5 inventory challenges logistics teams face (and how BrainOS® helps solve them)

Inventory management is the lifeblood of logistics—but it’s no walk in the park. From stockouts to stalled supply chains, small errors can snowball into big headaches. 

Let’s break down 5 inventory challenges logistics teams are all too familiar with and how BrainOS® is helping them stay ahead of the curve.

1. When inventory doesn’t match reality

The struggle: Manual counts are, well, human—and that means errors. Maybe it’s a miscount during a busy shift or items misplaced on shelves. Either way, discrepancies between system data and actual stock create chaos, leading to missed or lost shipments and wasted time trying to track things down. 

To prove this further, a study by Management Science analyzing nearly 370,000 inventory records from 37 stores of a U.S. retailer found that 65% of the records were inaccurate, highlighting how widespread inventory discrepancies truly are.

The solution: BrainOS®-powered autonomous mobile robots (AMRs) take the guesswork (and stress) out of inventory tracking. With AI, computer vision, and advanced 3D LiDAR sensors, these robots scan shelves with precision, keeping your records accurate and up-to-date. They even catch those “oops” moments—like missing items—before they cause bigger issues.

2. Flying blind without frequent updates

The struggle: Without live inventory data, you’re stuck playing catch-up. Decisions about restocking, forecasting, and order fulfillment turn into a guessing game—one that can cost you customers. 

The solution: BrainOS® Sense Suite delivers real-time insights straight to your team. Robots scan inventory continuously during regular hours, feeding up-to-date info into your inventory management system. The result? Faster decisions, smarter forecasts, and fewer surprises. Bonus: optimizing space in packed warehouses becomes way easier.

3. Labor shortages throwing a wrench in operations

The struggle: The logistics industry is no stranger to high turnover, and frequently training new hires eats up time and money. Meanwhile, tasks like inventory accuracy often take a back seat when teams are stretched thin.

According to a 2024 article, the turnover problem is especially severe in areas like trucking, where rates can soar past 90% for large truckload carriers. Even across the broader industry, turnover averages around 31%. This revolving door of employees leads to significant expenses for recruitment and training, while operations slow down as new hires adjust to their roles.

The solution: Think of BrainOS® robots as the ultimate team player. They handle tedious, repetitive tasks like scanning inventory, freeing up your workforce to focus on tasks like order fulfillment, inventory planning, and improving operations. The best part? Robots don’t need onboarding, and they never call in sick.

4. Sky-high operational costs

The struggle: From overtime to fixing errors, inefficiencies in inventory management add up fast. And let’s not forget the hidden costs of keeping extra safety stock because no one trusts the data. 

According to the 2023 report “Inventory Distortion–The Good, the Bad, the Ugly", inventory distortion will cost retailers $1.77 trillion globally, with $1.2 trillion lost to out-of-stocks and $562 billion tied to overstocks. These figures highlight the significant financial burden of inaccurate inventory data and ineffective management systems.

The solution: AAutomating inventory management with BrainOS® eliminates unnecessary waste—from overtime to redundant processes—and reduces the need for excess safety stock. By restoring trust in your inventory data, you can cut costs and streamline operations. It’s like rewriting your inventory playbook for success.

5. Audits that take forever

The Struggle: Traditional inventory audits are slow, resource-heavy, and disruptive to daily operations. Nobody likes shutting things down just to get a count done. 

The solution: BrainOS®-powered robots can handle audits in record time without turning your workflow upside down. They operate during regular (or after) hours and work around your team, giving you accurate, comprehensive data without any downtime.

The future of logistics is smarter

Inventory challenges don’t have to be the norm. By integrating BrainOS®-powered robots into your operations, you’re not just solving today’s problems—you’re setting the stage for a more efficient, accurate, and future-proof operation.

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Safety and security are at the core of everything we do. Brain Corp follows "security by design" principles with ISO27001-aligned policies, regular testing, and the BrainOS® Sense Suite—with its sophisticated sensors and UL-certified controller—ensures accurate data capture and reliable, secure performance. All support and data is housed in the USA, ensuring reliable, secure performance you can trust.