Introduction
Unlocking warehouse efficiency is a top concern for most managers and teams. Automated Storage and Retrieval Solutions, AS/RS systems, can help achieve this goal. AS/RS technology is rapidly evolving, offering immense capabilities and opportunities to save money and time throughout warehouse operations.
Benefits of Implementing AS/RS Technologies
An AS/RS is a type of automated technology that helps streamline inventory storage, retrieval, and buffering. These systems integrate with warehouse management systems (WMS) and other essential software to enhance efficiency. The capabilities of an AS/RS provide many benefits:
- Floor space utilization: AS/RS technologies maximize warehouse square footage from floor to ceiling in a compact footprint. An AS/RS can organize inventory and increase storage capacity with bins, totes, or trays. Integrating this solution with inventory management software can further impact operations by enabling fast and accurate material retrieval or replenishment. Increasing available floor space is a significant advantage. It allows for expanding workflows and more storage without needing additional real estate.
- Improved picking accuracy: Picking operations demand precision, but manual processes are prone to human error. AS/RS systems improve accuracy by communicating with a WMS or other integrated software to locate items and guide employees. These systems can pinpoint exact material locations and precise quantities, reducing errors, improving operational efficiencies, and increasing accuracy.
- Precise inventory control: Streamlining inventory management is one key method for creating a resilient supply chain. A significant advantage of an AS/RS is the ability to optimize and maintain inventory control. An AS/RS helps ensure items are stored securely by preventing unauthorized access with user controls. This also helps prevent inventory from being damaged, reducing loss and keeping stock levels accurate.
- Increased throughput: An AS/RSnearly eliminates most manual steps in the picking process, increasing throughput by reducing the need for employees to search for and identify items. AS/RS systems can communicate with a WMS to identify exact material locations and optimize robot paths to retrieve items. Manual picking operations typically enable workers to complete one order at a time, limiting output. Depending on the AS/RS solution, throughput rates can be increased further by completing multiple orders simultaneously.[VC1]
AS/RS Selection: 3 Main Types
Although the benefits of AS/RS systems are clear, finding the most suitable solution for your operations is important. Warehouse automation will most impact your team when you use it to optimize your operations. Consider the three main types of AS/RS systems:
- High-density systems: A high-density automated storage and retrieval system (AS/RS) features a compact storage racking structure that utilizes autonomous mobile robots (AMRs) or automated guided vehicles (AGVs) to move through the racking system. These robots are responsible for locating and retrieving totes or trays. Once retrieved, the inventory is delivered to an integrated workstation, where an operator can perform various warehouse activities.
- Autonomous Mobile Robots (AMR): AMRs navigate storage systems and retrieve products to reduce repetitive actions for employees. These systems can pair with other AS/RS to increase efficiency.
- Goods-to-person: These systems also reduce repetitive actions for employees by bringing products to workers. Goods-to-person systems align with SKU sorting processes and work with AMRs to improve distribution.
How to Find the Right AS/RS Solution
There are several factors you should consider when determining which option is best for your team.
1. Set Your Budget
Your budget will drive most of your business decisions, including which AS/RS is the provides the best return-on-investment (ROI) or is the most cost-effective option. The best AS/RS solution for your business will show promise of reducing labor, resource, and overhead costs while increasing your bottom line over time.
Some systems will have a higher initial investment, but provide significant cost savings to help recoup the upfront expenses. Other systems may have a lower initial price but offer fewer opportunities for cost savings over time. Either way, it’s crucial to consider your budget needs and what you hope to gain from your AS/RS.
2. Consider Maintenance Requirements
Regular maintenance not only extends the lifespan of your system but also enhances its efficiency, making it a critical factor in your budgeting decisions. To maximize your investment, understand the specific maintenance requirements of any system you’re evaluating and proactively establish routine schedules to address them.
3. Evaluate Workflow Expansion Opportunities
Operations with complex SKU organization or limited space should look for an AS/RS solution that can optimize warehouse layouts, simplify organization, increase floor space, and allow for additional workflows. A dense-storage AS/RS solution utilizes vertical warehouse space that is typically unreachable by employees. This helps to free up valuable floor space, allowing facilities to create new inventory lines without requiring additional square footage.
4. Establish System Storage Capacity
Manufacturers that make, deliver, or ship materials in large quantities can benefit from automated inventory storage. Dense AS/RS can manage large material amounts with high efficiencies and make information trackable and visible. Consider the quantity you need to store and the available space you have to accommodate solutions.
5. Determine Integration Capabilities
Many warehouse facilities use multiple software solutions. To get the most out of your AS/RS solution, compare the integration capabilities of each model you’re considering. Ask support teams about the process of integrating the solution into your operations and what to expect as you make the transition.
Find a Comprehensive AS/RS Solution at OPEX®
OPEX has nearly 50 years of experience providing automation solutions that improve efficiency and meet client-specific needs. At OPEX, we offer several products and services that can transform your business, including Infinity® and Perfect Pick® AS/RS solutions.
Infinity AS/RS maximizes inventory storage density, offering up to 35% more storage than competing AS/RS systems. This solution accelerates order fulfillment and item-picking applications with cutting-edge technologies including iBOT® automated robots, presentation ports, and dense racking structures.
Perfect Pick AS/RS aids in transforming large-scale operations. This solution boosts throughput and accuracy to transform high-demand environments. Perfect Pick maximizes your existing real estate and allows you to scale operations as needed, all while keeping downtime to a minimum.
To learn more about Infinity or Perfect Pick AS/RS, connect with the OPEX team today.
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