One go-to solution is adopting automated storage and retrieval systems (AS/RS). A tech-driven solution used in warehouses to automatically retrieve and store inventory, AS/RS technology can enhance efficiency, accuracy, and scalability.
Read on to learn how AS/RS works, its benefits, and when to use it. You’ll also learn whether your 3PL is ready for AS/RS adoption.
How automated storage and retrieval systems work
AS/RS systems comprise several components that automatically place and retrieve items from storage locations. These include:
Storage structures and vertical lift modules
Rather than relying on sprawling racks and manual picking, AS/RS warehouse automation systems use high-density storage designs. Vertical lift modules (VLMs), for example, use two columns of trays with an extractor running between them. The extractor automatically delivers trays to a workstation at an ergonomic height, so operators can fulfill orders faster and with less physical strain.
Besides boosting efficiency, VLMs also maximize vertical space by condensing thousands of SKUs into a fraction of the footprint of traditional shelving. As such, the money that would ordinarily go toward warehouse leases and costly facility expansions can be funneled into bigger-picture planning and scaling.
Automated handling equipment
AS/RS systems use automated handling equipment such as shuttles, cranes, and automated lifts to store and retrieve items. By relying on these machines instead of human pickers, you can dramatically increase throughput, reduce picking errors, and minimize the time and money lost when human pickers walk long distances to search for inventory.
Control software and warehouse integration
Every AS/RS system is powered by control software that directs storage location, retrieval logic, and integration with your fulfillment management systems.
This software acts as your command center, coordinating VLMs, cranes, shuttles, and storage racks so each mechanism knows exactly which storage location to access and how to place or retrieve items with maximum efficiency. Ultimately, it boosts throughput, reduces human labor, and keeps operations running smoothly even during peak demand.
Additionally, control software eliminates fatigue-related errors and improves inventory accuracy, ensuring orders are fulfilled correctly the first time. The result? Fewer returns, lower rework costs, and more satisfied customers.
Request a free demo to learn more about Logiwa WMS.
Top benefits of AS/RS automation for 3PLs
Warehouse executives are increasingly adopting AS/RS automation due to its many benefits. Here are the top benefits of AS/RS automation for 3PLs:
- Higher throughput: Robotic handling means more picks per hour than even the most efficient human team. As such, you can better manage peak volumes without having to hire seasonal labor.
- Improved accuracy: Automated retrieval reduces picking errors, resulting in fewer costly returns and rework.
- Better space utilization: High-density storage means more efficient use of your existing space. As such, you don’t have to invest in facility expansions.
- Lower labor costs: As wages, labor shortages, and turnover rates rise, you need a way to make the most out of your current team without exhausting them or driving them away. Shifting repetitive and exhausting storage and retrieval tasks to machines does just this and gives employees more time and energy for higher-level work.
- Improved safety: AS/RS automation minimizes forklift traffic and high-reach tasks, lowering the risk of workplace accidents.
Types of AS/RS systems and their ideal uses
There are several types of AS/RS systems. Here are the ideal uses for each type:
- Unit-load systems: Built for large, heavy pallets, unit-load cranes are common in high-volume manufacturing or bulk storage operations. They’re ideal for large warehouses where full pallets are the standard for retrieval.
- Mini-load systems: These target totes and cases are ideal for mid-sized warehouses with a mix of medium-sized items and moderate SKU counts.
- Carousels: Horizontal or vertical carousels rotate trays of inventory to operators. They’re good for smaller warehouses and ecommerce facilities with a high SKU variety but lower unit volume, such as small electronics and spare parts distribution.
- Shuttle systems: High-speed robotic shuttles run within racking aisles to move bins and cartons at lightning speed. They’re best for large, high-throughput warehouses that manage thousands of SKUs and need near-real-time picking speeds.
- VLMs: These store trays in tall enclosures and automatically deliver them to waist-high access points. They’re a fit for warehouses of any size that want to maximize vertical space without building out new floor space.
Is your 3PL ready for AS/RS automation?
AS/RS can deliver big efficiency gains. However, to make the most out of your investment, you need to pick the best time to implement it. Here are the signs your 3PL is ready to take the next step into AS/RS automation:
- Labor shortages or rising costs: If overtime or seasonal staffing struggles are constant, AS/RS automation can stabilize costs.
- Space limitations: When expansion is too expensive or risky, high-density AS/RS systems can help use existing square footage more efficiently.
- Multi-site growth: If your 3PL is expanding into new areas, you need scalable, standardized processes like AS/RS automation to streamline multi-warehouse management.
- High service level expectations: Omni-channel retailers and online brands often require sub-24-hour fulfillment. AS/RS can help you accomplish that.
If these pressures sound familiar, your 3PL may be ready to explore AS/RS adoption by adopting software like Logiwa IO. Designed to integrate seamlessly with leading solutions such as AutoStore, Logiwa ensures that AS/RS automation delivers immediate value rather than creating new silos.
Still not sure about the return on investment? You would be surprised just how much you can gain in terms of efficiency and productivity simply by upgrading your existing WMS. Request a demo to see how Logiwa IO can improve your productivity.
AS/RS automation FAQs
What does AS/RS stand for?
How much does an AS/RS system cost?
AS/RS costs vary widely based on system type, warehouse size, and integration needs. Smaller VLM installations may cost hundreds of thousands of dollars, while large shuttle or unit-load systems can reach several million.
Although AS/RS starting costs seem high, AS/RS often pays for itself over time. It can reduce labor expenses, eliminate or push back facility expansions, and cut the costs of errors, returns, and rework.
Who leads the market in warehouse automation?
Vanderlande Industries, Dematic, and Symbotic lead the market in warehouse automation. However, picking the right machine provider is only the first step.
After picking the best warehouse automation robotics provider, you must choose a WMS software that can seamlessly integrate AS/RS equipment into your daily operations. Platforms like Logiwa IO that optimize AS/RS systems and automated warehouse robots can give you a competitive edge.
