Automated Storage And Retrieval Systems – Boosting Warehouses 

Warehouses and distribution centres handle vast amounts of products and face intense pressure to quickly locate and move those products to meet customer demands. This pressure continually mounts as consumer expectations for faster order fulfilment and delivery accelerate. Warehouse managers strive to boost productivity and accuracy levels within their facility’s confines. However, space constraints as well as labour shortages amplify the challenge. 

Automated storage and retrieval systems (AS/RS) provide a high-density, operationally efficient solution that helps modern warehouses enhance capacity, speed, precision and productivity. These computer-controlled systems automatically place and retrieve loads within the system’s metal framing without human intervention. State-of-the-art AS/RS leverages advanced technologies such as artificial intelligence, machine learning, robotics and sophisticated software to optimise movements.

This post will delve into key benefits AS/RS delivers-

• Enhanced productivity  

• Heightened speed and efficiency  

• Pinpoint precision  

• Maximised capacity  

• Tighter inventory control and accuracy  

• Reduced labour requirements  

• Safer work environment

By integrating automated storage and retrieval systems into the warehouse environment, supply chain leaders can better meet customer expectations through faster fulfilment and delivery powered by streamlined, high-performing operations. The automated systems also allow management to allocate staff to more value-added tasks.

Skyrocketing Growth Trajectory For Automated Storage And Retrieval Systems Adoption  

AS/RS first emerged decades ago, yet adoption has recently hit an inflexion point with skyrocketing growth. This trajectory will continue as various technological advances make these solutions both more powerful and budget-friendly.

Research and consulting firm Interact Analysis projects the automated storage and retrieval systems market to expand at a 12.87 per cent compound annual growth rate (CAGR). Driving this astronomical growth include-

• Pressures for same-day and next-day order fulfilment capabilities as consumer delivery expectations shorten

• Labour shortages requiring automated approaches to handle certain tasks

• Technology enhancements making solutions more productive and affordable 

• Growing warehouse square footage and demand for optimised density

Heightened Productivity

A primary benefit that automated storage and retrieval systems deliver involves enhanced productivity. By using automated cranes and high-density storage systems, AS/RS can smoothly handle significantly higher throughputs and order volumes than traditional warehouse environments.

Inside facilities utilising automated storage and retrieval systems, computer-controlled robotic cranes swiftly carry out storage and order fulfilment duties across aisles of extremely compact and vertical pallet racking or shelving in which the systems place and pull inventory. This allows the automated storage and retrieval systems to make better use of cubic warehouse space compared to standard layouts. Denser storage also reduces the time-intensive nature and inefficiencies of forklifts crisscrossing a warehouse to put away and select items.

With AS/RS seamlessly taking over these functions, warehouse staff avoid bottlenecks and the additional motion and effort that eats into productivity. Instead, they can focus on more value-added tasks better aligned with an organisation’s strategic business objectives. For some companies, AS/RS delivers productivity gains ranging from 25 per cent to over 100 per cent.

Speed And Efficiency  

By automating significant materials handling work, AS/RS inject great speed into warehouse operations. The systems can rapidly store and retrieve inventory while optimising movements. This efficiency edge makes it possible to fulfil more orders with greater accuracy during a standard shift or to meet surging seasonal demand.

For instance, a robotic automated storage and retrieval system can retrieve a pallet in just seconds compared to a few minutes without automation. Some models allow storing and retrieving from both sides of inventory racks simultaneously, doubling throughput.

Many systems feature express lanes known as “fast movers” for very high-velocity products. The software assigns these best-selling items to racks situated closest to shipping docks for rapid access. Strategically placing fast-mover SKUs in these prime automated storage and retrieval systems positions slashes travel distances.

With immense speed comes greater efficiency and higher performance. Quickly storing and moving inventory out the door with minimised touches conserves time and effort.

Pinpoint Precision

Automation eliminates natural human margins of error in inventory handling activities. The latest computer-controlled automated storage and retrieval systems leverage a combination of sensors, scanning, software and circuitry to precisely track all products entering and exiting the system. This fosters extremely accurate visibility down to the SKU level into exactly what inventory sits where within the automated framework at all times.

By removing any uncertainty surrounding inventory positioning and quantities on hand, AS/RS fosters tremendous picking accuracy. Warehouse workers or robots pulling orders know definitively where to locate each item required. This heightens order quality and avoids costly misspeaks that erode customer satisfaction and profits. 

Moreover, should any inventory discrepancies arise, automated systems vastly simplify audits and reconciliation processes to pinpoint the source of variances and quickly resolve them. With nearly 100 per cent inventory accuracy and order perfection attainable, businesses minimise costly write-offs while protecting their brand reputation.

Maximised Capacity  

The ultra-dense configurations of automated storage and retrieval systems solutions maximise storage capacity within a fixed footprint. Unlike traditional warehouses that mainly use low-rise selective racking requiring aisles wide enough for pallet jacks and forklifts, automated systems utilise narrower aisles with storage levels reaching more than 130 feet high in some cases. 

By extending vertically and using the entire cube of a facility rather than just its floorspace, companies can accommodate two to five times more inventory. This liberates businesses from expanding warehouses or adding offsite storage that erodes staff productivity through elongated travel requirements between buildings. Even small-footprint facilities can now hold sizable stock volumes.

