Inventory Optimization ProAdvisory by Sharon Custer Free 30 minutes

20 Sep 2026

Where Your Inventory Number Is Actually Made

Margin moved again, and nobody could say why.

The books reconciled. The close went through. Nothing was flagged. And the number still moved.

When that keeps happening, the problem is usually not in the decision you are making. It is in where the number came from. An inventory figure is made in one place and spent in another, and almost all of the trouble starts in the first.

STAGE 1 · MAKE THE NUMBER TRUEalmost nobody works here1The item listDuplicate SKUs. Naming nobody agreed on. Pricing data that disagrees with itself.2The costThe COGS method changes. Two teams calculate landed cost differently. Nobody logs it.3The handoffPurchase order, receipt and invoice dated on three logics, so cost lands in the wrong month.4The floorReceiving, dispense, physical counts, returns, stock count. Record and reality separate here.THE INVENTORY NUMBEROne figure. On the balance sheet, inside every margin, under everything below.STAGE 2 · DECIDE WITH ITeveryone sells here1What is worth holdingABC analysis, stock level review, and the action plan behind it.2What is worth sellingProduct mix and channel. COGS, pricing and profit, by line.3What happens ifScenarios for cash, profit and working capital. Demand forecast by SKU.4What you commit toInventory budget, quantity and cash flow projection, the financial model, reporting.WHAT IT IS ALL FORWorking capital downProfit upCash flow upTime savedFewer people on itINVENTORYOPTIMIZATION.PRO
Four places an inventory number gets made, and the four decisions that spend it.

Stage 1 is where the number gets made

None of these four look like finance problems, which is exactly why they survive. A duplicate SKU is a tidiness issue until you notice that quantity, value and two years of sales history are split across both records. A change in costing method is a technical footnote until gross margin drops four points and nobody can say which month it started.

A medical consumables company I worked with had reconciled the same unexplained adjustments every month for two years. Purchase orders, supplier invoices and warehouse receipts were dated on three different logics, so cost kept landing in the wrong period. Twenty thousand dollars of adjustments, all reconciled, none of them explained. Nobody had ever mapped the timing across all three.

Stage 2 is where it gets spent

ABC analysis, product mix, channel profitability, scenarios, the inventory budget, the financial model, the board pack. All good work. And every one of them takes the Stage 1 number as given.

A packaging distributor was celebrating a carton size that made 35% of revenue. The analysis was not wrong. It just answered the question that was asked. That product turned 1.5 times a year, and nobody had put revenue contribution and capital consumption on the same page. It was the single biggest drag on their working capital and they had been doubling down on it.

Why this is getting worse, not better

AI reads the file in seconds and writes a clean summary. It cannot see that the costing method changed in March. It cannot see that two SKUs are the same product. It summarises what you gave it, confidently, and now the wrong number arrives faster and in better prose.

Where to start

Pick the station on that diagram you recognise, and ask one question about it this week.

If it is the handoff: which date decides the period a cost lands in, the purchase order, the receipt or the invoice? Ask purchasing, receiving and accounting separately, and do not tell them why. If the three answers differ, you have found it.

If it is the item list: ask two people for the inventory value without telling them you asked the other.

If it is the cost: ask who last changed how landed cost is calculated, and when.

The point of any of this is not a tidier warehouse. It is being the person in the room who can say where a number came from and what was checked, and have it hold when somebody pushes on it.


Is this your number?

If your close balances and the number still moves, this is the work: a month-end figure that matches what actually happened.

Trust the close