SBX WOS · Warehouse Orchestration System

Orchestrate Everything That Moves Inside Your Warehouse — in Real Time

Stackbox WOS thinks, plans, and executes across every operator, MHE, robot, and automation asset — simultaneously, continuously, and without waiting for a supervisor’s next radio call.

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A system that doesn't just track. It thinks.

Warehouse orchestration- the missing layer between your WMS and your automation hardware.

Traditional warehouse management systems track inventory and record transactions. Warehouse control systems direct individual machines. But neither was built to coordinate the full operational reality of a modern mechanized distribution center — where dozens of MHE operators, AMRs, AGVs, reach trucks, and fixed automation make thousands of interdependent decisions every hour. The result is predictable: aisle conflicts, pick starvation, MHE type mismatches, dock coordination failures, and supervisors spending every shift firefighting rather than managing. These are not equipment problems or people problems. They are orchestration problems. Stackbox WOS is the real-time orchestration layer that sits above your existing WMS — continuously answering four questions across every shift: What needs to be done right now? Who — operator and MHE — should do it? In what sequence? And how should the plan adapt when conditions change?

How Stackbox WOS Works

A persistent real-time orchestration layer between your WMS and your physical warehouse operation.

Planning & Optimization

Order & Wave Planning

Segments and sequences orders into optimized batches or waves considering dock capacity, cutoffs, and order mix

Containerization & Packing Logic

Determines quantity and type of containers (e.g., crates, totes, cartons) required for efficient dispatch or staging.

Material Flow Determination

Determines the most efficient execution path for orders, SKUs, and workloads based on velocity, SLA, and resource profiles

Resource Planning

Predicts required equipment, stations, manpower capacity for planned wave

Station & Zone Allocation

Optimally maps workload to execution zones, equipment, or GTP stations to balance utilization

Simulation & Scenario Planning

Enables “what-if” modeling of workload distribution, resource changes, or fulfillment constraints.

Multi Agent Orchestration

Task Granularization

Breaks high-level workflows into micro-tasks tailored to specific executor types (e.g., picker, AMR, sorter).

Dynamic Task Allocation

Assigns and sequences tasks based on real-time factors like proximity, priority, skill level, or equipment availability.

Unified task dispatcher

for AMRs, AGVs, AS/RS, conveyors, forklifts, and human operators including cross-agent collaboration and dynamic handoffs between automation layers

Workload Balancing

Distributes tasks intelligently across resources and zones to avoid congestion or idle time.

Task Interleaving

Combines compatible workflows to reduce redundant travel or touchpoints.

Real-Time Reprioritization

Adjusts task queues dynamically in response to SLA risk, system events, or exceptions

Exception Handling & Auto-Recovery

Detects failures, delays, or skips and reroutes or reassigns tasks without manual intervention.

Interoperability

Hardware Abstraction Layer (HAL)

Standardizes communication with automation equipment (e.g., AMRs, ASRS, conveyors, PTL, robotics).

Protocol Flexibility

Supports REST, MQTT, OPC-UA, TCP/IP, andcustom OEM integrations

Multi-Agent Synchronization

Enables real-time coordination between humans and machines as a single execution mesh.

Device-Aware Routing

Sends optimized task instructions based on each device’s constraints and state (e.g., charge, load, queue)

Fleet-Agnostic Support

Works with multiple vendors or mixed fleets within a single site or across sites.

Integration

ERP/OMS/TMS Integration

Syncs inventory, order, and shipment data bi-directionally with SAP, Oracle, NetSuite, Dynamics, and others.

Event-Driven Architecture

Enables responsive, low-latency system behavior via webhooks and message queues.

Data Normalization & Reconciliation

Ensures accurate alignment between physical operations and digital records

API Gateway & SDKs

Provides standard and extensible APIs for customer-specific integrations and partner ecosystems

External Visibility Readiness

Supports integration with control towers, analytics layers, and digital twin platforms.

12 Orchestration Levers. One Continuously Optimized Operation.

Stackbox WOS orchestrates every dimension of warehouse operations — from order planning to last-mile task execution — across humans, mobile robots, and fixed automation.

Stackbox WOS delivers warehouse orchestration through twelve interconnected levers — each addressing a specific dimension of coordination failure in the mechanized DC. Deployed together, they create compound returns no single lever achieves alone.

Vehicle Appointment Scheduling

Replaces unannounced vehicle arrivals and ad-hoc dock allocation with a pre-planned, capacity-matched schedule. Every carrier books a slot. Every dock door is pre-assigned. Every MHE team is positioned and ready before the vehicle arrives.

