Automated Storage and Retrieval System
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Be Efficient and Optimize Your Operations with Automated Storage & Retrieval Systems (ASRS) and Goods-to-Person (G2P) Technologies to reduce labor, increase floor space capacity and increase accuracy.
Is your organization struggling to keep up with labor, inventory levels, accuracy, cost per pick, and floorspace demands on your warehouse operations? Do you spend valuable time searching and retrieving items for your order fulfillment? It’s time to optimize your operations and improve efficiency with Automated Storage and Retrieval Systems (ASRS) and Goods-to-Person (G2P) technologies.
Type of ASRS-Good-to-Person System
Technologies
Each/Split or Case Picking or Both
Mini-Load ASRS
Mid-Load ASRS
Horizontal Carousel
Vertical Carousel
Vertical Lift Module
Shuttle
3D and Cube ASRS
Vertical Buffer System
AMR Shuttle
Shelf to Person
A Frame
TBD
Pallet Handling
Shuttle
Mid-Load ASRS
Unit-Load
AMR Based
For more information
Is your organization struggling to keep up with labor, inventory levels, accuracy, cost per pick, and floorspace demands on your warehouse operations? Do you spend valuable time searching and retrieving items for your order fulfillment? It’s time to optimize your operations and improve efficiency with Automated Storage and Retrieval Systems (ASRS) and Goods-to-Person (G2P) technologies.
In order fulfillment, up to 70% of order picking time is spent walking and searching for the correct SKU. An ASRS G2P system eliminates this wasted labor. Automated Storage and Retrieval systems automatically present the correct SKU to their workstation and direct the pickers as to the quantity, shelf, and cell location using an integrated pick-to-light system, virtually eliminating mispicks, reducing labor, and increasing throughput.
The major question about implementing automated storage and retrieval systems in your operations always revolves around:
When should we automate? How much automation makes sense? What type of ASRS or G2P technologies and systems make sense? The manufacturers, models, styles, and types of ASRS can be mind-blowing. This is why ISD utilizes its OptimalOps Process, an eight-step program, which mathematically helps determine not only when it makes sense to implement ASRS into your operations but also helps assure the correct technology and implementation processes are employed.
See below for the types and styles of ASRS systems available. For decades, ISD has worked with thousands of OEMs from around the world to determine the best solution for your specific industry, application, and organization.
How ASRS Works
The implementation of Vertical Carousel ASRS provides a plethora of benefits that can transform an organization’s storage and retrieval operations. One of the most notable benefits is the significant improvement in efficiency. With real-time tracking and reporting capabilities, organizations can maintain accurate inventory levels, reducing the risk of stockouts or excess inventory.
The ergonomics of a Vertical Carousel ASRS also cannot be overlooked. By bringing items to the operator at an optimal height, this system minimizes the need for bending, reaching, or climbing. This reduction in physical strain can lead to fewer workplace injuries and lower healthcare and litigation costs for your organization.
Benefit of Implementing ASRS and G2P Technologies
Vertical Carousel ASRS systems are versatile and can be applied across a variety of applications, making them an asset for many organizations.
Factor to Consider When Choosing ASRS and G2P Technologies
A Vertical Carousel ASRS is equipped with several key features and components that contribute to its efficiency and effectiveness in inventory management. One of the primary components is the carousel mechanism itself, which consists of multiple carriers (or sometimes called trays or shelves) that rotate around a vertical axis. The carousel’s inherent design provides high density storage and rapid access to every part stored within the unit.
Carriers come in a variety of widths and heights. The carrier’s height is often based on available clear vertical height available to maximize density. The carriers can then incorporate additional shelves to increase storage capacity based on stored inventory’s required heights.
Another essential feature is the user interface, which usually includes a touchscreen, keypad, or PC that allows operators to manually input a part number or shelf level, scan a barcode or download orders to begin picking or replenishing. Some advanced systems can utilize voice recognition capabilities to streamline the retrieval process.
Software that operates the ASRS plays a crucial role, as it manages inventory data, monitors system performance, and provides reporting features that in turn helps organizations analyze their storage efficiency. This software will seamlessly integrate with existing WES, WMS, MES, and ERP software systems in place.
A locking bi-parting doors provide additional levels of security.
Safety features are also integral to the design of Vertical Carousel ASRS. These systems often come with photo beams, sensors, and safety guards to prevent accidents and ensure the well-being of operators and materiel. For instance, automatic shut-off mechanisms can be activated if an obstruction is detected during operation. Additionally, the systems may have weight sensors that ensure the trays are not overloaded, or hanging over the carrier’s lip, thereby prolonging the equipment’s lifespan and minimizing maintenance costs.
Factor to Consider When Choosing ASRS and G2P Technologies
A Vertical Carousel ASRS is equipped with several key features and components that contribute to its efficiency and effectiveness in inventory management. One of the primary components is the carousel mechanism itself, which consists of multiple carriers (or sometimes called trays or shelves) that rotate around a vertical axis. The carousel’s inherent design provides high density storage and rapid access to every part stored within the unit.
Carriers come in a variety of widths and heights. The carrier’s height is often based on available clear vertical height available to maximize density. The carriers can then incorporate additional shelves to increase storage capacity based on stored inventory’s required heights.
