Warehouse Cycle Count Agent
Runs automated cycle counting programs across warehouse zones, comparing physical scans to WMS records and flagging discrepancies for reconciliation.
Manual cycle counts are typically scheduled ad hoc, executed on paper or spreadsheets, and reconciled days later, by which time pick errors and stockouts have already occurred
Supervisors struggle to prioritize which SKUs or bins need recounting, so high-velocity items often go unchecked for weeks while slow movers get counted repeatedly
Discrepancy investigation is manual and inconsistent, with root causes rarely logged, so the same errors recur
This agent builds a risk-weighted count calendar, dispatches tasks to handheld scanners, and reconciles results against the WMS in real time
The agent is triggered on a rolling schedule and by inventory-accuracy risk signals such as recent pick errors, negative on-hand balances, or high shrink SKUs. It pulls WMS location and quantity data via API, generates a prioritized count list weighted by SKU velocity and dollar value, and pushes tasks to RF scanners or mobile apps. An LLM layer reviews variance patterns against historical adjustment logs to classify likely root causes (mis-pick, receiving error, damage, theft) and drafts adjustment tickets for supervisor approval. Approved adjustments post back to the WMS automatically, and a rolling accuracy dashboard is updated after each cycle.
Generate Risk-Weighted Count Plan
- Pull on-hand balances and movement history from WMS
- Score bins/SKUs by variance risk and dollar exposure
- Build daily count assignments by zone and shift
- Publish count list to scanner queues
Capture and Validate Counts
- Receive scan results from handheld devices
- Cross-check against expected system quantities
- Trigger blind recount on variances above threshold
- Flag serial/lot mismatches separately
Classify and Route Variances
- Apply LLM analysis to historical variance patterns
- Tag likely root cause per discrepancy
- Draft adjustment ticket with supporting evidence
- Route high-value variances to supervisor for approval
Post Adjustments and Report
- Push approved adjustments back to WMS
- Update rolling inventory accuracy metrics
- Log root-cause trends for process improvement
- Distribute weekly accuracy scorecard to operations leadership