Unplanned arrivals ↓75%Dock start delay ↓80%No-show rate ↓70%

Dock appointment scheduling interface for Vehicle Appointment Scheduling feature

Automated Dock Allocation

Once a vehicle is confirmed on-site, WOS assigns it to the optimal dock door in under 30 seconds — based on cargo type, vehicle size, inbound/outbound direction, weighted dock-to-storage distance, and current MHE availability. No supervisor intervention required.

Assignment time ↓95%Door mismatches → ZeroMHE ready rate ↑85%

Lever 02 feature visualization on the SBX WOS page

SLA & Resource-Constrained Work Planning

Shift plans are built against real constraints — carrier cut-off windows, order SLAs, operator certifications, MHE availability, and battery state — not static templates. The plan is feasible before the shift starts, and continuously reoptimized as conditions change.

SLA breach risk ↓80%Plan feasibility 95%+Deviation response <3 min

Automated Task Allocation

Tasks are pushed to operators — not pulled. WOS evaluates operator certification, current MHE, location in the DC, current task status, battery level, and workload balance before assigning. The highest-priority eligible task always goes to the most suitable available resource.

Idle time ↓40%Task allocation → SecondsWorkload equity ↑

Picking Orchestration

Dynamic wave formation, batch picking, zone-skip routing, and cluster optimization — all built around the live order profile, pick face availability, and carrier cut-off urgency. Pick travel distance reduces by 30–35% from day one.

Pick travel ↓35%Pick accuracy 99.5%+Units per trip ↑

Putaway Orchestration

Every putaway task is assigned to the optimal storage location based on product velocity, slotting strategy, aisle balance, and current racking occupancy. WOS prevents overloading of aisles and levels — and ensures high-velocity SKUs are always in the most accessible positions.

Putaway travel ↓25%Slotting compliance ↑Aisle congestion ↓

Task Interleaving

Instead of completing one task type before the next, WOS combines putaway, picking, and replenishment into a single MHE trip — eliminating empty travel between tasks. A reach truck that has just completed a putaway is immediately directed to the nearest pick task on the route back.

Empty travel ↓80%Productivity ↑25–40%Workload equity ↑

Replenishment Orchestration

WOS monitors pick face stock levels in real time and triggers replenishment before a stockout occurs — not after a picker shouts over the radio. Replenishment tasks are interleaved with active picking waves to ensure zero pick starvation.

Pick starvation → Near zeroReplenishment lead time ↓60%

Aisle & Traffic Management

Virtual aisle locking prevents two reach trucks from entering a narrow aisle simultaneously — eliminating deadlocks before they happen. WOS routes MHE across aisles based on real-time occupancy, task sequence, and aisle width constraints.

Aisle deadlocks → ZeroEmpty aisle travel ↓Peak-hour throughput ↑

Slotting Optimization

WOS continuously monitors your actual order profile against your current slotting configuration — and calculates a design compliance score. When compliance drops below threshold, WOS identifies the specific relocations that will recover throughput, and triggers a re-slotting plan.

Pick travel ↓15–25% post-reslotDesign compliance tracked continuously

Resource Orchestration

A system-level view across all twelve levers — tracking operator workload, MHE utilization, zone productivity, and SLA progress simultaneously. WOS surfaces redeployment recommendations when zones fall behind, and reallocates resources automatically where configured to do so.

Zone productivity variance ↓Supervisor radio calls ↓70%On-time dispatch ↑14%

MHE Fleet & Battery Management

WOS tracks battery state-of-charge for every MHE asset in real time — and rotates charging tasks into the shift plan before batteries reach critical levels. No mid-shift breakdowns, no aisle blockages from dead machines, no unplanned downtime during peak periods.

Mid-shift battery failures → Near zeroMHE uptime ↑Charging rotation automated

Why Stackbox WOS

Stackbox WOS is purpose-built for the complexity that WMS, WCS, and WES platforms were not designed to handle.

Design-Aware Execution

WOS closes the loop between facility design, daily planning, and task execution — continuously. It tracks a real-time design compliance score and triggers reslotting when throughput begins to degrade.

Vendor-Agnostic by Architecture

Integrate any AMR, AGV, MHE, or automation OEM without rearchitecting your stack. WOS becomes the stable orchestration layer as your hardware evolves beneath it.

Proactive, Not Reactive

In an unorchestrated DC, supervisors respond to problems after they occur. In a WOS-orchestrated DC, exceptions are detected, impact is calculated, and corrective action is recommended — in under 5 minutes, not 30–60.

