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.
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.
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.
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.
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.
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
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