Enhancing Order Accuracy and Speed with Automated Storage and Retrieval Systems (AS/RS)

How AS/RS Technology Transforms Order Accuracy

Automated Storage and Retrieval Systems address these challenges by fundamentally changing how products are stored, located, and retrieved. Here’s how AS/RS technology specifically reduces picking errors:

Goods-to-person Fulfillment

Unlike traditional models, where workers navigate warehouse aisles to search for products, a goods-to-person AS/RS brings items directly to operators at ergonomic picking stations. This approach eliminates navigation errors and fatigue-induced mistakes commonly occurring during long picking shifts.

Light-Directed Picking Technologies

Modern AS/RS solutions incorporate sophisticated pick-to-light systems and integrated software user interfaces. These tools visually guide operators to the exact item location, display detailed product information, and indicate required quantities—virtually eliminating guesswork from the picking process.

Enclosed Inventory Management

Advanced systems like the OPEX^® Perfect Pick^® operate within fully enclosed environments where inventory is tracked in real-time. This prevents common issues like misplaced goods and ensures items aren’t picked from incorrect locations or outdated inventory.

Batch Optimization Intelligence

AS/RS solutions use sophisticated algorithms to group similar orders together, reducing the handling complexity and minimizing opportunities for errors. By streamlining these processes, warehouses can achieve accuracy rates up to 96-98%.

Accelerating Order Fulfillment Without Sacrificing Accuracy

Speed without accuracy is meaningless in warehouse operations. An AS/RS delivers:

Automated Retrieval and Delivery

Robotic delivery systems such as OPEX’s iBOT^® wireless robots navigate storage aisles faster than human workers, capable of bringing products to picking stations in seconds. This automation eliminates time-consuming walks through warehouse aisles, dramatically reducing order cycle times.

Parallel Processing Capabilities

AS/RS solutions can process multiple orders simultaneously by utilizing multiple iBOTs and pick stations. This parallel operation enables warehouses to handle significant volume increases without proportional labor increases.

Extended Order Cutoff Windows

The dramatic speed improvements allow businesses to extend their order cutoff times—a critical competitive advantage in e-commerce where same-day and next-day delivery expectations are becoming the norm.

Real-World Success Stories: AS/RS in Action

The true measure of AS/RS effectiveness comes from examining how leading companies have implemented these solutions to transform their operations:

Biolegend: Maximum Storage in Minimal Space

For Bio-Legend, a life sciences company, space utilization was critical:

• Achieved 6,500 cubic feet of storage within just 1,500 square feet of floor space
• Created ergonomic picking stations that reduced worker fatigue and errors
• Maintained temperature-controlled environment for sensitive products

Knipper: Meeting Pharmaceutical Precision Requirements

Knipper, a pharmaceutical distributor with stringent accuracy requirements:

The warehouse fulfillment landscape is becoming increasingly complex:

•  Processes over 3,000 orders daily with near-perfect accuracy
•  Reduced presentation cycle times to six seconds per item
•  Virtually eliminated picking errors, achieving accuracy rates over 99.9%

Newegg: Peak Season Performance

The electronics retailer, Newegg, faced significant seasonal challenges:

• Handles 18,000+ daily orders during peak periods without accuracy degradation
• Secured high-value SKUs within the enclosed system, reducing loss and theft
• Scaled operations without proportional increases in labor costs

The OPEX^®Advantage: Perfect Pick^®and Infinity^®Solutions

OPEX’s AS/RS solutions have emerged as industry leaders through their unique design approach:

Perfect Pick

The Perfect Pick goods-to-person system features iBOT robots that travel horizontally and vertically within an enclosed aisle structure. Key advantages include:

• High-density storage maximizes vertical space utilization
• Wireless iBOT technology eliminates complex conveyor systems
• Direct delivery to ergonomic workstations enhances picking accuracy

Infinity

OPEX’s newest AS/RS solution, Infinity^®, offers enhanced scalability through:

• Modular design that allows easy expansion as needs grow
• Inventory intelligence that optimizes storage locations automatically
• Multi-level picking capabilities that increase throughput

Measuring the ROI: Quantifiable Benefits of AS/RS Implementation

The business case for AS/RS becomes clear when examining the metrics that matter most to warehouse operations:

Error Reduction

• Typical manual operations: 1-3% error rates
• AS/RS implementations: <0.1% error rates
• Cost savings: $25-$59 per error prevented

Labor Efficiency

• 60-70% reduction in labor requirements for the same throughput
• Reallocation of staff to higher-value activities
• Reduced training time and onboarding costs

Space Utilization

• 85-90% reduction in floor space requirements compared to traditional shelving
• Vertical utilization maximizing cubic storage capacity
• Ability to expand inventory without facility expansion

Throughput Improvements

• 3-10x faster processing compared to manual methods
• Extended cutoff times for same-day shipping
• Ability to handle volume spikes without service degradation