Staci Americas Goes Lights-Out With Corvus One® Across Its 3PL Warehouses
Nightly autonomous drone flights at Staci’s Atlanta and New Jersey 3PL facilities catch inventory discrepancies before the first shift, protecting OTIF performance across every client account.
Staci video transcript
Austin Feagins, Senior Director Transformation & Solution Design, Staci Americas
One of our favorite aspects about Corvus, and a big part of why, four years ago, we started talking with Corvus is the fact that we don't have to manipulate these drones. They sit on their landing pad. They charge themselves, they fly themselves, they dock themselves. We don't touch the drones at all. And the drones are flying overnight. We're getting a full inventory of the building every week. This technology really allows us to look and say, hey, we have these problems here. Why are we having these problems? Correct them before the shift starts, and then immediately go back and say, let's solve that problem.
Natalia Chevere, Regional Director of Operations, Staci Americas
We did not have to change anything about our existing workflow. We were able to just give the data needed. The Corvus team was able to handle the rest.
Austin Feagins, Senior Director Transformation & Solution Design, Staci Americas
Implementing these drones. It was fast. It was easy. Zero impact really on operations.
Natalia Chevere, Regional Director of Operations, Staci Americas
The data integration has been entirely easy. We have our reports, we're able to download, we're able to see if the team already made action on the items.
Austin Feagins, Senior Director Transformation & Solution Design, Staci Americas
For us in third party, we are playing a game of tenths of percentages. We're not talking a 99% accuracy is good enough. We need to be 99.5, 99.8, 99.9 for these clients. And these drones are able to help us get that extra little decimal of a percentage, which means make or break in some of these contracts. The drones are actually able to tell us, hey, you have product A in a couple different locations. Let's consolidate that and move it to one so we're not billing a client, but then we are more efficient in the warehouse.
Jackie Wu, CEO, Corvus Robotics
For a busy 3PL like Staci, they care not only about cutting costs, which improves their margin, but also figuring out how to drive new revenue. And we're able to help them optimize their inventory and figure out the fast moving versus slow moving inventory, as well as save costs on cycle counting and inventory control.
Natalia Chevere, Regional Director of Operations, Staci Americas
The employee reaction to the drones was a good one. It was fitting for them to have a partner at night to make their job more efficient and faster, to be able to give the best service to our clients.
Austin Feagins, Senior Director Transformation & Solution Design, Staci Americas
We really wanted to find an innovative solution technology that is at the front lines of, you know, what can be done in the industry. And so Corvus has been an excellent partner as we look to improve our inventory accuracy throughout the network.
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.
Being able to run inventory checks 24/7 without operator assistance has been a game changer. The lights-out capability allows our inventory teams to correct discrepancies off-shift and pre-shift before production starts each day, limiting fulfillment delays and production impacts.
What Autonomous Inventory Drones Unlock for 3PL Operators
In a multi-client 3PL building, autonomous inventory drones pay back across every margin line. What Staci’s deployment unlocks:
- One Corvus One system covers every client in the building, spreading the cost across the entire account roster
- Nightly discrepancy correction protects OTIF performance for every client simultaneously
- Skilled audit labor moves into onboarding, value-added services, and operational improvement
- Consolidated pallet positions create capacity for new clients without a building expansion
- Photographic, location-level evidence strengthens client trust at renewals and quarterly business reviews
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