Automated

Storage
Systems
YUNUS EMRE AL 214AU2285
What is Automated Storage &
Retrieval System (AS/RS)
 Used in warehouses

 Consists of shuttles, cranes, carousels, vertical lift modules (VLMs),

micro-loads, mini-loads, unit-loads, or other systems.

 Integrated with a warehouse execution software (WES), warehouse

management software (WMS) or other controls.

 Important supply chain component

 increase productivity, efficiency, and profitability

Advantages of AS/RS

 Reduced Labor Costs

 Fewer Labor Constraints

 Increased Safety

 Increased Accuracy, Productivity, and Efficiency

 Can be Modular

 Better Use of Space

Disadvantages of AS/RS

 High Initial Investment

 Maintenance

 Not Suitable for Highly-Variable Operations

 Can Require Technical Skill and Retraining

Uses & Applications of AS/RS

 Goods-to-Person for Order Picking and Packing

 Staging Orders for Shipping

 Managing Buffer Storage

 Storage and Point of Use Storage

 Goods-to-Person for
Order Picking and Packing
 In a goods-to-person order picking system, the worker does not
physically move from product location to product location to pick
an order.

 Instead, a mini-load AS/RS crane, shuttle, AMR, carousel or VLM is

able to retrieve the necessary stock from storage and delivery it
directly to the worker, who operates in a pick/pack station.
 Staging Orders for Shipping
 An operation can pick and process orders continuously
and use an AS/RS to place them in a buffer storage to
stage them until the shipping window is open.

 This saves time and allows an operation to continuously

produce, even when orders can not physically leave
the facility.
 Managing Buffer Storage
 Buffering aims to prevent breakdown by ensuring that enough
supplies/product are always on hand in different stages to keep
an operation running.

 But while buffering makes sense, poorly managed it can become

a logistical nightmare, requiring miles of conveyor to properly
buffer and stage.

 AS/RS has the potential to replace these conveyor buffering

systems, allowing an operation to efficiently store buffer product
and retrieve it as necessary.
 Storage and Point of Use Storage
 By implementing AS/RS, an operation can automate their long-
term storage of raw material or product and retrieve what they
need, when they need it.

 By integrating the AS/RS with their Warehouse Execution Software

(WES) it is also possible to intelligently utilize and optimize inventory
via FIFO (First in First Out), LIFO (Last In First Out), lot numbers,
expiration dates, order cut off times, packaging requirements and
many organization and industry specific requirements.
Types of Automated Storage &
Retrieval Systems (AS/RS)
 Unit-Load AS/RS Cranes (Fixed-Path & Moveable Path)

 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 Cranes
(Fixed-Path & Moveable Path)
 Large and heavy loads ranging from 500 to 2,500
kilograms.

 This capability allows to handle full or partial pallets

and cases.

 Usually, consists of narrow path racks can extend to

heights greater than 30 meters.

 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-path and moveable path cranes.
 Mini-Load AS/RS Cranes
 Mini-load AS/RS typically handles smaller loads up
to 35 kilograms.

 Instead of full pallets, mini-load AS/RS handles

totes, trays, and/or cartons.

 Well-suited for operations that require storage

locations for a large amount of SKUs.

SKU: Stock Keeping Unit

 Can be used to buffer and efficiently

release/sequence product to picking or palletizing
stations.
 Shuttle and Bot-based AS/RS
 Shuttle-based AS/RS delivers inventory via a
shuttle or “bot” that runs on a track between a
racking structure.

 Can operate on a single level or multiple levels

and can be battery powered.

 Delivers the tote or carton to a workstation

integrated to system.

 If an item is requested it can transport the

product.
 Carousel-based AS/RS (Vertical, Horizontal,
and Robotic)
 Carousel-based systems consist of bins of product or
inventory which rotate continuously along a track.

 If operator requests a particular item, system will

automatically rotate so the item can be picked.

 Consist of either a horizontal carousel or a vertical

carousel

 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.
Vertical Lift Module (VLM) AS/RS
 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.

 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.

 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.
Conclusion

 AS/RS is a great system which was developed to improve the

storage systems used in industries to handle, store and retrieve
materials with precisions, accuracy and speed under defined
degree of automation.

 AS/RS is a powerful tool that can dramatically increase productivity,

efficiency, and profitability for many operations in many industries.
 Video

https://www.youtube.com/watch?v=g0yLEzRGro0