Automated Storage and Retrieval Systems (AS/RS) are warehouses controlled by computers where automated cranes or shuttle vehicles move, store, and organise pallets containing raw materials, parts containers, product cases, and other cargo onto shelves and racks automatically. In addition to making effective use of vertical space, AS/RS promotes labour and workforce savings and improves inventory control accuracy. They are utilised in a range of operations, from storing work-in-progress and finished products in the manufacturing sector to storing inventory and sorting in the distribution sector. AS/RS, along with robots for advanced automation, is currently the standard machinery leading the digital revolution in the logistics industry.
Key Benefits of Automated Storage Systems
Automated Storage and Retrieval Systems (AS/RS) offer numerous benefits that significantly improve warehouse operations. One of the most significant advantages is the effective utilisation of unused vertical space. By building upwards, businesses can increase their storage capacity without needing additional floor space. This higher storage density accommodates more products, which is especially beneficial for warehouses with limited area. Furthermore, with automated systems, the speed of storing and retrieving items is greatly enhanced, leading to increased throughput. This allows businesses to handle more orders and manage inventory more efficiently while reducing the risk of human error in order picking.
AS/RS also improves workplace ergonomics by reducing the need for manual handling of heavy items, creating a safer working environment, and enhancing employee well-being. Improved product security is another benefit, as these systems minimise the risk of theft and damage. Additionally, automation reduces the dependency on manual labour, leading to significant cost savings and fewer labour constraints. This ensures that businesses are less affected by labour shortages and can maintain consistent operations.
Types of AS/RS Solutions
Automated warehouses use various devices to transport goods, with the most common being stacker cranes and shuttle vehicles. Stacker cranes, ranging from 5 to 40 metres high, move along rails and lift or lower loads to the desired rack bay. These cranes are used in unit load systems for heavy items and in mini load systems for lighter items. Shuttle systems are becoming more popular for their flexibility, as they can move in multiple directions within racks or on structural grids, making them ideal for high-density storage and pre-shipment sorting.
Automated warehouse structures
There are two primary types of racking structures for automated warehouses. Free-standing rack AS/RS are separate from the building’s structure and can be installed in both new and existing buildings. In contrast, rack-supported buildings (AS/RS have racks that support the building’s walls and roof. This type is used in large-scale warehouses and requires architectural expertise due to building regulations. Mini-load automated warehouses are rarely done as rack-supported AS/RSs because the racking strength is typically not suitable as a building frame. As a result, free-standing racks are the norm. Two types are widely used: open-face and shelving, selected according to the stored items and the type of crane or shuttle vehicle required.
AS/RS Environments
AS/RS can operate in various environments, including cold storage facilities. Automated warehouses have been implemented in many frozen and refrigerated storage facilities. Historically, automated pallet warehouses have been the primary form of automated warehouses. Nevertheless, the quantity of cold storage miniload AS/RSs has been on the rise in recent years due to the increasing demand for high-mix, low-volume distribution and greater emphasis on enhancing working conditions.
Maintenance and Useful Life of AS/RS
Regular maintenance is crucial for the longevity and efficiency of AS/RS. Scheduled inspections and updates to inventory control systems help prevent malfunctions and ensure smooth operations. With proper upkeep, these systems can have a long operational life, often exceeding 20 to 30 years. Delays in shipping operations may occur due to the deterioration of consumable parts or malfunctions in inventory control computers. For this reason, automated warehouse manufacturers offer a maintenance menu that includes periodic inspections and computer system maintenance.
Conclusion
At Krost Shelving & Racking, we understand the significant impact that AS/RS can have on your business. By improving efficiency, accuracy, and safety, these systems provide a robust solution for modern inventory management. For more information on how we can help you implement AS/RS in your operations, contact us today. With advancements in technology and an ever-increasing need for efficient inventory management, integrating AS/RS into your logistics strategy can provide a competitive edge in today’s fast-paced market.
