How Stackbox WMS Improves Inventory Productivity and Reduces Carrying Costs

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Venktesh Kumar

MD, Co-Founder | Stackbox

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‍HowStackbox WMS Improves Inventory Productivity and Reduces Carrying Costs

Inan era of increasing SKU complexity and omnichannel demand, inventory is nolonger just stock — it’s working capital, service capability, and a sourceof competitive leverage. Yet, many warehouses struggle with bloated inventory,poor visibility, and low inventory turnover, leading to inflated carryingcosts and compromised service levels.

StackboxWMS bringsa new approach to inventory productivity — using real-time data, intelligentautomation, and AI-native features to reduce waste, increase turns, and boostaccuracy.‍

 A.   TheProblem: Inventory That Works Against You

Wheninventory 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)

Resultingin poor customer experience, high costs, and lower warehouse efficiency.

B.   StackboxWMS Inventory Management

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

 Here’show Stackbox delivers best-in-class inventory performance:

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

Quicklylocate 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-TimeInventory 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

Avoidstock 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-GuidedCycle Counting

System-GuidedCycle Counting

Keepinventory accurate without disrupting operations.

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

AdvancedCross Docking

Maximizeflow-through fulfillment.

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

YardStock Visibility & Norm-Based Prioritization

Connectinbound 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-ReplenishmentRules

Eliminatestockouts 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

IntelligentSlotting & Allocation

Ensurehigh-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-TimeIntegration with ERP, TMS & OMS

Stackboxconnects 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-DrivenInventory Optimization

Atthe heart of Stackbox is the Inventory Health Agent — an AI-poweredassistant 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

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

C.   MeasurableImpact from Deployments

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

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

 D.   ReducedCost 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

Inventoryis 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.

Inventoryproductivity is no longer about counting better — it’s about thinkingsmarter.

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