Automated Storage and Retrieval System (ASRS) refers to warehouse equipment used to store and retrieve loads from predefined storage locations with minimal human involvement. ASRS systems use autonomous vehicles, cranes, or shuttles to transport unit loads or bins within an automated warehouse. They are designed to improve inventory handling efficiency, reduce labor costs and errors, optimize space utilization, and support high throughput in distribution and fulfillment facilities. This article provides an overview of ASRS technology, its key components, workings, benefits and future outlook.

Types of ASRS

There are mainly three types of ASRS systems in use today based on their configuration and operation:

Vertical Lift Modules (VLMs): VLMs consist of racks arranged in vertical columns with loads stored in defined locations. An automated crane or shuttle travels vertically and horizontally to retrieve and store pallets/boxes. VLMs provide very efficient use of floor space but have lower throughputs than carousels.

Mid-Load AS/RS: These systems use shuttles or cranes that travel on overhead rails to transport and store pallet loads in aisles of racking on both sides. Shuttles can access both sides of racks for multi-deep storage. Mid-load systems have higher throughputs than VLMs.

Mini-Load AS/RS: Mini-load Automated Storage and Retrieval System are optimized for small item storage using totes, trays or bins. Robotic cranes or shuttles with miniature forks lift loads from stacker racks arranged in rows. They offer extremely efficient utilization of space and are ideal for e-commerce order fulfillment of smaller SKUs.

Key Components

The main hardware components of an ASRS include:

Storage Racks: Steel racking structures arranged in aisles/columns provide storage locations for pallets, totes, bins etc. Rack designs vary depending on load capacities and type of ASRS.

Retrieval Equipment: Includes cranes, automated guided vehicles (AGVs), shuttles, hoists or robotic arms to move loads within the system. They are controlled by the warehouse execution software.

Identification System: Often based on barcodes, RFID tags, or vision-guided systems to track individual load locations and direct retrieval equipment.

Conveyors: Used for input and output of loads from the ASRS. May include roller, belt, chain, horizontal slider bed or vertical lifts.

Control System: PLC-based controls interconnected with warehouse management software perform functions like route optimization, load verification, error handling etc.

Workings of an ASRS

When an order is released into the system:

1) The WES software determines the optimal route for pickup and deposit of all loads.

2) Identification technology is used to scan load locations going into/coming out of storage.

3) Retrieval equipment like shuttles and cranes are dispatched to pick up loads from predefined rack locations.

4) Onboard controls guide lifting/lowering and transport of loads within the storage infrastructure.

5) Deposition takes place by lifting loads vertically or horizontally to their storage bin/container.

6) Conveyors connect ASRS to loading docks, sorting areas and order fulfillment stations.

Benefits of Automated Storage

Some key advantages that ASRS provide include:

- Optimized real estate usage through dense vertical storage in multilayer racking. Floor space savings of 30-55% over manual alternatives.

- Increased inventory accuracy through automated tracking and auditing of every load movement. Eliminates human errors.

- Higher productivity and throughputs of up to 400 picks per hour in mini-load systems. 24/7 operations possible.

- Labor costs are reduced by 70-80% with minimal human intervention needed for loading/unloading.

- Flexibility to reconfigure storage through parameters in software without changing physical infrastructure.

- Improved order fulfillment through very fast retrieval times ranging 30-60 seconds on average.

- Higher levels of security for valuable inventory through controlled access and no manual handling.

Future Outlook

With growing e-commerce volumes, demand for automated fulfillment solutions is on the rise. Some technologies being explored are:

- Self-learning systems using AI/machine vision for tasks like Bin-to-Part order fulfillment.

- Integrated ASRS-robotics using cobots for picking, sorting and consolidation of multi-line orders.

- Multi-shuttle guided systems with dynamic load leveling for simultaneous storage/retrieval.

- Warehouse digitization through integration of ASRS, IoT sensors and analytics for predictive maintenance.

- Environment-controlled units for storage of sensitive goods like pharmaceuticals and chemicals.

- Micro-fulfillment centers combining mini-load ASRS with automation for decentralized faster delivery.

As supply chain complexities increase, advanced ASRS will continue to play a crucial role in improving inventory handling efficiencies, supporting omnichannel fulfillment and powering flexible automated warehouses of the future.

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