Automated Storage and Retrieval Systems (AS/RSs)
An AS/RS (also known as ASRS) improves product handling efficiency and provides a safe warehouse environment
AS/RSs have long been game-changers in warehouse management, automating how retailers, wholesalers, and manufacturers organise, access, and manage their stock. These systems optimise space, reduce labour reliance, and enhance efficiency.
Typically, an automated warehouse storage system consists of high-density shelving and robotic load-handling devices that efficiently move products in and out of storage. Whether handling pallets or finished goods with a unit-load system or managing smaller items like cartons, cases, or totes with a miniload or a multishuttle system, going from manual processes to automation can significantly improve product handling efficiency and enhance warehouse safety.
Typical applications and uses of Automated Storage and Retrieval Systems
AS/RSs are incredibly versatile, offering a wide range of applications across various industries:
- Long-Term Storage: They are ideal for operations with items that need to be stored for extended periods without frequent access.
- Goods-to-Person Order Picking: They enhance picking efficiency by automatically bringing items to operators, reducing travel time and errors.
- Staging Orders: AS/RSs organise and create a buffer for orders in preparation for processing or shipping, ensuring quick and accurate dispatch.
- Buffer Storage: AS/RSs provide temporary storage for inventory not currently needed for order processing.
- Inventory Management: Automated Storage and Retrieval Systems offer real-time tracking and management of inventory, ensuring optimal stock levels and reducing stockouts or overstock situations.
Key features and benefits of Automated Storage and Retrieval Systems in warehouse management
Implementing AS/RSs in warehouse management comes with several advantages:
- Space Optimisation: They maximise storage density, allowing more to be stored in less space.
- Enhanced Accuracy and Productivity: They lead to higher productivity by reducing human error and increasing picking and handling speed.
- Reduced Labour Costs and Increased Safety: AS/RSs automate repetitive tasks, reducing the need for manual labour and minimising workplace injuries.
- Real-Time Inventory Management: AS/RSs provide accurate, real-time data on inventory levels, enabling better decision-making and planning.
- Scalability and Flexibility: They can easily scale to accommodate growth, allowing businesses to expand their storage capacity without major infrastructure changes.
- Increased Throughput: Automated Storage and Retrieval Systems result in higher efficiency significantly enhancing the rate at which goods are processed, stored, and retrieved.
- Energy Efficiency: Advanced AS/RSs consume less energy, contributing to cost savings and sustainability.
Types of Automated Storage and Retrieval Systems: Pallet Handling
What is a unit-load AS/RS?
Unit-load AS/RSs (sometimes referred to as high bay warehouses or pallet crane systems) are fully automated storage and retrieval systems designed to handle heavy loads and bulky items, typically stored on pallets. They provide high-density storage and are ideal for operations that require handling large loads.
Key features and benefits of unit-load AS/RSs
- High-Density Storage: Can handle loads up to 1,800 kg and store them in structures up to 45 metres tall and in multiple temperature environments, including frozen.
- Higher Throughput: Capable of moving up to 60 loads per hour with minimal labour.
- Efficient and Reliable: Proven technology ensures maximum uptime to keep operations running efficiently.
- Enhanced Performance Visibility: Make informed decisions with real-time visibility of inventory and performance metrics.
Applications and use cases of unit-load AS/RSs
- Increase Density in New Buildings (Greenfields): Unit-load AS/RSs captures vertical space and builds density from the start of your project to provide capacity to meet current and future demand.
- High Product Variation: Single or double-deep pallet storage reduces shuffling of deep lane pallets to quickly access a variety of palletised inventory.
Types of Automated Storage and Retrieval Systems: Carton/Tote Handling
What is a miniload AS/RS?
Miniload AS/RSs are fully automated storage and retrieval systems for handling small parts, totes, and cartons in a high-density storage environment.
Key features and benefits of miniload AS/RS
- High-Density Storage: Optimized for small items — can handle loads up to 160 kg and store them in structures up to 20 meters tall.
- Rapid Access: Capable of handling up to six loads in a single cycle, offering quick and efficient access.
- Modular and Flexible: Available in single and double-mast models, adaptable to various storage needs.
- Storage Configuration: single deep, double deep
Applications and use cases of miniload AS/RSs
- Small Parts Storage: Ideal for applications requiring efficient storage and retrieval of small parts.
- Automated Tote Handling: Ideal for operations needing compact, high-density storage solutions.
Which Dematic Automated Storage and Retrieval System solution suits your needs?
Choosing the right AS/RS solution depends on several factors:
- Number of Stock Items: Consider the diversity of items in your inventory.
- Throughput Rate: Evaluate the speed at which you need to move items in and out of storage.
- Physical Size and Weight of Items: Determine the appropriate system based on the size and weight of the items you handle.
- Growth Expectations: Choose a solution that can scale with your business needs.
The right AS/RS solution can transform your warehouse operations by optimising space, improving efficiency, and enhancing service levels. Whether it's a Dematic Unit-Load AS/RS for heavy-duty storage, a Dematic Miniload AS/RS for small parts, a Dematic Multishuttle AS/RS for high throughput, or an AutoStore system for space optimisation, Dematic offers a comprehensive range of options to meet your specific needs.
What criteria should you use when evaluating an automation partner?
It is critical to select the right supplier - one that will be a trusted partner throughout the entire process.
As a company that’s led innovation in Supply Chain for more than 200 years, Dematic provides the widest range of solutions and the expertise to build the solution you need for complete control and visibility over your operation.
Our solutions are tailored to your business challenges. Using standardised sub-systems and industry-leading insight and expertise, Dematic provides world-class integrated hardware, software, and support to help you empower people, optimise space, drive growth and improve efficiency.
With Dematic, you can grow your business to compete locally, retain customer loyalty, and deliver with speed and accuracy on a global scale.