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ASRS system
What is ASRS? Automated Storage and Retrieval System Defined
Automated Storage and Retrieval Systems are just that – automated systems that efficiently and securely store items in a compact footprint. They also allow users to easily and quickly retrieve items when needed. Several companies manufacture a wide variety of self-contained, goods-to-person, automated storage and retrieval systems (ASRS). The technologies handle different volumes, types and velocities of non-palletized inventory at variable speeds to accommodate varying throughput demands. When considering the options, keep in mind both the storage density your facility needs as well as your throughput goals.
Automated Storage and Retrieval Systems also have a laundry list of alternative names such as dynamic storage systems, high density storage and retrieval systems and goods-to-person picking technology.
Automated Storage and Retrieval System Technologies
The ASRS technologies on the market handle different volumes, types and velocities of non-palletized inventory at variable speeds to accommodate varying throughput demands.
Automated storage can be broken down into 7 major technologies:
Vertical Carousel Modules (VCMs)
A series of carriers traveling bi-directionally in a vertical loop around a track, vertical carousels deliver stored items safely and quickly to an ergonomically positioned work counter at the operator’s command.
Horizontal Carousel Modules (HCMs)
Highly dense storage bins mounted on an oval track which rotates horizontally to deliver product storage locations to an operator, for quick order fulfillment.
Vertical Lift Modules (VLMs)
These enclosed automated storage and retrieval systems consist of two columns of trays with an inserter/extractor in the center delivering trays of stored items to an operator as needed.
Crane Based Mini Load AS/RS
With a single, crane-mounted load handling device dedicated to each extremely dense storage aisle, mini-loads handle loads in cases, totes or trays.
Vertical Buffer Modules (VBMs)
A cost effective, tote handling system consisting of an enclosed shelving system with a movable mast in the center. It stores and retrieves totes, delivering them to an ergonomic picking station or automatically delivering them via an outbound conveyor.
Robotic Cube Storage
All inventory is placed into bins and stacked inside a cube. Smart robots work at the top of the cube to shuffle, sort and retrieve bins and deliver them to a workstation (port) as needed. This type of goods-to-person automated storage system can deliver increasingly higher throughput based on the number of independently moving robotic shuttles inducted into the system.
Floor Robots (AGVs/AMRs)
This solution stores inventory on portable storage shelving that is retrieved and transported from storage to an operator access area by a fleet of autonomous, mobile robots.
10 Signs it’s Time for ASRS Systems
- Replenishment Overload – If workers are spending just as much time replenishing as they are picking you’re wasting time – consider automation!
- Extensive Travel Time – If workers are wasting time traveling several miles during a shift to access inventory – consider automation!
- Excessive Search Time – If, upon arrival at a picking destination, workers must spend time visually search for the correct item and match up part numbers – consider automation!
- Rising Picking Errors – If picking errors are on the rise, wasting money and risking your company reputation – consider automation!
- Struggling Throughput – If you’re struggling to keep up with order cut-off time, or hiring seasonal workers to keep up with demand – consider automation!
- Damaged Items – If valuable inventory is often found damaged and unusable – consider automation!
- Misplaced Inventory – If inventory is frequently misplaced or temporarily lost – consider automation!
- Pilfered Product – If inventory is often unexplainably missing – consider automation!
- Facility at Max Capacity – If you’re building is bursting at the seams and there’s no room for growth – consider automation!
- Risk of Operator Injury – If workers are at risk of injury – consider automation!
Benefits of Automated Storage and Retrieval Systems
There are many benefits of Automated Storage and Retrieval Systems – they include:
- Compact Footprint – ASRS technologies provide highly dense storage and can save up to 85% of floor space occupied by shelving. Calculate the True Cost of Storage Space
- Reduced Labor Requirements – ASRS systems require 2/3 less labor to operate when compared to manual shelving. Calculate the True Cost of Labor
- Improved Pick Accuracy – automated ASRS uses pick to light technology to direct the operator to the exact location of the stored item, achieving 99.9% pick accuracy rates. Calculate the True Cost of Accuracy
- Greater Inventory Control – ASRS solutions manage inventory so you always know what you have and more importantly – where it is. 6 Ways to Increase Inventory Control
- Improved Safety & Ergonomics – ASRS technologies create a safe and ergonomic working environment for employees. Position Your Order Picking Team for Success
Common ASRS Systems Applications
These automated storage systems are used to manage small parts inventories, sub-assembly, work-in-process, maintenance and repair parts and large tools and dies in a variety of applications found within manufacturing and distribution facilities. Common applications include:
- Storage: Providing high density storage parts and components used in a manufacturing process
- Order picking: Offering compact, fast and reliable access to items required for distribution, bringing stored items to the operator for fast order fulfillment, supported by software integration
- Kitting: Managing the process of receiving inventory, group (kitting) component parts for assembly and storing kits until required
- Order Consolidation: Providing a compact solution to temporarily hold incomplete orders awaiting additional items before shipment
- Buffering: Offering a highly dense storage solution for inventory or process buffering
- Assembly: Storing work-in-process or sub-assemblies for later use
- Tools, Dies & Molds: Ergonomic and secure handling of heavy and often expensive tooling required in an automated production process
- Maintenance & Repair Parts: Providing compact storage of maintenance parts onsite to reduce downtime
- Replenishment & Returns: Managing inventory for replenishment and returns processes
- Climate Controlled and Clean Room Environments: Provides cold, clean and dry management of storage
ASRS Solutions by Industry
From manufacturing and distribution to hospital supply rooms, government and administration, organizations can benefit from automated storage and retrieval systems (ASRS) in several areas throughout their facility. Whether your application requires a simple storage solution or a more complex system, there are different types of automated equipment to meet your needs. Implementing goods to person, dynamic storage and retrieval systems at your facility can save floor space, increase productivity, improve picking accuracy, increase inventory control and improve worker ergonomics.
Industries benefiting the most from ASRS include:
- Administration/Services
- Automotive/Transportation Equipment
- Chemicals
- Consumer Goods
- E-Commerce/Retail/Wholesale
- Electronics
- Energy/Mining
- Hospital
- Mechanical Engineering
Pharmaceuticals - Public Administration/Government
- Third Party Logistics
ASRS Costs and ROI
The cost of an automated storage and retrieval system (ASRS) includes the cost of the equipment/technology, accompanying software, controls, delivery & installation, and implementation of the solution into your production system. Ongoing costs include updated training and regularly scheduled maintenance.
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