ASRS Integration, Do’s & Don’ts

October 1, 2024|Material Handling, Storage

The following first appeared on the MHI AS/RS Industry Group blog

Asrs Can Serve As The Cornerstone Of Any Material Handling Automation

At some point, most warehouses will face a time when they begin to run out of space. Options for how to handle that dilemma run the gamut, and include moving into a new, larger facility. But there are ways to increase your storage density without building out a new greenfield operation. In either case, automated storage and retrieval systems (ASRS) are one of the better solutions to consider.

An ASRS is a high density, secured, vertical system that, as its namesake implies, automatically manages inventory storage areas without human involvement. There are many types of ASRS applications – automated goods-to-person, order fulfillment, and bulk material handling to name a few. In this article we will explore what you need to know for automated storage and retrieval systems for your palletized goods.

If you’re looking to increase your storage density and utilize a smaller footprint, ASRS can be the right option. Where a standard rack and forklift solution allows for storage up to 20 or 30 feet high, ASRS can reliably support product up to 150 feet high. That maximizes your cube and prevents the need for an expansion or new facility.

ASRS also provides for greater storage density. Rather than one pallet on a rack, ASRS can manage to store 25 to 30 racks deep, all managed by an automated shuttle or carrier. Likewise, if you need to gain pallet throughput, ASRS can improve that, as well. When you accomplish this, you also free up your employees to tackle other value-added tasks that are more difficult to automate. That’s more cost effective in the long run, and helps in the current environment where labor is hard to come by.

If you’ve decided that pallet ASRS may be the right solution for your operation, key things to consider are the product you are moving as well as the speed with which you are moving the product. Pallet/product length, width, height and weight are critical items that drive the technology selection and design along with the peak hourly throughput of your system. Additional factors such as product flow, case/layer picking operations along with other value add processes also need to be considered when designing a system that is custom fit to your operational needs.

Finally, if your pallets are going into a brownfield or greenfield location is another consideration. Each has its own challenges, but both can be automated. When adding ASRS to a new facility, local permitting, design and other constraints can be an issue. With a brownfield operation, the challenge might include designing around an existing operation.

Once you and your OEM have signed off on the project, the real work begins. Your partner will put eyes on your operations, confirm all the details of the proposal, and work to finalize mechanical layout for all equipment. Once the mechanical design layout is locked, controls and software functional specific documents will be developed to ensure the system meets the operational demands of the customer. On average, pallet storage automation projects typically range anywhere from 12 to 24 months from start to finish. The complete schedule is dependent on the size and complexity of the project, along with external factors, such as building construction timelines (if greenfield), and supply chain demands at the time of the project award.

Source: Eric Kinn, Bastian Solutions

Before Implementing An Asrs, Carefully Consider A Few Things To Do And Not Do

Do:

Think of high-density storage when considering ASRS: One of the biggest benefits to ASRS is its ability to utilize the cube without wasting available space in the facility. You’ll be able to store and retrieve products much higher than you would without the system in place. Using software like a warehouse management system (WMS) and warehouse execution software (WES), combined with cranes, conveyors, and shuttles, you’ll have built-in high density.

Operate safely: With an ASRS in place, you’ll remove humans from the equation because you’ll minimize the need for manual materials handling. This frees your employees to perform more value-added services and avoid potential injury.

Boost your accuracy: Humans performing manual labor can make mistakes. ASRS removes that propensity from the equation, boosting accuracy rates across the board.

Increase your productivity: When an ASRS is in charge of storage and retrieval, you’ll boost your turnaround times, becoming smoother, faster, and more efficient.

Reduce labor: With the ongoing labor shortage, perhaps the biggest do from an ASRS implementation is labor reduction. Automation will allow you to do more work with fewer people.

Don’t:

Get hung up on the initial cost: An investment in an ASRS doesn’t come inexpensively, but you need to account for all the long-term benefits you’ll achieve by adding a system. Beyond reduced labor costs, you’ll save many other expenses over the lifetime of an ASRS, making it worth the price tag.

Overlook the need for skilled maintenance: An ASRS requires talented, skilled labor personnel to keep it operational. Make sure you’ve got someone on staff who can prevent downtime by maintaining upkeep.

Forget to plan ahead: While highly beneficial, ASRS isn’t the most flexible type of material handling system you can add to your warehousing floor. Think through the loads you’d like your system to handle and plan ahead for them. Before investing, make sure it’s suitable for changes and your long-term goals.

Overlook the contingencies: ASRS is automation, and therefore, it is subject to occasional downtime and breakdowns. Think through your contingency plans in advance.

Forget you need trained labor: You’ll need competent, tech-savvy staff to work with an ASRS, so make sure you have that skilled labor available on every shift.

An ASRS can serve as the cornerstone of any material handling automation. While it won’t replace your staff, it will supplement and protect them, leading to productivity gains. WMHS

Source: Jason Stahl, Murata Machinery USA/Muratec

MHI’s AS/RS Industry Group is comprised of leading suppliers of automated storage/retrieval systems. They supply systems worldwide and in virtually every major manufacturing and distribution sector. For more information about the AS/RS group: mhi.org/as-rs