Running an efficient, optimized warehouse isn’t easy, and operators can encounter several challenges along the way. For instance, you might face challenges related to a lack of space, intensive labor demands (particularly during peak periods of demand), or difficulty meeting the growing fulfillment expectations of modern customers.
Fortunately, technological solutions exist to help you overcome these challenges, such as an automated storage and retrieval system. An automated storage and retrieval system (AS/RS) can improve storage density, throughput rate, picking accuracy, and other important performance metrics.
In this blog, the automation experts at BoxLogix will explain what an automated storage and retrieval system is, how it works, and the benefits it brings.
“Automated storage and retrieval system” is a broad term, referring to an array of technological solutions that all serve the same core purpose: automating the storing and retrieving of goods within a warehouse or distribution center environment.
An AS/RS can be made up of various hardware components, including cube-based storage, crane-based systems, pallet shuttle systems, and autonomous mobile robots (AMRs), as well as software components, like a warehouse management system (WMS) or warehouse execution system (WES).
Different types of AS/RS can handle different sorts of inventory, from pallets to totes, cartons, and individual items, and they form the backbone of the goods-to-person (G2P) model. This involves automated systems taking goods to workers, rather than workers having to travel to them.
The exact way in which an automated storage and retrieval system works can vary, depending on the specific technologies in use.
In general, however, AS/RS solutions function according to a step-by-step pattern, combining storage infrastructure, automated equipment, and software to manage inventory movements, such as:
First, products are identified and introduced into the system. They may be fed into the AS/RS via a loading station, a conveyor belt, or some other induction point. Identifying labels or codes will be scanned, and all relevant information will be logged in the WMS or other software.
Once the software receives information regarding the incoming inventory, it determines an appropriate storage location based on preset rules and policies. Automated equipment (i.e., conveyors, robots, etc.) then transports the inventory to the designated location.
When an order or replenishment request enters the system, the software can locate the required item and direct the relevant automated equipment to retrieve it. The item is then transported to a worker station, loading hatch, or other area where workers can collect it.
As the inventory proceeds onward towards its destination, it is tracked and scanned so that the WMS (or other warehouse software) can be updated accordingly with the most accurate information.
As stated, the term “automated storage and retrieval system” covers a broad range of technologies, and it’s important for companies to be aware of the options and their uses to choose the most appropriate solutions for their own facilities.
These are some of the different types of AS/RS:
AS/RS can be classified in several ways, including by the size and type of load they handle. Two major categories are unit-load and mini-load systems. Unit-load systems are the more heavy-duty of the two, built to handle larger and heavier loads, such as pallets, typically weighing 1,000 pounds or more.
Crane-based AS/RS systems use automated cranes that travel along storage aisles to place and retrieve inventory from racks. Depending on their design, these systems can handle pallets, totes, and other loads and are commonly used in high-density warehouses where maximizing vertical storage space is a priority.
A mini-load AS/RS is built to tackle smaller, lighter loads, such as totes, trays, and cartons. So, when choosing between unit-load vs. mini-load systems, operators need to consider the size and weight of their warehouse inventory.
As the name implies, a shuttle-based automated storage and retrieval system uses automated shuttles to transport goods across storage racks. These systems are popular in high-density and high-throughput facilities, thanks to their speed and efficiency.
A vertical lift module (VLM) is an enclosed AS/RS solution that features trays of goods stacked vertically on top of one another, with a central elevator-style mechanism that can find and retrieve individual trays and lower them down to a hatch, where workers can retrieve them.
A carousel or carousel-based AS/RS is one of the oldest types of automated storage and retrieval systems, but still popular and useful to this day. It consists of a rotating track that suspends multiple items or storage solutions and drops them off at bins or workstations, as needed.
This type of automated storage and retrieval system involves inventory being placed into bins and stacked inside a large cube. Robots then operate at the top of the cube to sort and retrieve individual bins and transport them to access ports.
|
Type |
Characteristics |
Common application |
|
Unit-load |
Copes with heavy loads |
Heavy and large goods |
|
Crane-based |
Automated cranes move loads between storage racks |
High-density and high-bay storage |
|
Mini-load |
Designed for smaller loads |
Smaller, lighter goods |
|
Shuttle-based |
Fast-moving transportation |
High-density warehouses |
|
Vertical lift module |
Enclosed trays and elevator |
High SKU counts |
|
Carousel |
Versatile rotating track |
General-purpose |
|
Robotic cube storage |
Multiple items stored in a cube |
High-velocity small items |
Compared with manual storage and retrieval methods and person-to-goods (P2G) systems, AS/RS solutions can help warehouses make better use of available space while reducing the amount of manual work required to store, locate, and retrieve inventory.
