The Hidden Risks of Inaccurate Stock Checks in 3PL Warehouses and How to Get It Right

The Hidden Risks of Inaccurate Stock Checks

• Operational disruption and downtime: A leading 3PL provider needed full inventory counts across their facilities. Without accurate stock checks, operations can stop and order fulfilment can be delayed, damaging customer service. RGIS delivered wall‑to‑wall counts over a weekend with minimal disruption, restoring accuracy rapidly without halting the business activity. (see case study: Third Party Logistics Distribution Centre Warehouse Count)
• Misplaced SKUs and inventory variances: A menswear retailer found nearly 2.1% variance, units located in the wrong bin or mixed with other brands, when audited by RGIS. These errors, left unchecked, can result in lost sales, overstock, or write‑offs. (see case study: Third Party Logistics Warehouse Count of Menswear Retail)
• Scale limitations with internal resources: A fashion group collaborating with its 3PL saw declining stock accuracy. RGIS deployed hybrid teams. 232 auditors plus trained 3PL staff, to count over 2 million units across 527,000 SKUs and 60,000 bins in eight days. Only by outsourcing did the client achieve reliable baseline data and a platform for ongoing cycle counts. (see case study: Combined Internal and External Third Party Logistics Warehouse Count)

How to Get Inventory Right with RGIS

• Rapid mobilisations, without business interruption: RGIS designs projects for minimal impact, full warehouse counts done across multiple locations in constrained timeframes, with audit shifts scheduled out of hours or over weekends
• Scalable audit teams with assured accuracy: From dozens to hundreds of experienced auditors, RGIS flexes capacity to suit facility size and complexity, using wireless scanners for speed and precision
• Insight that drives action: Variance reporting and root‑cause diagnostics uncover systemic errors, whether poor bin setup, mislabelling, or pick zone gaps, so issues are addressed proactively rather than reactively.
• Real‑time reporting and system integration: With data captured electronically, clients receive immediate digital results for upload into Warehouse Management Systems, plus dashboard insights to monitor trends and drive continuous improvement

Business Benefits of a Third-Party Inventory Specialist

• Minimised risk, maximised trust: Accurate, validated inventory counts build internal and external confidence, especially when retailer and 3PL systems don’t align.
• Improved service levels and availability: Correct stock data ensures the right items are in the right place, reducing stockouts, returns, and customer complaints.
• Reduced costs, better margins: With shrinkage, dead stock and mis‑shipments reduced, profitability improves, especially when counts feed into refined claims management and supplier performance reviews.
• Future‑proof operations: With a solid baseline from wall‑to‑wall counts and routine cycle audits, companies can move into predictive analytics and optimisation models.

Outdated inventory data in 3PL environments poses serious, but often invisible, risks. RGIS combines precision, scale and insight to eliminate data speculation and arm businesses with accurate, actionable inventory intelligence. From full warehouse counts without disruption to ongoing cycle audits and trend reporting via our dashboard. We don’t just help you manage your stock, we help you master it.

Let’s turn stock accuracy from a risk into a competitive advantage. Get in touch with the RGIS Ireland team if you would like to find out more.