Fast Implementation. Measurable Value.

Capital-efficient deployment with measurable operational outcomes — not multi-year rollouts. Stackbox customers see throughput improvement and MHE utilization gains before full go-live.

MHE-First Orchestration

WOS was built for mechanized DCs where Reach Trucks, BOPTs, HOPTs, and Stackers are the primary assets. Every task assignment checks MHE type, certification, battery state, and current location before dispatch.

Augments Your Existing WMS

Stackbox WOS integrates with SAP, Oracle, Manhattan, and all major WMS platforms. There is no rip-and-replace. WOS becomes the orchestration intelligence layer above your existing warehouse software.

Planning & Optimization

Order & Wave Planning

Segments and sequences orders into optimized batches or waves considering dock capacity, cutoffs, and order mix

Containerization & Packing Logic

Determines quantity and type of containers (e.g., crates, totes, cartons) required for efficient dispatch or staging.

Material Flow Determination

Determines the most efficient execution path for orders, SKUs, and workloads based on velocity, SLA, and resource profiles

Resource Planning

Predicts required equipment, stations, manpower capacity for planned wave

Station & Zone Allocation

Optimally maps workload to execution zones, equipment, or GTP stations to balance utilization

Simulation & Scenario Planning

Enables “what-if” modeling of workload distribution, resource changes, or fulfillment constraints.

Stackbox UI design portfolio for logistics software

Stackbox UX design case study for warehouse operations

Multi Agent Orchestration

Task Granularization

Breaks high-level workflows into micro-tasks tailored to specific executor types (e.g., picker, AMR, sorter).

Dynamic Task Allocation

Assigns and sequences tasks based on real-time factors like proximity, priority, skill level, or equipment availability.

Unified task dispatcher

for AMRs, AGVs, AS/RS, conveyors, forklifts, and human operators including cross-agent collaboration and dynamic handoffs between automation layers

Workload Balancing

Distributes tasks intelligently across resources and zones to avoid congestion or idle time.

Task Interleaving

Combines compatible workflows to reduce redundant travel or touchpoints.

Real-Time Reprioritization

Adjusts task queues dynamically in response to SLA risk, system events, or exceptions

Exception Handling & Auto-Recovery

Detects failures, delays, or skips and reroutes or reassigns tasks without manual intervention.

Interoperability

Hardware Abstraction Layer (HAL)

Standardizes communication with automation equipment (e.g., AMRs, ASRS, conveyors, PTL, robotics).

Protocol Flexibility

Supports REST, MQTT, OPC-UA, TCP/IP, andcustom OEM integrations

Multi-Agent Synchronization

Enables real-time coordination between humans and machines as a single execution mesh.

Device-Aware Routing

Sends optimized task instructions based on each device’s constraints and state (e.g., charge, load, queue)

Fleet-Agnostic Support

Works with multiple vendors or mixed fleets within a single site or across sites.

Stackbox supply chain app user interface design

Integration

ERP/OMS/TMS Integration

Syncs inventory, order, and shipment data bi-directionally with SAP, Oracle, NetSuite, Dynamics, and others.

Event-Driven Architecture

Enables responsive, low-latency system behavior via webhooks and message queues.

Data Normalization & Reconciliation

Ensures accurate alignment between physical operations and digital records

API Gateway & SDKs

Provides standard and extensible APIs for customer-specific integrations and partner ecosystems

External Visibility Readiness

Supports integration with control towers, analytics layers, and digital twin platforms.

The Material Graph

A real-time graph of every material movement, handoff, and decision node — from goods receiving to dispatch.

From the moment a carrier books an appointment to the moment the last outbound trailer departs, Stackbox WOS models every task, handoff, delay point, and decision node in your facility. This material graph is the operational intelligence that enables predictive intervention before bottlenecks compound across the shift, system-wide optimization across inbound, storage, and outbound flows simultaneously, seamless integration of new automation assets without operational disruption, and digital simulation of layout changes, slotting strategies, and flow configurations before implementation.

Stackbox WOS manages fixed automation, mobile robot fleets, and human workforces under a single orchestration layer — with no vendor lock-in.

