How Stackbox WMS Improves Inventory Productivity and Reduces Carrying Costs

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Venktesh Kumar

MD, Co-Founder | Stackbox

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‍How Stackbox WMS Improves Inventory Productivity and Reduces Carrying Costs

In an era of increasing SKU complexity and omni channel demand, inventory is no  longer just stock — it’s working capital, service capability, and a source  of competitive leverage. Yet, many warehouses struggle with bloated inventory, poor visibility, and low inventory turnover, leading to inflated carrying costs and compromised service levels

StackBox WMS bringsa new approach to inventory productivity — using real-time data, intelligentautomation, and AI-native features to reduce waste, increase turns, and boost accuracy.‍

 A.   The Problem: Inventory That Works Against You

When inventory is poorly managed, it leads to:

• Overstocking and obsolescence
• Missed FEFO/FIFO expiry handling
• Inaccurate bin-level visibility
• Excessive working capital tied up in stock
• Operational firefighting (stockouts, expedites, returns)

Resulting  in poor customer experience, high costs, and lower warehouse efficiency.

B.   StackBox WMS Inventory Management

Modern inventory isn’t just about having stock — it’s about having the right stock in the right place at the right time, with complete control and visibility. Stackbox WMS is built ground-up to enable this, blending deep operational logic with automation,real-time data, and AI.

 Here’s  How StackBox delivers best-in-class inventory performance:

KU ,Batch , Lot & Serial # Search at Bin Level

Quickly  Locate any item in the warehouse — by SKU, batch, lot, or serial number.

• Bin-level tracking ensures audit readiness
• Full traceability across the inventory lifecycle
• Accelerates QC, recalls, and expiry-based prioritization

Real-Time Inventory Visibility

Gaina single source of truth for inventory — from inbound dock to last outboundpick.

• Live updates across every movement
• Accurate down to LPN, Bin, SKU, Lot, Serial
• Supports both bulk and serialized handling

Expiry & Shelf-Life Management

Avoid stock aging and write-offs with built-in expiry control.

• Enforces FIFO/FEFO rules automatically at pick time
• Flags aged, expiring, or blocked stock
• Works seamlessly across pharma, food, and CPG SKUs
• System-Guided Cycle Counting

System-Guided Cycle Counting

Keep inventory accurate without disrupting operations.

• Intelligent ABC classification
• Trigger-based or schedule-based cycle counts
• Real-time reconciliation with minimal manual effort

Advanced Cross Docking

Maximize flow-through fulfillment.

• Supports Push, Pull, and Opportunistic cross-docking
• Matches inbound goods to pending outbound orders
• Reduces storage touchpoints and speeds up dispatch

Yard Stock Visibility & Norm-Based Prioritization

Connect inbound planning with yard execution.

• See what's in the yard before unloading
• Prioritize vehicle processing based on stock norms, urgency, or zone availability
• Improves dock utilization and reduces bottlenecks

Auto-Replenishment Rules

Eliminate  Stock Outs in pick faces and active zones.

• Configurable threshold-based replenishment
• Order-driven and forecast-driven logic
• Dynamically assigns replen tasks to nearest worker or AMR

Intelligent Slotting & Allocation

Ensure high-velocity SKUs are always easy to access.

• Slotting by SKU velocity, dimensions, frequency
• Allocation rules based on batch, expiry, FIFO/FEFO,customer priority
• Reduces travel, improves pick rates

Real-Time  Integration with ERP, TMS & OMS

Stackbox connects inventory updates to your entire fulfillment stack.

• Live APIs and native connectors (SAP, Oracle, NetSuite,MS Dynamics)
• Syncs orders, stock, movements, and statuses acrosssystems
• Ensures alignment across warehouse, transportation, andorder platforms

AI-Driven Inventory Optimization

At the heart of Stackbox is the Inventory Health Agent — an AI-powered assistant that helps supply chain teams:

• Identify stockouts before they occur
• Detect slow/non-moving SKUs
• Flag imbalanced stock across zones or sites
• Recommend reallocation or replenishment

“Stackbox doesn’t just track inventory — it thinks about it.”
— Global Inventory Manager, FMCG Customer

C.   Measurable Impact from Deployments

Across deployments in CPG, Pharma, and 3PL environments, Stackbox has delivered:

• 🎯 99.95% inventory  accuracy
• 📦 30–40% reduction stock
• 🔁 15–20% increase in  inventory turns
• ⏱️ 80% reduction in stock  reconciliation time
• 🧾 Improved audit readinessand traceability (by SKU, batch, and user)

 D.   Reduced Cost of Carrying Inventory

Byimproving inventory productivity, Stackbox helps reduce:

          Capital  Cost.                           Less  working capital locked in slow stock

          Storage  Cost                          Optimized  space via dynamic slotting

          Risk  Cost                                 Lower  expiry, obsolescence, and write-offs

          Handling  Cost                        Fewer  picks, touches, and recounts

          Insurance  / Shrinkage            Real-time  visibility & accountability

E.   Final Word: Make Every Unit of Inventory Work Harder

Inventory is one of the most controllable — yet under-optimized — levers in fulfillment.With Stackbox WMS, you transform it from a passive cost to a productive, traceable, and intelligent asset.

Inventory Productivity is no longer about counting better — it’s about  thinking  smarter.

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