Miscounts during warehouse operations often happen in bulk storage areas without proper organization or labeling. These mistakes can slow down shipping, disrupt counts, and lead to lost inventory.
To prevent miscounts, use labeled zones, assign clear pallet locations, and follow a step-by-step counting process. These simple changes help maintain accuracy and improve efficiency.
How to Organize Bulk Storage Areas
Why designated spaces matter
When we first set up a bulk storage area, our main focus is to break the floor into smaller zones. Instead of keeping 100+ pallets in one wide open space, we divide them into smaller sections that each hold 10 to 20 pallets. This makes it easier for our team to locate and count them correctly.
Use visual tools for better tracking
We always recommend:
- Paint striping on the floor to show where each pallet goes
- Location IDs painted on the floor for each section
- Signs hanging overhead with the same IDs, which can include barcodes for faster scanning
These steps help any team member instantly recognize where things belong, which keeps our counts accurate.
Pro Tip: Match the painted location IDs with what’s in your inventory system. That way, there’s no mix-up between physical storage and digital records.
Best Practices for Staging Before Counting
Why staging is important
You can’t count what you can’t see. In bulk storage, pallets are often stacked close together or on top of each other. It’s almost impossible to count them accurately without moving them first.
Before we begin a cycle count, we always stage the pallets. This means pulling them out of tight spaces and spreading them out in an open area. It might take extra time up front, but it saves us from recounting later.
Where to stage pallets
If your space is tight, you can use:
- The drive path if it’s wide enough
- A shipping or receiving area
- Any open floor space not in use at that moment
Just be sure there’s enough room for the counter and verifier to walk around each pallet.
Key Takeaway: Staging gives you a clear view of each pallet, reducing the chance of missed or double-counted items.
Need expert help with bulk storage layout or inventory setup? Contact Monarch Inventory Services for a free consultation. We’ll help you prevent miscounts and keep your warehouse running smoothly.
How to Count Pallets with a Single SKU
Step-by-step counting method
When pallets have just one SKU (item type), counting is easier. Here’s the method we follow:
- Identify the pallet’s location
Use a scanner to enter the location ID. - Scan the item label
Most pallets will have a front label with the item number. Scan it to confirm what you’re counting. - Check the tie and high
- Tie = number of cases on one layer
- High = number of layers on the pallet
- Multiply tie × high to get the total number of cases.
- Multiply by units per case
For example, if each case has 3 units, and you have 40 cases:
40 × 3 = 120 total units. - Submit the count
Enter the final number into your system. - Mark the pallet
Stick a pink dot on the front of the pallet. This tells everyone the count is done.
Why this works
This process keeps things simple and fast. As long as your label is correct and easy to scan, your team can complete the count without second-guessing.
Avoiding Miscounts in Bulk Storage
Stay ahead with good labeling
We prevent most miscounts in bulk storage by making sure every pallet has:
- A clear, scannable label
- An assigned floor location
- A painted section or barcode overhead
This way, nobody has to guess where something goes or whether it’s already been counted.
Train your team
Even with a great system, people still make mistakes. That’s why we train every worker on:
- How to stage pallets
- How to read tie/high configurations
- How to use scanners and software correctly
- How to flag any problems during a count
Final Thoughts: Keep It Simple and Clear
Preventing miscounts in bulk storage starts with a smart layout, clear labels, and simple steps. By staging pallets, using floor markers, and training your team, you can reduce errors and save hours of work.
If you’re ready to make your bulk storage more accurate and efficient, we’re here to help. Call us at Monarch Inventory Services today to schedule a quote or learn more about our warehouse solutions.
