Field Notes
Dual-control counting when high-value SKUs share a bay
Not every pallet needs two people. Dual-control earns its keep on SKUs where a single miscount moves the financial statements — or where theft risk is known.
Draw the dual-control map early
On the zone map, mark cages, locked cabinets, and open bays that still hold serialised goods. Observers should know these borders before the briefing, not discover them mid-count.
Separate the recorder from the picker
One person handles units; another records. Swapping roles mid-bay invites shortcuts. We watch for that swap more often than for arithmetic errors.
Serial lists beat “approximate boxes”
For electronics and watches, count serials or sealed inner packs — not “about twelve per carton.” If seals are broken, open and count; log the break.
Do not dual-control the whole warehouse as theatre
Spreading dual-control everywhere exhausts the night shift and dilutes attention. Concentrate observers where the risk sits, and keep standard two-person spot checks elsewhere.
For a full coordination engagement that includes dual-control zones, see inventory count audit coordination.