programmes that match each customer’s profile. As a result, fast-moving or sensitive SKUs receive more frequent checks, while random spot audits ensure accuracy across the board.
- Investigate the root cause, not just the symptom
Fixing an inventory error means understanding how and where it happened. A proper investigation includes:
- Checking location history
- Reviewing inbound records
- Analysing picking activity
- Confirming quantities physically
- Validating system syncs
This identifies patterns, not just isolated mistakes.
At Denholm Good Logistics, we perform detailed root-cause analysis using WMS data, staff input, and physical checks. Then, we agree on corrective actions with clients. This prevents repeat issues and builds long-term stability.
- Improve or update SOPs to prevent recurrence
Errors aren’t just fixed. They’re prevented. Strong SOPs turn lessons learned into better processes.
This may include:
- New scanning procedures
- Updated location labelling
- Revised packing rules
- Improved goods-in checks
- Enhanced documentation
At Denholm Good Logistics, we take a process-driven approach to preventing recurrence. We design bespoke SOPs for each client, adapting processes as volumes shift or new products launch. Every correction leads to an updated procedure, making operations continually stronger.
- Strengthen communication channels
Inventory issues escalate when communication is slow, unclear, or inconsistent. You should expect:
- Named contacts at your 3PL
- Clear reporting structures
- Quick responses to discrepancy alerts
- Scheduled operational review meetings
We maintain open, proactive communication with every client at Denholm Good Logistics. This is further supported by named account managers and regular review meetings to address performance, changes, and improvement opportunities.
- Track performance with SLAs and KPIs
Measurement drives improvement. Use SLAs and KPIs to monitor progress, including:
- Inventory accuracy targets
- Picking accuracy rates
- Goods-in accuracy
- Cycle count results
- Time-to-resolution for errors
- Lead time consistency
To ensure accountability, we report openly against agreed SLAs and KPIs. Our high standards in customer service and visibility at Denholm Good Logistics have been recognised through Supply Chain Excellence Awards submissions, demonstrating how seriously we take service levels and continuous improvement.
When to Reassess Your 3PL Relationship
Repeated delays, persistent errors, or lack of transparency may indicate deeper issues. It may be time to reconsider your partnership if you notice:
- Frequent stock discrepancies
- Slow responses from your provider
- A pattern of missed SLAs
- Limited access to tracking or data
- Poor peak performance
- No appetite for process improvement
Remember, a strong 3PL provider doesn’t shy away from accountability. They embrace it.
How Denholm Good Logistics Helps Prevent and Correct Inventory Errors
At Denholm Good Logistics, we treat accuracy as non-negotiable. Our systems, processes, and people are built around transparency and control.
We provide:
- Real-time WMS integration
- Structured cycle counts and audits
- Root-cause analysis for every discrepancy
- Bespoke SOPs aligned to your operation
- Clear communication and named contacts
- SLA-driven performance reporting
- Award-recognised service culture
Our goal is simple: give you full confidence in your stock, your orders, and your supply chain so you don’t have to worry about how to correct inventory errors in the first place.
Accuracy Comes from the Right Partnership
Inventory issues will happen, but with the right partner, they don’t need to interrupt your business. Understanding how to deal with inventory issues is the first step. Working with a proactive, transparent 3PL that prevents them in the first place is the real solution.
If you’re tired of correcting the same inventory issues or dealing with avoidable delays, it may be time for a more proactive logistics partner. At Denholm Good Logistics, we don’t just fix problems when they surface. We work to prevent them. If you want a partner who treats your stock as carefully as you do, get in touch with us to discuss a smarter, more reliable inventory approach.
- SHARE
