Inventory & Warehouse Operations Intelligence

Crestline Distribution Corp • 3 Sites • 14,200 Active SKUs • $340M Annual Revenue

North Star Metric
18.4%
Inventory-to-Revenue Ratio
+2.4% vs Target (14.0%)
Inv. Turnover (A-Class)
6.8×
+0.4×
Days Inventory Outstanding
53.7
-2.1 days
Fill Rate (Order Line)
94.2%
-2.8% (Alert)
SLOB Inventory %
11.2%
+1.4%
$7.0M Obsolete
Warehouse Utilization
87.3%
+3.1%
Near Capacity
Pick/Pack Accuracy
98.6%
+0.2%
137 errors/90d

Inventory Position Matrix — SKU Classes by Turnover & DIO

A-Class (High Velocity)
B-Class (Medium Velocity)
C-Class (Slow Movers)

Fill Rate by Order Line – 90-Day Trend

Target: ≥97.0% • Current: 94.2% (Apex Supply disruption weeks 7-10)

Stockout Events by SKU Class

Last 30 Days • Total 47 Stockout Days Across 22 SKUs

Warehouse Zone Utilization by Site & Category

Site / Zone Capacity (Pallets) Occupied Utilization % Status
Columbus OH – Electronics 2,840 2,614 92.0% Critical
Columbus OH – Industrial 3,200 2,784 87.0% High
Columbus OH – HVAC 1,600 1,328 83.0% High
Memphis TN – Industrial 1,920 1,497 78.0% Normal
Memphis TN – Electronics 1,280 947 74.0% Normal
Phoenix AZ – Industrial 1,440 1,022 71.0% Normal
Phoenix AZ – HVAC 960 624 65.0% Normal

Supplier Lead Time Variance (Top 6 Suppliers)

Standard Deviation in Days • Apex Supply Disruption Flagged

Receiving Dock Cycle Time by Site

Average Hours from Arrival to Put-Away Complete

Reorder Point Accuracy

88.4%
1,647 SKUs Triggered Reorder in Last 30 Days
On-Time Replenishment1,456
Early (Excess Inv)114
Late (Stockout Risk)77

Inventory Value by Class

$62.6M
Total Inventory on Hand
A-Class (High Turn)$28.4M
B-Class (Medium)$21.2M
C-Class (Slow/SLOB)$13.0M

Order Accuracy Rate

98.6%
Pick, Pack & Ship Combined
Orders Shipped (90d)9,847
Total Errors137
Error Rate1.4%

SKU Inventory Detail — Critical & At-Risk Items

Sorted by Stockout Risk Score • Showing 10 of 14,200 Active SKUs
SKU Description Class On Hand Reorder Pt On Order DIO Status
SKU-8832 Allen-Bradley PLC Controller 5/03 A 0 18 0 0.0 Stockout (8d)
SKU-9241 Schneider Electric VFD 10HP 480V A 2 22 40 3.2 Below ROP
SKU-7634 Siemens Motor Starter 3-Phase 30A A 5 16 25 8.4 Below ROP
SKU-10423 Honeywell Thermostat 7-Day Prog B 8 12 0 22.1 Below ROP
SKU-5129 Eaton Circuit Breaker 100A 3P A 42 35 50 18.6 Normal
SKU-6847 Grainger Pneumatic Valve 1/2" NPT B 134 45 0 67.3 Overstock
SKU-11290 Legrand Outlet 20A GFCI White C 1,847 120 0 241.8 SLOB
SKU-3492 Milwaukee Cordless Drill Kit M18 A 29 28 60 11.2 Normal
SKU-14052 Trane HVAC Filter 20x25x5 MERV13 B 86 60 120 28.4 Normal
SKU-2183 3M Safety Glasses Clear Lens 12pk C 421 80 0 154.2 SLOB

Critical Action Items

High-Priority Inventory Interventions
1
Emergency PO for SKU-8832 (Allen-Bradley PLC)
8-day stockout on A-class item. Issue expedited PO to alternate supplier (Rockwell Direct) with air freight approval. Estimated recovery: 4 business days.
2
Review Apex Supply Relationship & Lead Time Assumptions
Carrier change caused σ=4.2d variance on 34 A-class Electronics SKUs. Negotiate SLA with guaranteed lead times or diversify to second supplier.
3
SLOB Liquidation Campaign — Target $2.4M Reduction
C-class items with DIO>180 days (SKU-11290, SKU-2183, 18 others). Partner with sales for markdown promotion or return to vendor negotiations.
4
Columbus Electronics Zone Expansion Feasibility
92% utilization approaching critical threshold. Evaluate temporary overflow storage or postpone Q3 A-class inventory buildup until capacity freed.

Working Capital Improvement Path

Roadmap to 14.0% Inventory-to-Revenue Target (3-Quarter Goal)
Q1: SLOB Reduction & Reorder Point Calibration -$2.8M
Target: Reduce SLOB from 11.2% → 8.0% while maintaining 97% fill rate via refined ROP logic.
Q2: Supplier Lead Time Stabilization -$1.4M
Apex Supply SLA renegotiation + second-source Electronics suppliers → reduce safety stock by 18%.
Q3: B/C-Class Turnover Acceleration -$1.0M
Sales incentive on slow movers + vendor managed inventory (VMI) pilot with Grainger for C-class consumables.
Total Inventory Reduction Target -$5.2M
Projected Inv-to-Rev: 16.9% → 14.0% by Q3 end while sustaining 97%+ fill rate.