Yearly FBA Inventory Prep and Optimization
I run a medium-sized FBA operation with about 40 active SKUs, and every single year around late January, I sit down and go through the same exercises to make sure my inventory strategy is solid before peak season hits. This isn't about some magical system or secret software. It's mostly about being methodical with data you already have access to. The annual review I do covers inventory health, repricing adjustments, removal order planning, and a deep look at IRR and TACR numbers. Most sellers skip IRR entirely, which is a mistake. If your inventory reserve rate is sitting above 5%, that's capital locked up that could be working elsewhere. I track this by pulling the Inventory Performance dashboard every year and comparing it against the previous twelve months. A drop from 8% to 4% between years usually means you're making better placement decisions or your sell-through rate has improved enough that Amazon trusts you more. Here's something most people miss about TACR, the tracked chargeback rate. You can have a legitimate business with a TACR around 5% and never get flagged, but if your chargebacks cluster around two or three specific SKUs, that's a product quality issue, not an account health issue. I learned this the hard way when I had a supplier switch materials on a silicone kitchen product without telling me. My TACR jumped from 1.2% to 6.8% in six weeks, and I was spending days trying to fix my account health when the real problem was just one bad batch. Took me about forty phone calls with the supplier and a return to manufacturing specs to bring it back down to under 2%.
The Practical Cleanup Cycle
Every year, I run through these steps and they take me roughly three to four hours total if everything goes smoothly, which it usually doesn't: Step one is the stranded inventory sweep. Go to Manage Inventory, filter for Stranded, and figure out why each one is stranded. Sometimes it's a pricing issue, sometimes it's a category restriction, and occasionally it's a sourcing problem where your supplier stopped manufacturing the exact SKU. I keep a spreadsheet with columns for SKU, ASIN, reason code, and estimated recovery time. The ones that don't get moved within sixty days usually get pulled and converted to disposal or a liquidation channel rather than letting them sit there eating storage fees. Step two is the storage fee calendar check. Amazon changes their storage fee tiers almost every year and the penalty thresholds shift. For 2025, the seasonal penalty period runs from October through December, and the per-cubic-foot rates are higher than the standard monthly rate. I map out my incoming shipments against the storage calendar so I'm not receiving pallets right before the October surge. Getting caught with excess inventory in early October can cost you an extra dollar or two per cubic foot for the remainder of the year, and on a full pallet that adds up fast.
Step three is the long-term storage audit. This one sounds basic but I still see sellers ignore it. Check for units sitting in fulfillment centers beyond 180 days. Amazon charges $6.90 per cubic foot or 22% of the total storage cost, whichever is greater. I pull the report, cross-reference with my profit margins, and if a SKU has been sitting there for a year and a half with no sales velocity, I cut my losses. It's better to take a removal cost hit than to keep paying storage on dead stock. I've found that about 8% of any given catalog ends up in this category every year.
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The Repricing Strategy Reset
After I've cleared the inventory, I reset my repricing strategy for the coming year. This is where most sellers lose margin without realizing it. I review the Buy Box history for my top ten SKUs and compare the average price point against what competitors are running. Amazon's own algorithms favor price competitiveness, and if you're consistently priced above market average by more than five percent, you'll slowly lose the Buy Box to other sellers on the same ASIN. I use a manual repricing approach for my high-volume items and an automated tool for my long-tail SKUs. The automated tools are fine for slow movers where the margin impact is negligible, but for anything moving more than fifty units a month, I watch the prices myself. There's a fine line between competitive pricing and race-to-the-bottom pricing, and the algorithm won't draw it for you. One edge case that trips people up: the FBA carbon footprint labeled items. Amazon now flags certain products based on their emissions score, and these items can see a slight decrease in organic ranking. It's not a dramatic drop, maybe five to ten percent in visibility depending on the category, but over a year that adds up to significant revenue loss. I review my carbon footprint labels annually and factor the potential ranking impact into my ad spend for affected SKUs.
Removal Order Strategies
When I pull inventory out of Amazon's warehouses, I don't just dispose of it. I evaluate whether it can go to a liquidation buyer, get returned to my supplier, or be shipped to a third-party warehouse for later sale. The removal fees are roughly $0.85 per unit plus a handling fee, and on a large removal batch that adds up. I typically save about thirty percent of my removal inventory through liquidation channels rather than letting it go to landfill, and the remaining portion I either return to suppliers or store locally for later Fulfillment by Merchant campaigns. There's also the question of aging removal orders. If you submit a removal request and the items sit in a removal center for more than thirty days without being picked up, you might get hit with additional storage fees at the removal facility itself. I track my removal order status weekly during the quarterly review periods to avoid this.
What This Doesn't Fix
I want to be clear about the limitations here. None of this replaces having good products, reliable suppliers, or accurate demand forecasting. If your core issue is a low-quality product with consistent returns, no amount of inventory optimization will save your account. The annual review helps you manage what you already have more efficiently, but it won't turn a failing product line into a profitable one. If you're dealing with chronic supply chain disruptions or your product has fundamental market fit issues, focus your time there instead of going through this checklist. It's maintenance, not a cure. The Fba Tricks Yearly process takes about three to four hours if you have good data organization and maybe eight to ten hours if you're starting from scratch with messy records. Setting up a proper tracking spreadsheet ahead of time cuts that in half, and I'd recommend doing that setup during the quieter months of February and March rather than cramming it all into a busy quarter.
