Are you considering an automated storage and retrieval system for your materials handling operation?
ASRS systems are among the most established warehouse automation solutions available today. These automation systems are designed to improve warehouse operations by automating inventory storage and retrieval. This helps distribution centers and manufacturers keep up with growing demand while managing labor and space constraints.
Using an asrs solution offers five primary benefits for warehouse operations:
- Streamline inventory management and inventory control
- Improve throughput and support fluctuating order fulfilment volumes
- Reduce hiring challenges and dependence on manual labor
- Reduce labor costs over the long term
- Maximize available floor space and vertical storage capacity
What are Automated Retrieval Systems?
When someone says “AS RS,” they are not referring to one specific technology; they are referring to automated storage and retrieval systems. It is similar to saying “transportation.” The requirements for moving a single package are very different from moving hundreds of pallets per hour.
A fully automated storage and retrieval system combines software such as a warehouse management system (WMS) and execution controls with material handling equipment like storage racks, conveyors, cranes, shuttle systems, and robots. Together, these components allow managed inventory to be stored and retrieved efficiently to support order picking, order fulfilment, and buffering processes.
How ASRS Works
How an as/rs solution is designed depends on several factors. To understand how ASRS works for your specific building, you must look at the item types and dimensions. You also need to consider the weight of products and how often people order them. The amount of available warehouse space and your specific picking workflows also play a large role.
Most of these solutions fall into two broad categories: unit load for larger loads such as pallets, and mini load for smaller items such as totes or cases.
Unit Load Systems
Unit load systems use narrow aisles and racking to store and retrieve full pallets in high-density vertical storage. These systems are commonly used in large distribution centers where maximizing storage capacity is critical. There are fixed aisle systems where a crane stays in one lane, and moveable aisle systems where cranes move between different areas.
Mini Load Systems
Mini load systems are built to store and retrieve smaller loads, such as totes or trays. While they work like unit-load systems, they carry less weight and are designed for higher SKU counts. These are great for e-commerce and order picking, where speed is very important.
Shuttles Systems and Carousels
Tote shuttle and pallet shuttle systems are often used in goods-to-person areas. Shuttles travel along rails to retrieve inventory and deliver it to a picking station. This simplifies warehouse operations because workers do not have to walk to find items.
Horizontal and vertical carousels are another great way to optimize space. Vertical carousels move inventory up and down like a Ferris wheel. These systems improve ergonomics for warehouse workers by bringing items to them at a comfortable height.
Vertical Lift Modules (VLM)
Vertical lift modules vlms store trays between two vertical columns. An inserter moves up and down to retrieve trays and deliver them to an operator. After the worker finishes order picking, the tray goes back to its spot. These are best when you have a lot of vertical space but very little floor room.
When is an ASRS Solution Financially Viable?
Not every warehouse needs an automated storage and retrieval system. The cost varies based on the types of automated storage you choose. However, these systems usually make sense if your operation runs two or three shifts. This allows the machines to operate 24 hours a day without overtime, helping you achieve a return on investment much faster.
If you have six or more people performing materials handling, or if labor costs are high and hiring is difficult, automation can help. It reduces human error and lowers the reliance on hard-to-hire warehouse workers. If you have a lot of unused vertical space, building up with ASRS is often cheaper than moving to a new building.
Real Examples of ASRS Automation
Automated retrieval systems are used across many industries. A manufacturer of automotive seats implemented a three-lane AS RS to store and retrieve finished products, achieving a throughput of 290 pallets per hour. A large distribution center used a goods-to-person AS RS to process 30,000 items per eight-hour shift, supplementing human labor with automated systems. A beauty company distribution center built four vertical storage levels with over 40,000 storage locations, expanding capacity within a limited footprint.
“You really have to start by doing an analysis of an operation and understanding a customer’s needs,” says Tony Morgott, ISD’s VP of Sales. “Some operations need pallet AS/RS, others need to store and retrieve small items. Some need dense storage, while others move fast and need to keep product flowing.”
Deciding if ASRS is Right for You
Determining whether ASRS is the right path starts with a detailed needs assessment. This includes reviewing your inventory levels and order velocity. At the end of the day, an automated storage and retrieval system offers a more reliable and repeatable way to move goods than relying only on manual labor.
Research from MIT’s Sloan School of Management and Department of Mechanical Engineering found that the largest source of shipping delays in a distribution center is variability in task completion time. Their recommendation was to adopt AS RS to reduce material processing time and support direct-to-consumer deliveries. Their findings showed that implementations reduced storage and retrieval processing time by 67 percent.
Next Steps
Many ISD customers achieve fast returns on their automation projects. Meet with us and tell us about your operation and what you are trying to accomplish. We will tell you honestly and at no charge whether AS/RS makes sense for your warehouse.
If it is right for you, we will work together to engineer the ideal solution. If it is not, we will help you find a better approach that improves efficiency and helps you grow.
About ISD – Integrated Systems Design
ISD is a leading systems integrator. We help companies use warehouse automation to reduce costs and improve order fulfilment. Our 8-step framework is designed to future-proof your business by optimizing how you pick, sort, and ship.
For more information: Contact Ed Romaine, VP Marketing & Business Development, Email: eromaine@isddd.com, Phone: 215-512-7711
Would you like me to help you draft some internal interview questions to ask your floor managers to see if they feel your warehouse is ready for this tech?
