What is an automated storage and retrieval system? AS/RS ...

Automated storage and retrieval systems (AS/RS) are computer- and robot-aided systems that can retrieve items or store them in designated locations. The system consists of predefined locations where machines can follow established routes to access items.

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When all items are stored in their proper places, these systems help speed up manufacturing and shipping processes. Generally, automated storage and retrieval systems are used for high-volume loads that need to be moved quickly and accurately. Let’s explore the main types of AS/RS systems, how they work, and their advantages and disadvantages.

In this article, we will explore:

Types of automated storage and retrieval systems and examples

The two primary types of AS/RS are unit-load and mini-load systems. Unit-load AS/RS is used for large loads, such as handling full pallets or cases of items. These systems are designed to manage high-weight objects, sometimes weighing several thousand pounds. A typical unit-load AS/RS incorporates moveable-aisle cranes or fixed-aisle cranes:

• Fixed-aisle cranes remain stationary in one area or row of pallets, moving along a designated path to retrieve items.
• Moveable-aisle cranes can retrieve or store items in multiple areas rather than just one path or aisle.

Mini-load AS/RS, such as case-handling or tote-stacking systems, are smaller cranes or robots that manage lightweight loads like trays or cartons. Mini-load AS/RS generally uses cranes or shuttles:

• Mini-load AS/RS cranes operate along narrow aisles, functioning as smaller versions of fixed-aisle cranes.
• Mini-load AS/RS shuttles run along tracks and transport items between automated racking systems. They can function at various levels when designed for such tasks, although most operate along a single path.

Other types of AS/RS include carousel-based systems and vertical lift modules (VLMs). Carousel-based AS/RS use an inserter extractor to retrieve and store products. The carousel spins until the shelf or bin is correctly positioned for the inserter extractor to place or remove the item. These systems usually handle lighter loads compared to unit-load systems.

Vertical lift modules (VLMs) operate similarly to carousel-based systems. The inserter extractor is positioned in the center of an enclosed structure, surrounded by columns of trays. Upon request, it retrieves the correct tray and delivers it to an operator, who then completes the order before returning the tray.

How automated storage and retrieval systems work

Each AS/RS type functions slightly differently, but all aim to enhance warehouse processes. These systems automate the storing and retrieving of products in suitable bins, shelves, or other locations, significantly reducing the time and labor associated with managing inventory.

Advantages of automated storage and retrieval systems

Automated storage and retrieval systems provide several advantages, including:

• Lower labor costs
• Enhanced accuracy, efficiency, and productivity
• Reduced safety risks for employees by minimizing the need to lift and move heavy items

AS/RS can operate in environments unsuitable for human workers, such as frozen storage areas. Furthermore, they can function at heights that are challenging for workers, allowing warehouse operators to utilize vertical space more effectively.

Disadvantages of automated storage and retrieval systems

Despite their benefits, AS/RS solutions come with drawbacks. The equipment is often bulky and may entail significant initial investment and structural changes to existing warehouse layouts.

Regular maintenance is necessary to ensure optimal performance of AS/RS systems. Breakdowns can lead to substantial productivity losses, potentially halting operations. Additionally, warehouses managing various products during seasonal changes may encounter reduced productivity while retraining the AS/RS to handle new products.

How to choose the right automated storage and retrieval system

To meet consumer demand and maintain competitive advantages, businesses must optimize warehouse space, asset utilization, and labor efficiency. Consequently, many companies opt to implement AS/RS to automate storage and retrieval processes.

The complexity of AS/RS systems can make selecting the most suitable option challenging. Below are some key features and factors to consider.

Reliable software

ASRS systems have four main components:

• Storage and retrieval (S/R) equipment
• Input/output system
• Storage rack
• Computer management system

The computer management system oversees loading and unloading of SKUs, using dedicated software that tracks inventory details such as:

• Specific locations of items
• Duration of storage
• Origins of items

The ideal AS/RS will feature robust software that enables seamless scheduling of retrieval and storage operations. Ensure the software is user-friendly, dependable, and free from technical issues.

Height and weight limitations

Although AS/RS systems can be tailored for various items, some systems are better suited for specific products. It's essential for the system to accommodate the maximum weight per unit load for your operations. Shuttle and mini-load systems are designed for light loads, while unit-load AS/RS are appropriate for heavier items.

Additionally, the vertical height of the system should align with your facility's overhead space. Common storage racks reach approximately 40 feet, though some systems can extend up to 100 feet. Higher systems often reduce costs per vertical foot.

Speed

Your chosen AS/RS should occupy minimal floor space and feature multiple speed options suitable for peak demand periods in picking and order fulfillment. For e-commerce operations, a high-speed buffer system is recommended for quickly managing large volumes of storage. High inventory accuracy allows companies to reduce safety stock levels and accommodate additional SKUs in the same warehouse space, providing customers with more product choices and faster fulfillment.

Customer service

Select an AS/RS provider that offers prompt and reliable customer service. A malfunctioning AS/RS can disrupt productivity and result in unfulfilled orders, negatively impacting supply chains and customer satisfaction. Access to quick professional assistance is crucial to safeguarding your reputation and profitability.

How much do automated storage and retrieval systems (AS/RS) cost?

The costs associated with automated storage and retrieval systems can vary widely. Factors influencing costs can range from $70K for a single vertical carousel to over $5 million for a fully integrated mini-load system managing tens of thousands of SKUs.

Components affecting the overall cost include:

• Equipment cost
• Size and weight of products handled
• Storage space
• Operating environment (climate-controlled or cleanroom environments are more expensive)
• Special handling requirements
• Throughput needs
• Complexity of software and machine controls
• Costs for customizing and reconfiguring the equipment and facility
• Shipping, delivery, and installation expenses
• Integration with existing processes

Aside from the upfront costs, the operational and maintenance expenses of an AS/RS system can be substantial. Estimates indicate that a sophisticated automated storage and retrieval system may achieve measurable ROI in about five years, considerably longer than alternative automation solutions like collaborative mobile robots.

A better alternative: collaborative mobile robots

An alternative to AS/RS is autonomous mobile robots (AMRs). These robots assist human workers in enhancing productivity and accuracy without requiring substantial infrastructure adjustments. They are intuitive and can be deployed quickly, in contrast to the longer implementation time associated with AS/RS systems. AMRs aid warehouse associates in completing tasks, complementing rather than replacing human labor.

Moreover, autonomous mobile robots offer scalability. In peak periods, companies might rent AMRs as needed, allowing for adjustments in workforce levels to meet demand.

To learn more about the advantages of autonomous mobile robots, download our white paper, 8 Reasons Why Warehouse Robots Beat Traditional Automation. We can also discuss solutions tailored to your needs. Contact us today.