Inventory discrepancies discovered at stocktake, not in the system, mean your decisions between stocktakes are based on numbers that aren't real.

Lot tracking records the origin lot for every unit of stock from goods receipt through dispatch. Expiry date management assigns an expiry date to each lot at receipt and enforces FEFO (first expired, first out) picking so the nearest-expiry stock is always picked first. Quality hold at receipt prevents out-of-specification lots from entering available stock. Forward traceability from a lot to all customer shipments containing that lot supports recall management. The specific configuration of lot attributes (batch number format, expiry date format, quality attributes captured at receipt) is designed around your product and regulatory requirements.

E-commerce integration (Shopify, WooCommerce, Magento) creates sales orders in the inventory system from web orders, decrements stock on fulfilment, and updates the e-commerce platform with tracking information. 3PL integration requires an API or EDI connection to the 3PL's WMS to send pick instructions and receive confirmation. The integration approach depends on what interfaces your 3PL exposes, most large 3PLs have EDI or API connectivity, smaller 3PLs may require file-based integration.

Inventory accuracy between full stocktakes is maintained through cycle counting, counting a subset of locations on a rotating schedule so every location is counted multiple times per year without disrupting operations. Discrepancies found during cycle counts are investigated and adjusted before they accumulate. High-value or fast-moving items are counted more frequently. The cycle count programme is configured in the system with count assignments generated automatically, results recorded by scan, and discrepancies flagged for investigation before adjustment posting.

Reorder point is average daily demand multiplied by supplier lead time in days, plus safety stock. Safety stock comes from a target service level (the Z-factor), demand variability, and lead-time variability, so a SKU with erratic demand or an unreliable supplier carries a larger buffer than a steady one. The system recalculates both per SKU per location as demand and actual receipt lead times change, so reorder points track reality instead of a number someone set once and forgot. When on-hand plus on-order falls below the reorder point, a purchase requisition generates automatically with the preferred supplier and expected delivery date pre-filled.

A first inventory module covering real-time stock visibility, goods receipt, pick-pack-ship, and basic replenishment starts around $30,000 to $50,000. The full platform, adding lot tracking, multi-warehouse management, 3PL integration, and e-commerce connectivity, grows to $100,000 to $150,000 over time. The price is fixed and agreed before each phase starts, so you fund the next module once the last one is live and earning its keep.