Industrial Cables & Connectivity

LAPP USA Multiplies Warehouse Counts 13x with Corvus One®

Continuous warehouse visibility replaces manual cycle counting and protects on-time delivery for industrial cable customers.

LAPP video transcript

Robert Hoffbauer, Inventory & Quality Control Coordinator, LAPP USA

The drone's preventing delays because we're not having to check all this inventory all the time or go looking for this inventory all the time. It's exactly where it says it should be. Just boom. Grab it and go.

Jason Beltran, Facility Manager, LAPP USA

The Corvus system has been able to help us by providing better service to our customers. Getting the inventory in in real time, seeing where it is, and being able to allocate it right away to the customer is tremendous benefit for us.

For us to really hit our cycle counts and our goals that we needed to, we would have to run usually 3 to 4 people in our inventory team. So once we implemented, the Corvus drone, we were able to reduce the headcount immediately to two people and save that labor to put it, whether it was in a picking project, whether it was in a cutting project, being able to use that labor somewhere else to help that part of the operation.

Robert Hoffbauer, Inventory & Quality Control Coordinator, LAPP USA

Don't have to hop on the scissor lift every single day. I'm hopping on the scissor lift once a week, if that.

Say, on Monday we'll set the drone to fly four flights or so overnight. We'll see what it gave us a discrepancy report for, how many things were missing a label. How many things were in the wrong location. How many extra pieces of material were in a location, and then we're able to do our cycle counts just straight from that count.

Jason Beltran, Facility Manager, LAPP USA

If a picker goes to a location and the item is not there, sometimes that can cause an inventory adjustment out. But being able to reference a camera view from the previous day, or even to set up a customized flight to go and scan that aisle, we're able to find that by using the drone to really narrow down where the last trail of that item was.

With the Corvus drone, we're able to see a wide view location. So being able to verify that all five items are there could stop a cycle count from going up there and validating that information by seeing that whole frame, basically, of the drone going from that whole location and getting that whole view.

Robert Hoffbauer, Inventory & Quality Control Coordinator, LAPP USA

Corvus team is very, very responsive. I can send the text and I'm getting the message same day next day. "Oh yeah. You have this issue it'll be fixed today." Fantastic.

Jason Beltran, Facility Manager, LAPP USA

Those two teams coming together and figuring out how we can customize this to make it work for our operation, I can't say enough about how easy and how quick it was for us to realize the benefits of having a great vendor.

Overview

LAPP USA manufactures and distributes industrial cables, connectors, and connectivity solutions from its 134,000 sq ft facility in Brownsburg, Indiana. The site runs both cable manufacturing and nationwide distribution. With customers in automotive, machine tools, medical electronics, robotics, and industrial automation, LAPP operates against tight delivery commitments where every misplaced reel translates directly into a delayed shipment.

The Challenges

  • Limited Coverage: Cycle counting was a manual process that produced only two full warehouse passes per year, leaving long gaps between accurate facility-wide data.
  • Heavy Labor Burden: Five associates, roughly 12.5 percent of the warehouse team, ran weekend cycle counts and still missed targets.
  • Customer Impact: Misplaced reels and slow reconciliation slowed order processing and put on-time delivery at risk for industrial cable customers.
A Corvus One autonomous inventory drone scans cable reels stored on rack location 23 at LAPP USA's Brownsburg, Indiana distribution center
Each Corvus One mission across LAPP's 134,000 sq ft Brownsburg facility produces pallet validation, discrepancy and occupancy reporting, and photo and video evidence of every pallet position.

The Corvus Solution

LAPP USA deployed the Corvus One Autonomous Inventory Management System inside its Brownsburg distribution center. Corvus One brings Physical AI to warehouse operations, running in GPS-denied environments with onboard AI and computer vision and feeding consistent inventory and discrepancy data into the AIMS platform. Drones fly nightly missions starting at 6 PM after associates leave, scanning thousands of pallet locations and capturing imagery without human pilots or infrastructure modifications.

A Corvus One autonomous inventory drone scans cable reels in an aisle at LAPP USA's Brownsburg, Indiana distribution center
Corvus One’s onboard AI allows it to perceive, navigate, and scan LAPP’s warehouse without manual oversight.

The Impact

  • 13x More Inventory Coverage: 26 full-warehouse counts per year, up from two manual cycles.
  • 60% Labor Reduction: Inventory team cut from five associates to two, with the remaining three redeployed to picking and manufacturing.
  • Zero Weekend Overtime: Cycle counting overtime eliminated, freeing the warehouse for weekday operations.
  • Faster Error Detection: Automated discrepancy reports flag mislabeled, misplaced, or missing reels for next-day resolution rather than next-quarter reconciliation.
  • Improved SOPs: Drone scans surfaced label-placement inconsistencies, leading to standardized practices and stronger scan accuracy across the warehouse.
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The Corvus One system has been able to help us by providing better service to our customers. Getting the inventory in, in real time, seeing where it is, and being able to allocate it right away to the customer is a tremendous benefit for us.
Jason Beltran, Facility Manager at LAPP USA
Jason Beltran Facility Manager, LAPP USA
Team members from LAPP USA and Corvus Robotics standing together in front of cable reel racks and the Corvus One landing pad at LAPP's Brownsburg, Indiana distribution center
The Takeaway

From Weekend Cycle Counts to Nightly Autonomous Coverage

For industrial distributors operating against tight delivery commitments, inventory accuracy is directly tied to customer service. Manual cycle counting consumes weekend labor, leaves long gaps between accurate counts, and rarely keeps pace with consolidation and growth.

LAPP's deployment demonstrates how autonomous inventory systems can:

  • Increase count frequency 13x without adding labor
  • Run nightly without disrupting daytime warehouse throughput
  • Replace manual cycle counting with photographic, location-level evidence
  • Surface SOP gaps such as label placement that erode scan accuracy
  • Protect on-time delivery commitments to downstream customers

More Use Cases

Continuous accuracy across industries, from manufacturing to distribution.

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