Staci Americas Goes Lights-Out With Corvus One™ Across Its 3PL Warehouses

Overview

Staci Americas operates multi-client 3PL warehouses where each facility manages 5,000 to 10,000 unique SKUs and 10,000 to 30,000 pallet positions for a roster of more than 50 brands. In that environment, every misplaced pallet shows up on a different client’s invoice, every delayed outbound order trips a contractual OTIF penalty, and every locked-up storage location blocks new business from coming through the door. Manual cycle counting was not built for that math.

The Challenges

• Fulfillment Speed Suffered: A single misplaced pallet could take 6 to 8 hours to locate, sometimes the better part of a day. While inventory teams searched aisle by aisle, outbound orders waited to ship and production stalled around them.
• Labor and Equipment Costs Mounted: Hours spent hunting for inventory pulled associates off fulfillment work, and forklifts and cherry pickers stayed tied up on counts instead of picking. Both cost lines hit 3PL margins directly.
• OTIF Penalties and Locked Space: Late outbound shipments triggered contractual OTIF penalties from clients and parcel partners. At the same time, storage locations sat 20 to 50 percent full because no one had time to consolidate them, blocking new client onboarding.

The Corvus Solution

Staci Americas deployed the Corvus One™ Autonomous Inventory Management System at its Atlanta headquarters and New Jersey innovation center, the company’s anchor multi-client fulfillment facilities. Corvus One brings Physical AI to 3PL 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 launch nightly while the buildings sit dark for six to eight hours, scanning thousands of pallet positions and uploading discrepancy reports to Staci’s WMS before the morning inventory team arrives.

The Impact

• Inventory Accuracy Lifted to 99.9%: Accuracy climbed from a 98 to 99.4 percent range into the 99.8 to 99.9 percent band. At 3PL scale, where margin sits on top of every percentage point, half a point of accuracy moves thousands of dollars in monthly OTIF and labor exposure across the client roster.
• Six to Eight Hour Searches Eliminated: Pallet hunts that once stalled up to 20 production employees per incident now end before the shift starts.
• Skilled Labor Redeployed: Audit specialists moved into higher-value functions instead of running manual cycle counts.
• Space Reclaimed for Client Growth: Consolidating partially full pallet positions freed storage capacity for new clients and existing client expansion.
• Lower MHE Load: Fewer forklifts and cherry pickers tied up on counts means lower equipment wear and lower emissions.