Inventory management is one of the most common challenges for warehouses and distribution centers. In this context, automated shelving systems appear as an efficient solution and alternative to traditional production and distribution.
Automated shelving systems, such as automated storage and retrieval systems, in short, AS/RS or ASRS, refer to different computer-controlled systems that help deposit and retrieve items to and fro from a specific storage location or shelving system with precision and speed.
These systems can range somewhere from very simple, manually managed order-picking machines to extensive, computer-controlled storage/retrieval systems fully integrated into the facilities.
While operating as a modern logistics system, the automatic storage and retrieval system offers various advantages over human-operated ones, some of which include inventory control, simplified operations, efficiency, accuracy, and cost-effectiveness. These are also key inventory upkeep challenges that businesses often deal with.
Typical Types of Automated Storage and Retrieval Systems
1) Automated Guided Vehicles (AGVs): Often considered a part of the AS/RS system and often used as high-density storage solutions, helping move goods in and out of the storage area to the manufacturing zone or docks. AGVs are best for facilities where floor space is less, but vertical is there.
2) Shuttle AS/RS: As the name implies, shuttle AS/RS is based on shuttle technology. Herein, various independent shuttles move horizontally to move inventory within the warehouse. The robotic shuttles work on a single level of racks. There is a vertical lift fixated on the rack that does the vertical movement. The shuttle can be used as a single unit or integrated into workstations for inventory management.
3) Right Angle Fast Transfer (RAFT): This is a specialized form of automated shelving system that can move both horizontally and vertically and has an AutoStore feature. RAFT systems can be easily integrated with conveyors, robotics, and even traditional manual picks (like independent and forklifts).
How Do Automated Storage and Retrieval Systems (AS/RS) Work?
AS/RS is operated by a perfectly synchronized combination of hardware and software systems. This is how it works:
1) Item Receiving: In a typical warehouse setup, items are received at the warehouse or distribution center and placed on a conveyor or in a designated location. The AS/RS system can check the barcodes or RFID tags on these items and identify and segregate them.
2) Depository: The AS/RS system then uses various transfer vehicles to store these items in hard-to-reach and heightened warehouse racks. The AS/RS system is the best choice for businesses with limited floor area, helping them maximize the available space by optimizing vertical storage.
3) Order handling: Once an order is received, the AS/RS looks for the ordered item, gets it, and puts it at the pickup station. Various material handling equipment is used, such as conveyor systems, cranes, and shuttles to fulfill the order as quickly as possible.
4) Inventory management: The AS/RS helps businesses manage their stock levels, reduces the risk of overstocking or understocking, and speeds up replenishment through real-time inventory tracking.
The Benefits of Automated Storage and Retrieval Systems: What They Offer?
1) Better space usage: One of the most valuable resources in any warehouse is undoubtedly space. Businesses can effectively use space by storing products along the vertical space with AS/RS. Warehouses with substantial vertical height but little floor area can particularly benefit from it. More products can fit in the small storage areas without the need for expansion. It turns out to be a significant benefit for densely populated cities or small warehouses.
2) Pronounced productivity: AS/RS significantly speeds up warehouse operations by automating the storage and retrieval process. Traditional manual systems require workers to navigate aisles and shelves to pick and store items, which can be time-consuming and inefficient. In contrast, AS/RS removes the human need as it handles all of the retrieval and heavy lifting, freeing up staff to concentrate on their actual work.
3) Accurate storage and retrieval: In manual systems, human error is often noticeable and can result in misplaced products, wrong orders, or variances in inventory. AS/RS systems embedded with highly urbane software and automation perform tasks with precision, thus reducing any error chances. These automated systems ensure that products are stored accurately in the correct locations and retrieved whenever needed, reducing significant errors and the associated costs.
4) Cost Savings: A large number of the warehouses and distribution centers’ expenses go for labor wages. By lowering the human intervention, AS/RS can contribute to significant cost savings. Apart from reducing labor costs, these systems will help improve operational efficiency and minimize energy expenses, which, by streamlining the flow of commodities and cutting down on machine and equipment idle time.
5) Faster orders shipped out: Maximum throughput and prompt delivery are essential for e-commerce companies to ensure customer satisfaction. Businesses may fulfill orders more quickly because of AS/RS’s contribution in reduction in product retrieval time. In a competitive market, quicker order processing and shipping times boost customer satisfaction and a business’s reputation.
6) Better hold over inventory: AS/RS gives businesses a clear and accurate picture of their stock levels and allows them to manage inventory in real-time. Businesses can also better manage inventory using real-time tracking and identify low-stock items and prevent complete stockouts. As a result, optimum quality is always available with automated technologies that manage optimal stocks.
7) Safer workplace: Safety is one of the most important considerations in warehouse environments because of manual labor and heavy machinery. AS/RS minimizes the potential risk of accidents and injuries that can be caused due to “human error” by automating storage and retrieval processes. Most tasks are handled by machines, thereby reducing the harm to employees and improving overall workplace safety.
Concluding Thoughts
Automated storage and retrieval systems can be a revolutionary move for businesses. These technologies help companies fulfill the increasing demands of their customers while remaining competitive, improve space usage, boost productivity, reduce errors, and save expenses. Businesses can set themselves up for success and take the lead in an increasingly demanding and complex industry by implementing automation.
As the editor of the blog, She curate insightful content that sparks curiosity and fosters learning. With a passion for storytelling and a keen eye for detail, she strive to bring diverse perspectives and engaging narratives to readers, ensuring every piece informs, inspires, and enriches.
