🔢 SOP 27 — Stock Counting

SOP Name:         Stock Counting
Process Code:     STOCK_COUNT_V1
Version:          V1
Owner:            Factory Supervisor
Applies To:       Factory Supervisor, Labour Team
Frequency:        Daily (end of day) and weekly full count
Last Updated:     2026-06-25
Review Frequency: Monthly

1. Purpose

Count finished brick stock accurately so reports, dispatch and planning use real numbers.

2. Who Is Responsible

Factory Supervisor — runs the count and records totals.
Labour team — assists with counting by batch.

3. When To Use This SOP

End of each production day (quick count) and a full count weekly.

4. Visual Process Flow

flowchart TD
A[Start count] --> B[Count by mini-stacks x 20]
B --> C[Total by product type]
C --> D[Separate approved / hold / reject]
D --> E[Compare with batch cards]
E --> F{Match?}
F -- Yes --> G[Record stock]
F -- No --> H[Recount + investigate]

5. Step-by-Step Visual SOP

Count using mini-stacks of 20 (STACK20_SLEEPER_V1) for speed.
Total separately by product: MIB 8", MIB 6", CIB, solid block.
Keep approved, hold and reject counts separate.
Cross-check totals against batch cards.
Recount any batch where the card and physical count disagree.
Record the final stock figures.
Note any damage/loss found during counting.

6. Do / Don't

✅ Do	❌ Don't
Count in 20-brick stacks	Estimate by eye
Keep product types separate	Lump all products into one total
Reconcile with batch cards	Ignore card vs physical mismatch

7. Checklist

[ ] Counted by mini-stacks of 20
[ ] Totals split by product type
[ ] Approved / hold / reject separated
[ ] Reconciled with batch cards
[ ] Mismatches recounted
[ ] Stock figures recorded
[ ] Damage/loss noted

8. Records To Update

🔵 Stock register / count sheet
🔵 Daily Production Report
🔵 Future: Odoo stock.quant adjustment

9. Escalation Rule

Inform Ram/Srinivasan if physical stock does not match batch cards/records after recount, or if unexplained loss/damage is found.

10. Common Mistakes

Estimating instead of counting stacks.
Mixing product types in one total.
Not investigating a card-vs-physical mismatch.

11. Improvement Suggestion

If you find a better way to do this process, add a comment below or submit an improvement request in the SOP Improvement Register.

Automation Readiness

Telegram command: /stock
n8n workflow:     wf_stock_count_v1
Odoo object:      stock.quant
Approval role:    Factory Supervisor
Supabase table:   stock_counts
Status:           Future automation