Another essential feature is the user interface, which usually includes a touchscreen, keypad, or PC that allows operators to manually input a part number or shelf level, scan a barcode or download orders to begin picking or replenishing. Some advanced systems can utilize voice recognition capabilities to streamline the retrieval process.
Software that operates the ASRS plays a crucial role, as it manages inventory data, monitors system performance, and provides reporting features that in turn helps organizations analyze their storage efficiency. This software will seamlessly integrate with existing WES, WMS, MES, and ERP software systems in place.
A locking bi-parting doors provide additional levels of security.
Safety features are also integral to the design of Vertical Carousel ASRS. These systems often come with photo beams, sensors, and safety guards to prevent accidents and ensure the well-being of operators and materiel. For instance, automatic shut-off mechanisms can be activated if an obstruction is detected during operation. Additionally, the systems may have weight sensors that ensure the trays are not overloaded, or hanging over the carrier’s lip, thereby prolonging the equipment’s lifespan and minimizing maintenance costs.
Why Using ISD for Your ASRS and G2P Solutions Makes Perfect Sense
Implementing a Vertical Carousel ASRS can significantly enhance an organization’s operational efficiency. One of the primary advantages is the substantial increase in space utilization. By leveraging vertical storage, businesses can reclaim valuable floor space for other uses. This can be particularly beneficial in urban settings where real estate is expensive, allowing companies to maximize their storage capacity without the need for costly expansions.
Another advantage is the reduction in labor costs. Traditional storage methods often require employees to spend considerable time searching for items, which can lead to inefficiencies and increased labor expenses. The Vertical Carousel ASRS automates this process, bringing items directly to the operator and reducing the time spent on picking and retrieval. This efficiency not only minimizes labor costs but also allows staff to focus on higher-value tasks that can contribute to overall business growth.
Furthermore, the improved accuracy in order fulfillment is another critical benefit. The automated nature of the Vertical Carousel ASRS reduces the likelihood of human error during the picking process. Operators are less likely to misplace items or select the wrong products, which leads to higher customer satisfaction and fewer returns. In industries where precision is crucial, such as pharmaceuticals or electronics, this feature becomes even more valuable, ensuring compliance with regulatory standards and enhancing overall quality control. - Order picking
- Inventory storage
- Parts storage
- Tool management
- Kitting operations
- Goods-to-person picking
- Batch picking
- Buffer storage
- Quality control
- Returned goods processing
- MRO (Maintenance repair operations)
- Spare parts storage
- Assembly line support
- Manufacturing
- Packaging materials storage
By understanding the diverse applications of VLM systems, organizations can better evaluate and implement the right solution to meet their specific storage and operational requirements, ultimately enhancing their overall competitiveness and performance.
Common Questions and Answers (Q&A) for Vertical Carousel ASRS Systems
When does a vertical carousel make more sense than a vertical lift module (VLM)?
There are many factors, but when the height of the unit is under 16 feet, the vertical carousel will often provide denser storage. Likewise, when your inventory is heavy, imbalance loading, and the running of the vertical carousel can be an issue. In this case, a VLMs tray system does not have these issues. Restricting access to inventory in a vertical carousel is possible. The carousel can be equipped with locking doors, in which the carousel will rotate with the doors closed and then open when the exact shelf level is presented. The user will only be able to access material on that one shelf level. If restricted access is a major issue, a VLM can restrict trays to specific individuals and might be a better solution.
How much does a vertical carousel cost?
VLMs can save up to 85% of floor space by utilizing vertical storage, often reaching heights of up to 30 meters.
How much space can a Vertical Carousel ASRS save compared to traditional storage methods?
Vertical Carousel ASRS systems can increase space utilization by up to 75% compared to conventional shelving or racking systems. By utilizing vertical space effectively, businesses can store more items in a smaller footprint, making it ideal for facilities with limited ground space.
What types of items are best suited for storage in a Vertical Carousel ASRS?
A wide variety of items can be stored in a Vertical Carousel ASRS, including small to medium-sized products, tools, components, pharmaceuticals, and retail merchandise. The system is especially effective for high-velocity items that are often accessed, as well as for items that require secure storage.
What is the typical return on investment for a Vertical Carousel ASRS?
A wide variety of items can be stored in a Vertical Carousel ASRS, including small to medium-sized products, tools, components, pharmaceuticals, and retail merchandise. The system is especially effective for high-velocity items that are often accessed, as well as for items that require secure storage.
Can a Vertical Carousel ASRS be integrated with existing inventory management systems?
Yes, most Vertical Carousel ASRS systems can be integrated with existing inventory management software. This integration allows for real-time inventory tracking, better data management, and improved visibility across the supply chain, enhancing operational efficiency.
What maintenance is needed for a Vertical Carousel ASRS?
Regular maintenance for a Vertical Carousel ASRS typically includes routine inspections, cleaning, and lubrication of moving parts. It is also advisable to have a qualified technician perform periodic checks to ensure the system operates optimally and to address any potential issues before they escalate.
Does my existing software need an upgrade prior to installation?
This will depend on how your organization is utilizing the vertical carousel. If you are simply typing in shelf or carrier levels, the answer is no. If you are using inventory management software to drive and manage the carousels then the answer is maybe. The inventory management software will need to be integrated into your existing WMS, WES, ERP system. The age and quality of your existing software will determine if any upgrades and/or modifications are required.
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