Auto Parts Annual Full Physical Inventory Prep Audit

Inspection template for a pre-physical-inventory walk in an auto parts facility, verifying back stock is zoned, labeled, accessible, and ready for an accurate annual full physical inventory count.

Inspection Scope and Count Readiness

• Inspection area and inventory date confirmed
  Verify the walk covers the correct sales floor, back stock, bulk storage, and any off-floor inventory areas scheduled for the annual count.
• Count freeze or movement cutoff communicated
  Confirm the team has been notified of the inventory freeze time, restricted movement rules, and who may authorize exceptions.
• Count maps, zone list, or location list available
  Verify current zone maps, bin lists, or location sheets are available for the areas being inspected.
• Inventory prep issues identified for follow-up
  Record any areas that need correction before the physical count begins, such as mixed locations, unlabeled bins, or blocked access.

Back Stock Zoning and Location Control

• Back stock is segregated by assigned zone or location
  Verify parts are stored in the correct zone, bay, rack, shelf, or bin location and are not mixed across count areas.
• Mixed or unassigned stock is isolated and tagged
  Confirm any stock without a clear location assignment is separated, labeled, and held for resolution before the count.
• Bin labels and location identifiers are legible and consistent
  Check that bin labels, shelf tags, and location codes are readable and match the location system used for the count.
• Overstock, top stock, and reserve stock are clearly marked
  Verify reserve inventory is identified as back stock or overstock and is not being counted as active pick-face inventory.
• Location exceptions documented
  List any parts found in the wrong zone, duplicate locations, temporary storage areas, or other location-control exceptions.

Inventory Organization and Count Accuracy

• Parts are grouped by part number and description
  Verify like items are grouped together and not commingled with similar-looking parts, superseded parts, or unrelated SKUs.
• Open cartons, loose pieces, and partial cases are identified
  Confirm partial quantities are clearly marked so counters can distinguish full cases from opened containers and loose units.
• Damaged, obsolete, return, or quarantine stock is separated
  Verify non-saleable or restricted inventory is isolated from countable stock and marked for review.
• Count sheets or system locations match physical layout
  Check that the count sequence, bin order, or system location list reflects the actual physical arrangement of stock.
• Organization issues affecting count accuracy
  Document any mixed SKUs, unlabeled containers, duplicate part placements, or other conditions that could cause count errors.

Accessibility, Housekeeping, and Safety Conditions

• Aisles and count access paths are clear
  Verify aisles, ladder access points, and count paths are unobstructed so stock can be safely reached and counted.
• Stock is stable and stored to prevent falling or shifting
  Check that stacked cartons, tires, batteries, fluids, and other parts are stored securely and will not shift during the count.
• PPE requirements are posted and available for the walk
  Confirm required PPE for the area is known and available, such as safety glasses, gloves, or high-visibility gear.
• Housekeeping issues that may affect the count are noted
  Record debris, spills, blocked racks, poor lighting, or other conditions that could affect safe access or inventory accuracy.

Exceptions, Corrective Actions, and Sign-Off

• Corrective actions assigned for all critical deficiencies
  Verify every critical deficiency has an assigned owner, due date, and follow-up action before the annual count begins.
• Inspector comments summarize readiness status
  Summarize whether the location is ready for the physical inventory count and note any remaining risks or open items.
• Inspector signature
  Inspector signs to confirm the pre-count walk was completed and findings were recorded.