Fixed Automation — AS/RS, Conveyors, Sorters, Palletizers

Orchestrates thousands of micro-decisions per second to maintain flow continuity

Interfaces with PLC and OEM WCS layers to issue live commands

Monitors asset health, cycle times, and congestion across zones

Syncs upstream/downstream systems to avoid overloading

Supports capacity-aware buffering and zone prioritization

Enables integration of multiple fixed systems as a cohesive network

Mobile Automation — AMRs, AGVs, Reach Trucks, Stackers, BOPTs, HOPTs

Unified fleet management across multi-vendor AMRs and AGVs

Real-time task assignment based on location, battery, load, and traffic

Intelligent routing with dynamic path replanning

Cross-zone coordination with human and fixed assets

Unified navigation map that harmonizes diverse SLAM schemas

Interoperability layer for mixed OEM coordination under one logic

Human Workforce

Skill-based task assignment and SOP guidance

Real-time collaboration with bots and machines via mobile apps

Supports interleaved workflows

Task escalation and exception handling built-in

Tracks fatigue, overutilization, and performance insights

Contextual nudges and adaptive task queues for continuous efficiency

Unified navigation layer

A Unified Navigation Engine that seamlessly augments, translates, and overlays navigation schemas from multiple mobile automation vendors — unifying them into a single global warehouse map.

Whether you're running AMRs, AGVs, or mobile pickers from different OEMs, Stackbox WOS eliminates silos by:

• Interprets SLAM/local maps into a shared spatial language
• Enables cross-vendor coordination
• Visualizes all movement in real time
• Supporting dynamic updates as new zones, racks, or routes are introduced

Your warehouse mission control

Real-time visibility + AI-powered foresight.

Live dashboards for asset health, task progress, and exceptions

Alerts, cycle-time trends, predictive congestion, and fatigue detection

Decision override capabilities and escalation workflows

Testimonials

Stackbox WOS transformed how we coordinate dock operations and MHE fleets. Our dock-to-stock time dropped by over 50% in the first quarter of deployment and our supervisors now manage by exception, not by radio.

Head of Supply Chain Operations

Head of distribution, Mumbai

Testimonials

The real-time orchestration WOS provides was the missing piece in our DC. Pick travel is down 35%, MHE utilization is up significantly, and our aisle conflict rate is essentially zero since go-live.

VP Warehouse Operations

Retail DC Operations, India

Testimonials

WOS integrated with our existing SAP environment without any rip-and-replace. We saw measurable throughput improvement within weeks, and the automated battery rotation has practically eliminated mid-shift MHE failures.

Director, Distribution & Logistics

3PL Operations, Southeast Asia

FAQS

Frequently Asked Questions

Want to know more? Email us at contact@stackbox.co.in

Get in touch

What is a Warehouse Orchestration System (WOS)?

A Warehouse Orchestration System (WOS) is an AI-powered software platform that thinks and acts in real time — continuously coordinating every operator, MHE, mobile robot (AMR/AGV), and fixed automation asset across a distribution center in real time. Unlike a warehouse management system (WMS) that tracks inventory, or a WCS/WES that controls individual machines, a WOS acts as the decision-making intelligence above both — continuously planning, executing, and adapting every task, resource, and route decision across the full shift.

How is Stackbox WOS different from a WMS or WES?

A WMS manages inventory and records warehouse transactions. A WES (Warehouse Execution System) translates WMS instructions into machine-level control. A WOS operates above both — continuously orchestrating every asset, task, and flow across the entire facility, including human operators and MHE fleets. The key distinction is real-time adaptability: WMS and WES systems are largely static and reactive. Stackbox WOS reoptimizes continuously, detecting exceptions and recommending corrective action in under 5 minutes.

Does Stackbox WOS replace my existing WMS?

No. Stackbox WOS integrates with and augments your existing warehouse management system — whether SAP, Oracle, Manhattan, or any other WMS platform. WOS adds an intelligent orchestration layer above your existing WMS without requiring a rip-and-replace. Most implementations go live with measurable operational improvements before the full WOS feature set is deployed.

Is Stackbox WOS suitable for FMCG and 3PL warehouses in India?

Yes. Stackbox WOS was purpose-built for the operational complexity of high-throughput FMCG, 3PL, and retail distribution centers. It is deployed across India and Southeast Asia with customers including Nestlé, P&G, Walmart, Unilever, and Coca-Cola. The platform handles the full range of mechanized DC environments — multi-tier racking, mixed MHE fleets, high SKU velocity, and omnichannel order profiles — that characterize FMCG and 3PL operations in India.

Does WOS work with any automation or MHE vendor?

Yes. Stackbox WOS is fully vendor-agnostic. Its interoperability layer standardizes communication across all OEMs — AMR vendors, AGV suppliers, AS/RS providers, reach truck telematics systems, and conveyor manufacturers. Mixed fleets from multiple vendors run under one orchestration logic. The platform supports REST, MQTT, OPC-UA, and TCP-IP protocols to cover the full range of automation hardware found in modern DCs.