What’s more, the high-density designs retain easy accessibility. When a specific pallet or tote is needed to fulfil orders, automated cranes rapidly retrieve the item from its compact storage location and move it to an access point.

The ultra-dense automated storage and retrieval systems configurations also promote superior inventory rotation and first-in-first-out picking patterns to minimise waste. With expansive visibility into all inventory within the system through warehouse management system integration, the software assigns optimal storage positions to avoid slow movers getting buried behind other items.

Enhanced Security And Damage Control

Traditional warehouses rely heavily on lift truck operators navigating narrow aisles crowded with merchandise, racks, machinery like conveyors and co-workers to repeatedly move loads. This frenzied setting leaves inventory vulnerable to impacts causing damage. It also amplifies safety risks to workers nearby from accidental collisions by material handling equipment. Vertically extending storage to extraordinary heights via automated storage and retrieval systems introduces potential perils as well.

However, automated environments protect inventory and human safety substantially better than older warehouses. Enclosing automated systems in cages with sensors halts equipment instantly if someone unexpectedly enters. Programing prevents accidents by directing cranes and other gear to avoid occupied spaces. Digital inventory tracking promotes accountability and deters theft.

Furthermore, without manual picking processes, merchandise avoids rough handling that innocently harms goods. Automation ensures smooth, secure grip and movement of each pallet or tote every time.

The confined storage frames also defend inventory from warehouse dangers. With external access barriers and closely configured interior racking, products stay shielded from impacts by machinery. Fire suppression equipment can readily permeate the automated enclosures as well.

Tighter Inventory Control

AS/RS solutions foster extremely tight inventory control. Advanced software integrated with warehouse management and enterprise resource planning systems govern all automated activities. This connectivity provides end-to-end visibility from the moment supply deliveries arrive at receiving docks until orders ship out.

Such holistic transparency, paired with sensors to track all storage and order fulfilment movements within the automated storage and retrieval system, heightens inventory accuracy. Businesses know precisely what merchandise they have on hand, where it sits and when to replenish stock. This prevents costly out-of-stocks that erode revenues and customer loyalty when consumers cannot obtain the items they want when they want them.

Having current, in-depth visibility into all inventory also minimises waste. The software can redirect soon-to-expire items to shipping queues first to avoid write-offs. Similarly, teams can suppress fast-moving products about to go on backorder to prioritise them.

Conversely, when certain SKUs accumulate through below-forecast sales, leaders can quickly run analytics to spot demand planning errors. This allows adjusting purchase orders to cut excess inventories that gobble up cash flow.

Lower Labour Requirements

AS/RS solutions minimise the gruelling manual efforts traditionally expected of warehouse personnel. Letting intelligent machines handle the bulk of repetitive, injury-prone material transports, workers avoid these physically taxing activities. Major productivity roadblocks from employee fatigue or turnover also decrease.

With automation crunching key data and directing movements, staffing needs may be reduced by 20-50 per cent in some situations. Even during peak volume periods, AS/RS can smoothly accommodate higher output without expanding headcounts or paying overtime.

Rather than cut employees, leaders can strategically redeploy talent saved through automation to tackle more rewarding initiatives that engage workers. Enriching order processing, supplier relationship management and inventory planning roles brings greater job satisfaction and adds more workplace value.

Investing financial savings from smaller labour budgets into employee training programs also boosts retention while preparing staff to operate alongside sophisticated automation.

Safer Conditions 

Automating demanding, dangerous materials handling activities cultivated safer working conditions. Without workers darting through narrow aisles on lift trucks, merchandise falling from racks and other safety risks diminish. Automation provides reliable, consistent handling every time.

Warehouses using automated storage and retrieval systems cut accident rates by over 65 per cent according to research published in the International Journal of Engineering and Innovative Technology. This decreased injury frequency lowers insurance premiums as well.

Implementing Leading-Edge AS/RS Solutions

The game-changing operational enhancements available through automated storage and retrieval systems prompt many supply chain leaders to evaluate implementing these solutions within their facilities. Leveraging automation helps warehouses boost productivity, speed, accuracy and responsiveness when meeting customer expectations.

However, comprehensively assessing an existing distribution centre’s physical infrastructure, storage profile, product mix and order patterns is imperative before moving forward. Companies must carefully consider if their needs and goals align with automation capabilities. The significant upfront investments required demand due diligence.

Once firms determine to integrate automated storage and retrieval systems, partnering with an automation expert is crucial. While various equipment manufacturers offer racking, conveyors, robotics and other components, system integrators customise total solutions. They combine the best technologies into unified systems with sophisticated software and controls tailored to each organisation’s requirements. By guiding firms through the end-to-end process, integrators simplify transitions to automated environments.

Boost Productivity With AS/RS Solutions 

As consumer demands and order volumes intensify, warehouses require high-performing systems to fulfil orders accurately and swiftly. Manual approaches strain to keep pace in modern supply chains. Integrating automated storage and retrieval systems solutions optimises previously labour-intensive processes. 

By deploying intelligent, fully integrated equipment under the guidance of automation specialists, distribution centres and other warehouses can maximise productivity. Automated storage and retrieval systems solutions transform storage density, speed, precision and inventory control – driving competitive advantages through superior shipping capabilities. Accelerating return on investment makes the systems indispensable for warehouses keen to excel.