The Automatic Storage and Retrieval System: An Overview

The global ASRS market size was valued at USD 9.23 billion in 2019 and is expected to reach USD 13.77 billion by 2027, growing at a CAGR of 5.1% from 2020 to 2027.

The Automatic Storage and Retrieval System (ASRS) is a mechanical system that automatically stores and retrieves goods from their designated locations in a warehouse or Distribution center. The system is designed to optimize storage space, increase picking and replenishment efficiency, and reduce labour costs.

ASRS consists of rack structures that are outfitted with a series of robotic shuttles or cranes that can move vertically and horizontally to access the stored goods. These robotic systems are controlled by computer software that directs them to the appropriate location in the warehouse where goods are stored.

The retrieval and storage process in ASRS is entirely automated, which results in faster storage, picking, and replenishment times. The system’s computer software is capable of communicating with a warehouse management system (WMS) to determine the optimal location for storing or retrieving goods. The WMS is also used to manage inventory levels and track orders.

There are several types of ASRS, including vertical carousels, horizontal carousels, and robotic arms. Vertical carousels consist of a series of rotating vertical bins connected by a conveyor, while horizontal carousels consist of pods that rotate on a horizontal axis. Robotic arms are used to move goods from one location to another and are typically deployed in high-speed environments.

The benefits of using ASRS include increased productivity, reduced labour costs, better inventory control, and improved customer service. The system can also improve safety by reducing the need for staff to access high shelving or lift heavy items manually. Overall, ASRS is an efficient and cost-effective solution that can help businesses optimize their warehouse operations and improve their bottom line.

Automated Storage and Retrieval Systems (ASRS) can benefit a wide range of industries that require a high level of efficiency and accuracy in their warehousing and inventory management processes, including:

Manufacturing companies - ASRS can help streamline the supply chain, reduce production lead times, and improve inventory control.

Distribution and logistics companies - ASRS can help increase picking and sorting efficiency, reduce picking errors, and improve order accuracy.

Retail and e-commerce companies - ASRS can help speed up the order fulfilment process, improve inventory management, and reduce the cost of last-mile distribution.

Pharmaceutical and healthcare companies - ASRS can help ensure maximum accuracy, reduce the risk of contamination, and improve traceability and compliance.

Food and beverage companies - ASRS can help reduce the risk of product damage and spoilage, improve stock rotation, and increase product traceability.

Automotive and aerospace industries - ASRS can help improve inventory management, reduce the risk of damage to high-value components and parts, and increase operational efficiency.

Types of ASRS

Unit-load ASRS: This type of ASRS is designed to handle large and heavy pallet loads. The ASRS is equipped with cranes that are capable of lifting and transferring these loads from the storage area onto the conveyor belt.

Mini-load ASRS: This type of ASRS can handle smaller loads and is designed for high-density storage. The mini-load ASRS uses robotic cranes to pick and transfer loads from storage locations to conveyor belts.

Vertical lift module (VLM) ASRS: VLM ASRS is a vertical storage system that stores inventory items in trays or drawers that are retrieved by an automated elevator. VLM ASRS is generally used for small to medium-sized items.

Automatic carousels: Automated carousels are designed to store and retrieve items stored in bins or containers. They are often used for applications where space is limited, and items need to be accessed quickly.

Robotic ASRS: Robotic ASRS is a highly advanced system that uses robots to perform the tasks of picking, placing, and transporting inventory items. It can be used for almost any type of storage and retrieval application.

Shuttle ASRS: This system uses shuttles to transport goods between storage locations and loading docks, speeding up the retrieval and delivery process.

Automated pallet shuttle: This is a system that uses automated shuttles to transport pallets of goods within a warehouse or distribution center.

Automated cold storage: An ASRS designed for the storage of perishable goods, which maintains a consistent.

Key features of an ASRS system:

Storage Rack: ASRS uses specially designed racks that are accessible by robots. These racks can store a wide range of loads, including pallets, bins, and cartons.

Retrieval System: The system uses robotic cranes or shuttles to retrieve items from the storage units. The retrieval system moves horizontally and vertically within the storage aisle to pick up and deliver goods.

Control System: The control system orchestrates the movement and storage of goods within the warehouse, eliminating the need for manual intervention. It manages the flow of goods between the ASRS and other functional areas of the warehouse.

Tracking System: The tracking system monitors the movement of goods within the warehouse, keeping track of inventory levels and providing real-time updates on the location of goods.

Advantages of ASRS

Increased Efficiency: With an Automated Storage and Retrieval System (ASRS), there is minimal human intervention required which results in increased efficiency and accuracy. This allows for shorter storage and retrieval times, which speeds up the entire operation.

Save Space: An ASRS utilizes vertical space more effectively than traditional racking solutions. The system can be designed to maximize the use of available floor and ceiling space, creating more storage options and freeing up valuable floor space.

Improved Inventory Control: ASRS tracks every item that enters or exits the storage unit. The system is synchronized with the warehouse management software which ensures that the inventory remains current, allowing better control of inventory levels and a significant reduction in stock discrepancies.

Safety Standards: ASRS are designed with safety in mind hence, they have features that ensure that the system is operated safely and efficiently. Automated safety features help to prevent damage to the products and minimise the risk of accidents, which is an essential requirement in warehouses.

Reduced Labour Costs: An ASRS uses automation technology to handle most of the tasks which traditionally are labour-intensive. This significantly reduces labour costs and frees up labour resources to perform other more productive and specialised tasks

Disadvantages of ASRS

High initial cost: ASRS systems have a high upfront cost, which includes the cost of purchasing and installing the equipment, as well as the cost of integrating the system into the existing warehouse management software.

Maintenance cost: ASRS systems require regular maintenance to ensure that they remain fully operational. This can be costly, especially if the system requires specialized technical knowledge.

Complexity: ASRS systems are complex and require technical expertise to design, install, and maintain. This means that companies may need to invest in specialized personnel to operate the system effectively.

Limited flexibility: While ASRS systems offer significant benefits in terms of space utilization and inventory accuracy, they can be inflexible when it comes to accommodating changes in product mix or storage needs.

Vulnerability to technical problems: Like any automated system, ASRS systems are vulnerable to technical problems that can result in downtime, lost productivity, and costly repairs.

Limited use for low-volume operations: ASRS systems are best suited for high-volume warehouses with a large number of SKUs. For low-volume operations, the cost of implementing an ASRS may not be justified by the benefits it provides

The Automated Storage Retrieval System’s history dates back to the early 1960s. Automated systems are generally used for providing extremely high-density storage in warehouses.SRS (Automated Storage and Retrieval System) technology was first introduced by the American company Remington Rand in 1962

ASRS systems are typically very tall, with some approaching 100ft tall. By using the height of your warehouse, ASRS mechanisms significantly reduce aisle space and achieve maximum density. This storage solution is much more compact than standard?pallet rack systems.