Automated Storage and Retrieval Systems
Automated storage and retrieval systems (AS/RS) provide dense inventory storage to maximize floor space.
Often used for tooling, components, documents or raw materials storage, vertical carousels are enclosed on all sides.
Automated storage and retrieval systems, sometimes known as ASRS or AS/RS, are made of a variation of computer-controlled systems that automatically place and retrieve loads from set storage locations in a facility with precision, accuracy and speed.
An Automated Storage and Retrieval System (AS/RS) is a combination of equipment and controls that handle, store and retrieve materials as needed with precision, accuracy and speed under a defined degree of automation. Systems vary from smaller automated systems to larger computer controlled storage/retrieval systems totally integrated into a manufacturing and/or distribution process.
Generically speaking, AS/RS refers to a variety of computer-controlled methods for automatically depositing and retrieving loads to and from defined storage locations. Within an AS/RS environment one would find one or more of the following technologies:
- Unit-load AS/RS – Machines that store large loads (usually 1,000+ pounds), typically on pallets with storage rack structure, reaching 100 feet or more tall.
- Mini-load AS/RS – Operating the same as a unit-load AS/RS, a mini-load AS/RS handle lighter loads, usually weighing less than 1,000 pounds
- Vertical lift modules (VLMs) – VLMs consist of a column of trays in the front and back of the module with an automatic inserter/extractor in the center that stores and retrieves the required trays
- Shuttles – Shuttles are used for the automated handling of totes, trays, cartons or all three in the same system – for either warehousing or manufacturing.
- Horizontal carousels – Ideal for storing small parts and pieces, horizontal carousels are comprised of a series of bins that rotate horizontally around a track.
- Vertical carousels – Rotating vertically, like a Ferris wheel, vertical carousels house a series of shelves or carriers to provide high-density storage.
- Cube-based storage – Ultra-high density goods-to-person piece picking system which utilizes robots to store and retrieve inventory bins from a cubical storage grid.
Automated storage and retrieval systems are used in a variety of areas to support processing and picking throughout a facility:
- Order picking: Retrieving and presenting required inventory to pickers
- Storage: Providing dense long-term buffering for small or large items that are slow- to medium-movers
- Kitting: Providing an area to group component parts for assembly
- Consolidation: Providing a dynamic area to hold parts and items until all pieces of an order can be merged ready for shipment. Often used for consumer, B2B and store orders.
- Assembly: Storing work piece components for later production
- Production: Storing tooling and component parts for manufacturing processes
- Replenishment: Storing excess inventory for restocking of ancillary picking systems
- Security: Providing an enclosed storage environment with software access controls
- Retail: Providing a large quantity of parts and items at a customer service desk. Keeps workers in front of customers instead of walking and searching in back rooms.
Automated storage and retrieval systems provide a variety of benefits:
- Increases throughput capabilities
- Increases accuracy levels to 99.99%+
- Increases ergonomics by delivering items to the operator at a convenient height, eliminating time lost to walking, searching, lifting, bending and twisting activities
- Provides highest possible storage density
- Saves up to 85%+ of otherwise wasted floor space
- Increases labor productivity up to 85%
- Enhances product security
- Provides real-time inventory control
Automated storage and retrieval systems are used in a variety of industries, including:
- Automotive
- Beverage
- Electronics
- E-commerce
- Food
- Hazmat
- Hospital
- Jewelry
- Life sciences
- Manufacturing
- Medical devices and equipment
- Maintenance & repair operations (MRO)
- Paper
- Pharmaceutical
- Plastics
- Spare parts handling
- Warehousing and distribution
Read more about how automated storage and retrieval systems are used in different industries and applications. Additional case studies can be found here.