What Is an Automated Storage and Retrieval System?

Automated Storage and Retrieval Systems (ASRS) have revolutionized warehouse and inventory management across industries. Designed to increase efficiency and optimize space utilization, ASRS allows businesses to store, manage, and retrieve products quickly and accurately without manual intervention. In this article, we will provide an introduction to ASRS, explore how it works, and discuss its advantages for modern businesses.

What Is an Automated Storage and Retrieval System?

Automated storage and retrieval systems (AS/RS, or ASRS) are computer- and robot-aided systems that can retrieve items and store them in flexible locations within a grid or shelving system. As a very high density storage solution, ASRS is used when high volume loads must be moved rapidly and accurately.

ASRS includes various components such as cranes, shuttles, conveyors, carousels, and software that work together to ensure seamless operation. The goal is to improve efficiency, reduce labor costs, and maximize the utilization of available space by automating the storage and retrieval process.

Largest Mini-load ASRS & AGV Project in Southwest China

How Does an ASRS Work?

ASRS relies on advanced software to manage and control the movement of goods within a facility. When a product needs to be stored, the system identifies an available storage location and automatically places the item in the correct position. Similarly, when a product needs to be retrieved, the system quickly locates the item and delivers it to the designated picking area.

The process is entirely automated, eliminating the need for manual labor. The software integrates with the facility's warehouse management system (WMS) to track inventory in real-time, providing businesses with accurate stock levels and ensuring the right products are delivered on time.

Types of Automated Storage and Retrieval Systems

There are different types of ASRS, each designed for specific applications and storage needs. Here are the most common types:

1. Unit Load ASRS: This system is designed for handling large, heavy loads, such as pallets. It uses cranes or shuttles to store and retrieve pallet-sized loads in high-density warehouses.

2. Mini Load ASRS: Ideal for smaller, lighter items, the Mini Load ASRS uses small bins or totes to store products. This system is commonly used in e-commerce fulfillment centers or facilities handling small parts.

3. Shuttle Systems: Shuttle systems use robotic shuttles to move products between storage racks and retrieval stations. This solution is highly flexible and is often used in facilities with high throughput requirements.

4. Vertical Lift Modules (VLM): VLM systems store items vertically in trays and automatically deliver the tray containing the requested product to an operator or picking station. VLM is perfect for space optimization in facilities with limited floor space.

As/Rs Automated Warehouses

Benefits of ASRS for Businesses

The implementation of an ASRS offers numerous advantages for businesses looking to improve their logistics and inventory management. Some key benefits include:

1. Increased Efficiency: ASRS can drastically reduce the time it takes to store and retrieve products, increasing overall operational efficiency. Automated systems perform tasks faster than manual labor, leading to faster order fulfillment and improved customer satisfaction.

2. Space Optimization: ASRS allows for high-density storage, maximizing the use of available space. By automating vertical storage, businesses can store more products within a smaller footprint, reducing the need for warehouse expansion.

3. Reduced Labor Costs: With ASRS, businesses can reduce the need for manual labor, which not only cuts labor costs but also reduces the risk of human error. Automation streamlines operations and allows employees to focus on more strategic tasks.

4. Improved Accuracy: ASRS systems are highly accurate, minimizing the risk of picking errors. With real-time tracking and inventory control, businesses can ensure that the right products are picked and shipped every time.

5. Enhanced Safety: By reducing the need for employees to manually handle products, ASRS improves workplace safety. Employees no longer need to operate heavy machinery or lift large loads, decreasing the likelihood of accidents.

As/Rs Automated Warehouses

What industries are ASRS best suited for?

Many industries are finding great value in automated storage and retrieval systems in their warehouses.

Fashion, Apparel and Department Stores 

The fashion and GM e-commerce sectors face ongoing challenges ranging from seasonality to high return rates.

Cube ASRS are extremely dense and perfect for holding large numbers of various SKUs, making them an ideal system for fashion and retail.

A mini-load automated storage system (ASRS) might also provide an effective solution, especially for smaller items. However, this technology is now outdated and prone to single points of failure.

Industries and OEMs 

Industries such as automotive, aerospace and manufacturing often handle bulky parts as well as smaller, high-tech assets.

For small to medium-sized parts, automated storage systems (ASRS) in cubes are able to meet the speed and precision required in fast-paced automotive or manufacturing environments. Cube ASRS are extremely space efficient and are ideal for use as post or pre-production buffer bins.

For palletised goods such as heavy machinery or large vehicle components, the Cell Load ASRS provides a robust and versatile solution, albeit at a lower throughput.

Pharmaceutical 

The pharmaceutical industry has its own specific industry requirements, including strict inventory control of controlled items and stringent temperature regimes.

Cube ASRS can provide many benefits to pharmaceutical operations such as thermal control, safety grid and traceability. 

Vertical lift modules also provide the necessary security for inventory as the entire system is encapsulated.

Third Party Logistics (3PL) 

The third party logistics sector must store and pick goods of all sizes and shapes from a wide range of industries, while at the same time dealing with labour shortages.

Cube ASRS offers a very high density solution for storing a wide range of items, although the dimensions are limited to what can be stored in a cube storage box.

mASRS solutions are attractive to 3PL providers because they can be installed quickly and scaled up or down as needed.

Systems such as shuttles can automate the transport, storage and retrieval of goods, thereby easing the pressure of labour shortages. 

Shuttles can also accommodate different goods handled by 3PLs.

CPG (Consumer Packaged Goods) 

Cubic ASRS allows for flexible, high-density storage of a wide range of SKUs, ideal for fast-moving items in the CPG space.

Shuttle-based ASRS can also handle a wide range of package sizes, providing adaptable solutions for everything from single pieces to multipacks and boxes.

Grocery 

Refrigerated or temperature-controlled cube-based automated storage systems (ASRS) can safely manage refrigerated, frozen or ambient commodities to meet the needs of the grocery industry.Ocado has been successfully operating its OSRS-based Ocado Intelligent Platform grocery solution globally for more than a decade.

The Unit Load ASRS system supports bulk storage of boxes and pallets of high-demand items. 

Shuttle-based ASRS helps maintain consistent inventory levels of fast-moving products, ensuring items are always available for order fulfilment.

Questions and Answers

What types of businesses benefit most from ASRS?

Businesses with high-volume inventory needs, such as warehouses, distribution centers, and manufacturing facilities, benefit greatly from ASRS. E-commerce companies, retailers, and industries with large inventories also find ASRS valuable for optimizing storage and improving operational efficiency.

Is ASRS scalable for growing businesses?

Yes, ASRS systems are highly scalable. Businesses can start with a smaller system and expand it as their storage needs grow. This flexibility makes ASRS suitable for both small and large operations looking to automate their storage processes.

What are the costs associated with ASRS implementation?

While the initial investment in ASRS can be substantial, the long-term benefits such as reduced labor costs, increased efficiency, and space savings often justify the cost. The total cost depends on the type of system, its complexity, and the size of the facility.

Can ASRS integrate with existing warehouse systems?

Yes, ASRS can be integrated with warehouse management systems (WMS) and other inventory management tools to ensure seamless operations. Integration allows businesses to maintain real-time visibility of their inventory and optimize workflows.

In conclusion, Automated Storage and Retrieval Systems (ASRS) are a powerful solution for businesses looking to enhance their warehouse efficiency, maximize space, and improve order accuracy. With various types of ASRS available, companies can choose the system that best fits their needs and scale it as their operations grow.