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CYCLE COUNTING

Count the warehousewithout stopping the warehouse.

Klovio schedules small, rolling counts by zone, ABC class, or velocity — so a slice of your inventory gets verified every single day. No annual count weekend. No shutting the floor down. Just accuracy that holds, quietly, all year.

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app.klovio.app/cycle-counts
ACCURACY
99.1%
COUNTED TODAY
142
OPEN VARIANCE
3
Today's count tasks · 4 zones
Zone A2 · Fast movers38 / 38Done
Zone B1 · Bulk dry24 / 41 ↑ countingOpen
Zone C4 · Slow movers0 / 19Queued
Cold A1 · Class A22 / 22Done
0
Shutdown days
Rolling counts run alongside the work. You never freeze the floor or lose a shift to counting.
99.1%
Sustained accuracy
Average count accuracy across customers running daily cycle counts in Klovio — and it holds all year.
3%
SKUs counted daily
A small, scheduled slice each day means every SKU gets verified several times a year, not once.
<24h
Variance to answer
A flagged discrepancy is investigated and recounted within a day — not discovered next December.
Why cycle counting matters

The annual count tells you you're wrong — a year too late.

A once-a-year physical count is a fire drill: you shut the warehouse, pull people off their jobs, and find out in one painful weekend exactly how far your numbers drifted over twelve months. By then the bad decisions are already made. Cycle counting flips the model — small, constant verification that catches drift the day it starts.

The shutdown you can't afford

The annual count means a frozen floor, a lost weekend, and a stack of overtime. And the moment you reopen, the count starts drifting all over again until next year.

The drift you never saw

Miscounts, mispicks, and shrink accumulate quietly for months. With one count a year, you discover the gap long after the trail of who, when, and why has gone cold.

The counter who already knows

When a counter sees the expected number first, they "find" it. Confirmation bias buries real variances. Without blind counts, your accuracy figure is partly a guess dressed up as a fact.

Before vs. after

Annual physical count vs. rolling cycle counts.

Same warehouse, same SKUs, same team. The only difference is whether accuracy is a once-a-year event or a daily habit.

❌ Without cycle counting
  • Shut the floor down once a year. A frozen weekend, overtime, and no shipping.
  • Drift runs unchecked for months. Errors compound silently until the big count.
  • Counters see the expected number. Confirmation bias quietly hides real gaps.
  • Variances are stale on arrival. No timestamp, no user, no trail — just a wrong number.
  • Recounts are chaos. "Count it again" with no defined task, owner, or record.
  • One number for the whole SKU. No idea which zone, lot, or location is off.
✅ With Klovio
  • Count a slice every day. Rolling tasks run around the work — zero shutdowns.
  • Drift is caught the day it starts. High-velocity SKUs get verified the most often.
  • Blind counts by default. The counter enters what they see — never what they expect.
  • Variances flag instantly. Every discrepancy has a user, device, time, and source.
  • Recounts are a workflow. Flagged items spawn a tracked recount task with an owner.
  • Per-zone, per-lot accuracy. Know exactly which location and lot is off, and by how much.
How it works

Three steps from schedule to settled count.

Klovio builds the day's count tasks automatically, hands the counter a blind list, and reconciles every variance against the live inventory the moment a number comes back.

STEP 01

Klovio builds the day's tasks

Set the cadence — by zone, ABC class, or velocity. Each morning Klovio generates the count tasks due today and routes them to the right counters and devices.

Auto-scheduled
STEP 02

The counter counts blind

The handheld shows the SKU and location — never the expected quantity. The counter scans and enters what's actually on the shelf, with no number to anchor to.

Bias-free
STEP 03

Klovio reconciles or flags

Matches settle silently and refresh the live count. Mismatches open a variance with full context and spawn a recount task — before stock ever moves on a bad number.

Instant variance
Variance tracking

Every gap, flagged with a paper trail.

When a counted quantity doesn't match the system, Klovio doesn't quietly overwrite it. It opens a variance — with the counter, device, location, lot, expected number, and counted number — and holds it for review before it touches your live inventory.

  • Auto-flag any variance over a threshold you set — by value, units, or percent
  • Every variance carries user, device, location, lot, and time
  • Approve, adjust, or send straight to recount in one tap
  • Every resolved variance writes a permanent entry to the audit log
See Audit Log →
Open variances · 3 to review
−6 Sea Salt 500g · Zone B1-04 · Lot 2241
Counted 12 · expected 18 · Daniel H · 8 min ago
+3 Brown Rice 5kg · Zone B1-09 · Lot 2198
Counted 97 · expected 94 · Daniel H · 11 min ago
−2 Honey 250g · Zone A2-B3 · Lot 1907
Recount requested · María R · 18 min ago
Olive Oil 1L · Zone A2-B1 · resolved
Recount matched · adjusted to 248 · 24 min ago
Count more where it matters
CLASS A
Weekly
CLASS B
Monthly
CLASS C
Quarterly
↓ Klovio builds today's queue ↓
Tasks generated today
142 SKUs
80% of value verified by counting 20% of the SKUs, every week.
Smart scheduling

Count your fast movers often. Count the rest enough.

Not every SKU deserves the same attention. Your Class A items — the 20% of SKUs driving 80% of throughput — drift fastest and cost the most when they're wrong. Slow movers can wait.

Klovio builds the schedule around that reality. Set a cadence per ABC class, per zone, or per velocity band, and the day's count queue assembles itself. High-value, fast-moving stock gets verified weekly; the long tail gets covered without burning your team's time.

  • Cadence by ABC class, zone, or movement velocity
  • Auto-balanced daily workload — no overloaded counting days
  • New high-velocity SKUs get pulled into rotation automatically
Under the hood

The life of a cycle count.

From a scheduled task on a handheld to a settled, audited number on every screen. A blind count in, a clean line item out.

SCHEDULE → SETTLED The life of a cycle count Blind in, audited out — no shutdown required. STEP 1 · DAILY Today's count tasks are generated Klovio assembles the queue by ABC class, zone, or velocity, and routes it to the right counters. blind list BLIND COUNT STEP 2 · ON THE FLOOR The counter enters what they see No expected quantity is shown. The handheld captures the scan, the count, the lot, the location, and the user. COUNT MATCHES Settle silently The live count is confirmed, the task closes, and accuracy ticks up — no one is interrupted. VARIANCE FOUND Flag & recount A variance opens with full context and spawns a tracked recount — before stock moves on a bad number. Every count writes to the audit log — accuracy you can prove. User, device, location, lot, expected, counted — captured on every single line. Counts feed the same live inventory engine your scans do. One source of truth, always.
The specifics

What cycle counting actually does in Klovio.

Related modules

Pairs well with.

Stop counting once a year. Start counting every day.

20 minutes is all it takes to see Klovio's cycle counting working on your zones, your classes, your velocity.

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