What industries does Stackbox WOS support?

Stackbox WOS is deployed across FMCG, retail, e-commerce, 3PL, pharma, and manufacturing distribution centers. The platform is particularly well-suited to high-velocity operations with complex MHE environments, multi-tier racking, and strict carrier SLAs — which describes the majority of large-format DC operations in India and Southeast Asia.

What measurable outcomes does Stackbox WOS deliver?

Based on deployments across global supply chain operations, Stackbox WOS consistently delivers: warehouse throughput ↑25%, MHE utilization ↑30–80–90% from 45–60% baseline, dock-to-stock time ↓50% (4–8 hrs to 2–4 hrs), on-time dispatch ↑14% (85–92% to 96–99%), empty MHE travel ↓30%, pick travel distance ↓35%, pick accuracy 99.5%+, and MHE-related downtime near-eliminated through automated battery rotation.

How long does a WOS implementation take?

Significantly faster than traditional warehouse software implementations. Stackbox WOS is deployed in phases — beginning with foundational orchestration levers (vehicle scheduling, dock allocation, work planning, task allocation) that deliver measurable ROI before the next phase begins. This phased approach means customers see operational improvement within weeks, not after a multi-year rollout.

How does WOS handle multi-warehouse and multi-site operations?

Stackbox WOS supports multi-warehouse and multi-DC deployments with centralized visibility and site-level orchestration. Each DC runs its own real-time orchestration layer, while the control tower provides cross-site inventory visibility, SLA tracking, and performance benchmarking. This makes WOS particularly suitable for FMCG and retail networks with regional DC footprints across India.

What is the difference between a WOS and a route optimization software?

Route optimization software (such as TMS-layer tools) optimizes transportation routes between facilities. A Warehouse Orchestration System optimizes the movement of people, MHE, and goods within a facility. These are complementary — Stackbox offers both WOS for intralogistics orchestration and TMS for transport management, which can be deployed as an integrated solution.

Orchestrate Everything That Moves Inside Your Warehouse — in Real Time

Warehouse orchestration- the missing layer between your WMS and your automation hardware.

Mobile Automation

Fixed Automation

Predictive Decisioning

Material Graph Simulation

Unified Navigation Engine

Intelligent Routing

Human Workforce

A persistent real-time orchestration layer between your WMS and your physical warehouse operation.

Planning & Optimization

Multi Agent Orchestration

Interoperability

Integration

Stackbox WOS orchestrates every dimension of warehouse operations — from order planning to last-mile task execution — across humans, mobile robots, and fixed automation.

Vehicle Appointment Scheduling

Automated Dock Allocation

SLA & Resource-Constrained Work Planning

Automated Task Allocation

Picking Orchestration

Putaway Orchestration

Task Interleaving

Replenishment Orchestration

Aisle & Traffic Management

Slotting Optimization

Resource Orchestration

MHE Fleet & Battery Management

Stackbox WOS is purpose-built for the complexity that WMS, WCS, and WES platforms were not designed to handle.

Design-Aware Execution

Vendor-Agnostic by Architecture

Proactive, Not Reactive

Fast Implementation. Measurable Value.

MHE-First Orchestration

Augments Your Existing WMS

Planning & Optimization

Multi Agent Orchestration

Interoperability

Integration

A real-time graph of every material movement, handoff, and decision node — from goods receiving to dispatch.

Stackbox WOS manages fixed automation, mobile robot fleets, and human workforces under a single orchestration layer — with no vendor lock-in.

Fixed Automation — AS/RS, Conveyors, Sorters, Palletizers

Mobile Automation — AMRs, AGVs, Reach Trucks, Stackers, BOPTs, HOPTs

Human Workforce

Unified navigation layer

Your warehouse mission control

Stackbox WOS transformed how we coordinate dock operations and MHE fleets. Our dock-to-stock time dropped by over 50% in the first quarter of deployment and our supervisors now manage by exception, not by radio.

Head of Supply Chain Operations

The real-time orchestration WOS provides was the missing piece in our DC. Pick travel is down 35%, MHE utilization is up significantly, and our aisle conflict rate is essentially zero since go-live.

VP Warehouse Operations

WOS integrated with our existing SAP environment without any rip-and-replace. We saw measurable throughput improvement within weeks, and the automated battery rotation has practically eliminated mid-shift MHE failures.

Director, Distribution & Logistics

Frequently Asked Questions

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