Automating Cycle Counts Without a WMS Overhaul

Published 2026-05-23 by Faraz Rahimi

You do not need a new WMS to stop counting the same empty bin with a clipboard. A queue, a phone, and a write-back will do.

Automating Cycle Counts Without a WMS Overhaul

Tags: Python, Inventory, Warehouse, SQL, Operations, unlisted

Cycle counts die when they are a yearly panic. They work when they are a daily trickle of the bins most likely to be wrong.

I pull a queue from SQL: high-velocity SKUs, bins with old last-counts, locations that had a mis-pick last week. The phone shows one bin at a time. Count, submit, next.

Do not fight the WMS if you cannot replace it

Write results to a table you own, then export in the format the WMS already accepts. A night job that posts adjustments is less risky than living in two systems that disagree all day.

Exceptions — cannot find the bin, cannot identify the item — should become visual-lookup jobs, not skipped rows.

Show the delta

People work harder when they can see variance dropping. A tiny dashboard of counted vs remaining beats a motivational poster.

Original post: https://farazrahimi.com/posts/automating-cycle-counts-without-a-wms-overhaul