Some of the most notable benefits of automated storage and retrieval systems include:
Automated systems allow companies to make more of the space available to them. A VLM, for instance, can store vast amounts of inventory while only taking up a comparatively small section of floor space, and other AS/RS solutions can vastly increase storage density and minimize aisle sizes.
With machines handling much of the movement and retrieval work, warehouse throughput rate can increase because workers spend less time traveling and searching for goods.
Warehouses following P2G models rely heavily on their workers to move across the warehouse floor, finding, storing, and retrieving goods. Those that invest in G2P technology can delegate large parts of these tasks to machines, allowing employees to focus their energies elsewhere.
AS/RS solutions are extremely effective at tracking the exact positions of inventory at all times, which leads to greater visibility and picking accuracy, with a much lower risk of goods going missing or mistakes being made.
With AS/RS solutions, workers don’t have to move around as much or put themselves in potentially hazardous situations. Many of these systems also incorporate ergonomic design elements, too. This can reduce some physical demands on workers and may help reduce ergonomic risks and fatigue.
Many AS/RS technologies are modular and scalable, so they can grow in alignment with your warehouse’s changing needs over time.
Automated storage and retrieval systems are used across a wide range of industries to store, organize, and retrieve inventory more efficiently. Because different AS/RS technologies can accommodate everything from small individual items to large pallet loads, these systems can be adapted to many different products, workflows, and facility requirements.
Some of the common applications of AS/RS technologies include:
There is no single price for an automated storage and retrieval system, as costs can vary significantly from one facility and application to another. The type and scale of the system, existing infrastructure, and level of integration required can all influence the total investment.
Some of the most important factors that can impact AS/RS costs include:
While the initial costs can be quite high when investing in this technology, once the payback period is over, they can provide a healthy return on investment in the form of labor savings, improved throughput, and storage efficiency.
With several types of automated storage and retrieval systems available, there isn’t a one-size-fits-all solution for every warehouse. That said, the best option depends on your inventory, available space, throughput requirements, existing technology, budget, and how you expect your operation to evolve over time.
Consider the following factors when selecting AS/RS technologies:
Considering all of these factors can be complicated, and it’s easy to make a mistake or feel unsure about which solutions to invest in. That’s where an experienced warehouse automation integrator, like BoxLogix, can help.
AS/RS technologies can transform your warehouse, improving all measurable metrics and helping you attain higher levels of performance and optimization. But, in order to experience those benefits, you have to both select the right equipment and understand how to make the most of it. That includes determining which products belong in the system and how to configure it for maximum efficiency.
And that’s where BoxLogix comes in. We help companies, great and small, choose and integrate the perfect automated systems to suit their specific needs and goals. Our team also helps evaluate inventory, picking frequency, and order volumes to determine which products are best suited for automated storage, helping customers get more value from their investment from Day 1.
Contact the BoxLogix team today if you’d like to learn more or speak to one of our experts to plan your warehouse’s automation revolution.
The main difference between AS/RS and traditional warehouse storage is how inventory is stored and retrieved. Traditional systems typically rely on workers to travel through the facility to locate and move goods, while AS/RS uses automated equipment and software to handle much of this work.
AS/RS refers to technologies that automatically store and retrieve inventory, while goods-to-person (G2P) automation is a broader approach that brings goods directly to workers instead of requiring workers to travel to them. AS/RS technologies can form an important part of a goods-to-person system.
Automated storage and retrieval systems can handle a wide variety of products, ranging from individual items and small parts to cartons, totes, and full pallets. The types of products an AS/RS can handle depend on the specific technology, its load capacity, and how the system is designed.
Yes, AS/RS can often be added to an existing warehouse, although the feasibility and complexity of the project depend on the facility’s layout, available space, existing equipment, and software. Some installations may also require facility modifications or integration with existing warehouse systems.
The best type of AS/RS for a warehouse depends on factors like inventory size and weight, SKU count, available space, throughput requirements, facility layout, and budget. An experienced warehouse automation integrator like BoxLogix can evaluate these factors, along with software compatibility and future growth needs, to help determine which AS/RS solution is best suited to your operation.