The Challenges
When LAPP consolidated operations into its 134,000 sq. ft. facility in Brownsburg, Indiana, keeping up with inventory became a daily struggle. The process was labor-intensive, time-consuming, and directly impacted customer service.
Key challenges included:
Limited Coverage – Manual cycle counts only covered the warehouse twice per year
High Labor Demand – 12.5% of the workforce dedicated to inventory counts, pulling staff from picking and manufacturing
Inconsistencies – Misplaced or mislabeled reels required extra searching and reconciliation
Customer Impact – These inefficiencies slowed down order processing and made it harder to ensure on-time deliveries
The Corvus Solution
Corvus One™ flies nightly missions, scanning racks and capturing images of pallet locations. By morning, the inventory team has a complete, accurate report that flags discrepancies like misplaced or mislabeled reels. This automated workflow has replaced a manual, time-consuming cycle counting process with a streamlined inventory monitoring system that lowers labor costs while improving accuracy and operational efficiency.
The Impact
13x More Coverage – Inventory counts increased from two per year to 26 per year, giving LAPP faster detection of errors that could affect shipments.
60% Labor Savings – Inventory staff reduced to two associates, with associates redeployed to support picking and manufacturing, directly speeding up order fulfillment.
Zero Overtime – Weekend cycle counting eliminated, allowing teams to focus on weekday operations and on-time customer deliveries.
Higher Accuracy – Automated discrepancy reports highlight mislabeled, misplaced, or missing reels for quick resolution, preventing errors from reaching customers.
Improved SOPs – Drone scans exposed label placement inconsistencies, helping LAPP standardize practices and improve accuracy across the warehouse.
“I like the Corvus Robotics drones because they are out of sight, out of mind. They’re doing things that there’s really not a lot of value to an individual on, but to the business, it’s priceless.”
Jason Beltran
VP of Distribution
Company Overview
LAPP USA products are proven to stand up to the most extreme conditions found in today’s industrial environment – vibration, temperature, oil, water, corrosion and wash-downs. They are used throughout the world in automotive plants, machine tools, instrumentation, medical electronics, telecommunications, robotics, industrial automation, transportation, general industrial control systems, and many more applications.
