Manufacturing and distribution facilities are continually on the lookout for ways to automate much of their work activities.
Increased efficiency, minimized error and injury risks, and maximized independence from human labor are some of the benefits warehouses and storages can expect upon integrating automation solutions.
Among the most popular warehouse automation solutions is ASRS – automated storage and retrieval systems.
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In this article, we discuss what ASRS systems are and how they work, as well as outline their types, applications, pros and cons, and integration costs.
What are ASRS systems?
Automated storage and retrieval systems are utilized in manufacturing and distribution facilities across sectors with the assistance of computers and robots. As their name suggests, ASRS systems are utilized for storing and retrieving items easily, quickly, and efficiently.
These systems are especially useful for moving high-volume loads accurately and rapidly. ASRSs require items to be stored in predefined locations so that the system can follow established routes to handle the items.
How ASRS Systems Work
ASRS systems operate in diverse ways depending on their application in a specific facility. Yet, they all share the goal of automating and speeding up storage and retrieval processes, reducing the time and manpower needed.
Automated storage and retrieval systems have four principal components:
- Storage and retrieval equipment
- Input/output system
- Storage rack
- Computer management system
The latter, i.e., computer management system, handles the SKUs management within an ASRS via dedicated software.
The software keeps track of inventory details such as their location, time spent in storage, and where the items came from. Also, the software is in charge of all instructions coming to the ASRS system.
ASRS System Types
Depending on the system’s potential of handling different volumes, item types, and velocities, ASRSs can must be divided into seven major technologies:
- Vertical Carousel Modules (VCMs) – which are enclosed systems made up of two columns of trays, are used to lift objects
- Horizontal Carousel Modules (HCMs) – Storage containers mounted atop a horizontally rotating oval track
- Vertical Lift Modules (VLMs) – enclosed systems consisting of the two rows of trays
- Crane-Based Mini Load AS/RS – a single load handling equipment installed on a crane for a narrow storage aisle
- Vertical Buffer Modules (VBMs) – consist of an enclosed shelving system with a movable mast located in the center
- Robotic Cube Storage – a robot-aided system that shuffles, sorts, and retrieves bins containing goods
- Floor Robots (AGVs/AMRs) – solution for storing inventory on portable shelving operated by a fleet of autonomous robots.
Typical Uses for ASRS Systems
In terms of applications, automated storage and retrieval systems can be involved across manufacturing and distribution activities, including storage, order picking, assembly, buffering, maintenance, and returns.
Industry applications of ASRS systems are vast, ranging from automotive, chemicals, consumer goods, retail, mining, medical, logistics, and many more.
Pros and Cons of ASRS Systems
Automated storage and retrieval systems offer an array of benefits to warehouses and storage facilities, such as:
- lowered labor costs
- enhanced pick accuracy
- increased productivity
- reduced error risks
- compact footprint
- greater inventory control
- improved workers’ safety
Moreover, these systems are advantageous for facilities not ideal for human workers, such as those with low temperatures, considerable heights, and others.
When it comes to disadvantages, ASRSs can be quite costly, requiring a substantial investment. These systems are large and bulky, so most facilities will need to make changes to their infrastructure and layout to make ASRSs operable.
In addition, ASRS systems require regular maintenance, and when breakdowns do occur, operations suffer substantially.
Another downside is that ASRSs rely on predefined item locations and paths, so facilities that frequently vary the handled products may experience lowered productivity until the system is retrained for new products.
Cost of ASRS Systems
The cost of implementing an automated storage and retrieval system in a warehouse facility can vary significantly, depending on a number of factors.
Some of the aspects influencing the cost of an ASRS system are:
- the price of the ASRS equipment
- size and weight of handled products
- storage facility space
- operating environment
- certain handling specifications
- the complexity of the ASRS software
- potential costs of equipment customization
- costs of the system’s shipping, delivery, installation, and integration with the facility’s existing operations
Roughly, a single standalone vertical carousel can cost around $70K, whereas opting for an ASRS system that can manage tens of thousands of SKUs can come with a price tag of more than $5 million.
Operating and maintenance costs of an ASRS system are also to be considered upfront. In general, automated storage and retrieval systems are predicted to achieve measurable ROI between two and five years after implementation.
