Automated Storage

and Retrieval Systems

Members:
Bañez, Marlon B.
Bonto, May-Ann B.
Cerillo, Ben Josef T.
 Automated Storage and Retrieval Systems (AS/RS)
Is a type or genre of warehouse automation technology
specifically designed to buffer, store, and retrieve product and
inventory on demand.
These computerized robotic systems are designed to automate
operations such as:
 unloading
 sorting
 put-away
 storage
 order-picking
 staging
 loading

AS/RS technology varies substantially, and can consist of

shuttles, cranes, carousels, vertical lift modules (VLMs), micro-
loads, mini-loads, unit-loads, or other systems. It is often
integrated with a warehouse execution software (WES),
warehouse management software (WMS), or other controls.

Benefits of AS/RS
By automating the low-value and easily repeated task of
inventory storage and retrieval, AS/RS brings benefits to the
operations that utilize it, including:
 More efficient use of floor space
 Ability to reclaim unused vertical space
 Increased inventory storage density
 Improved ergonomics and safety, resulting in fewer accidents
 Increased throughput
 Reduced labour costs
 Fewer labour constraints due to labour shortages
 Often modular design for maximum flexibility
 Increased order picking accuracy
 Improved product security for premium inventory

Types of AS/RS
Automated storage and retrieval systems (AS/RS) come in two
main varieties: Unit-Load AS/RS and Mini-Load AS/RS.
Between these two main buckets, there are six primary types of
AS/RS systems:
 Unit-Load AS/RS Cranes (Fixed-Aisle & Moveable Aisle)
 Mini-Load AS/RS Cranes
 Shuttle- and Bot-based AS/RS
 Carousel-based AS/RS (Vertical, Horizontal, and Robotic)
 Vertical Lift Module (VLM) AS/RS
 Micro-Load (Stocker)

Unit-Load AS/RS
Unit-load AS/RS systems are typically used to handle
exceptionally large and heavy loads ranging from 1,000 to 5,500
pounds. This capability allows for unit-load AS/RS to handle full or
partial pallets and cases.
Usually, unit-load AS/RS consists of narrow aisle racks, which can
extend to heights greater than 100 feet and which house pallets of
product and inventory. These racks are paired with a crane, which is
used to physically place and retrieve pallets as needed.
Unit-load AS/RS is a particularly helpful option when pallet-level
storage is limited and quick retrieval is critical.

The two primary forms that unit-load AS/RS takes are;

 Fixed-aisle
 Moveable aisle cranes.
Fixed-Aisle Unit Load AS/RS Crane
Pallet racks are arranged with narrow aisles between them. A
crane travels between these aisles moving both vertically and
horizontally to retrieve and store product. The crane is fixed to a
single aisle of pallets.
Moveable-Aisle Unit Load AS/RS
It consists of a crane moving between narrow aisles of pallets
along some kind of track. The key difference is that it is not fixed to a
specific aisle. This capability allows a single piece of equipment to
service multiple aisles and, ultimately, a greater working space.

(Fig.1 Fixed-Aisle) (Fig.2 Moveable-Aisle)

Mini Load AS/RS

Typically handles smaller loads (up to 75 pounds) compared to
unit-load systems. Instead of full pallets, mini-load AS/RS handles
totes, trays, and/or cartons. Sometimes, these systems are called
“case-handling” or “tote-stacking” systems.
Mini-load AS/RS is especially
well-suited for operations
that require storage locations
for a large amount of SKUs,
but which lack the floor
space required for traditional
carton-flow shelving to
provide a pick face for each
SKU. Mini-load AS/RS
systems can also be used to
buffer and efficiently
release/sequence product to
picking or palletizing stations,
and can be used to
automatically replenish pick locations like carton-flow.

Shuttle-based AS/RS
Shuttle-based AS/RS
delivers inventory via a
shuttle or “bot” that runs
on a track between a
racking structures.
They can operate on a
single level or multiple
levels, depending on the
needs of the operation,
and can be battery- or
capacitor-powered. The
shuttles deliver the tote or
carton to a workstation integrated with the system.
When an item is requested, the shuttle drives to the location of the
product and retrieves the tote or carton that contains the requested
item. The shuttle will then take the tote/carton directly to a
workstation or transfer it to a conveyor to convey the tote/carton to
a workstation.
Different shuttle models utilize different designs to provide different
benefits. For example, one model is vertically oriented to optimize
floor space. The shuttles move on the perimeter of the rack and then
move into an aisle to extract a tote and delivers it to its integrated
workstation.

A third shuttle model utilizes vertical rack, but each bot moves on
the floor and climbs vertically to extract its tote. Then it comes down
to the floor and independently delivers the inventory to a remote
workstation. It will queue at the workstation until picked and then is
automatically assigned a new task and it repeats the process.

Carousel-based AS/RS
Carousel-based AS/RS systems consist of bins of product or
inventory which rotate continuously along a track. When the
operator requests a particular item, the system will automatically
rotate so that the appropriate bin is accessible so that the item can be
picked. An integrated lightree will indicate to the picker which
carousel, shelf, and item to pick.
Carousel-based AS/RS may consist of either a horizontal carousel (bins move
horizontally, as on a merry-go-round) or a vertical carousel (bins move vertically,
as on a Ferris wheel). Horizontal carousels are often utilized for small items and
parts, as well as documents or raw materials.

Robotic horizontal carousel AS/RS is another variety which provides

fully automated AS/RS functionality.
In these systems, up to three tiers of carousels are stacked on
top of each other, and totes or cases are loaded on each shelf level.
All three vertical carousels work independently to present the
necessary inventory to an inserter/extractor device that runs
horizontally in front of them. The inserter/extractor takes as many as
two totes or cartons per trip to take-away conveyor, which delivers
the goods to a workstation, and picks up returning inventory, placing
it back in a waiting shelf. It is possible to increase capacity and
throughput by increasing the number of carousel rows with an
inserter/extractor in front of it.

Vertical Lift Module (VLM)

A vertical lift module (VLM) is an enclosed system consisting of
an inserter/extractor in the center and a column of trays on either
side. It is a form of goods-to-person technology.
When an item is requested, the inserter/extractor locates the
necessary tray, retrieves it, and delivers it to an operator, who
completes the order. Once the order is complete, the VLM will return
the tray to its proper location before retrieving the next requested
tray.
Trays may either be fixed or dynamic. In fixed systems, individual
trays will always be returned to the same location; in a dynamic
system, where individual trays are stored will vary.

Micro-Load Stocker
A Micro-Load Stocker provides discrete or individual totes or
carton storage and retrieval. It is ideal for buffering, sequencing, and
point-of-use items in a high-density footprint.
The system is enclosed, and has an inserter/extractor device that
runs in the centre of the system, picking a specific queue of
inventory and then discharging them onto awaiting conveyor or
workstation. Different models store and retrieve differently, by
taking either one item or a group of up to five items in one pass.
This system can also be used to store SKUs until needed, discharging
them onto awaiting conveyor. It can be integrated with other AS/RS
systems to improve the other systems’ performance and
dramatically reduce conveyor and floor space requirements.