Automated Storage and Retrieval System (AS/RS) is a warehousing system that achieves high-density storage, precise retrieval, and efficient scheduling of goods through automated equipment (such as stacker cranes, conveyor lines, AGVs/RGVs) and intelligent management systems (WMS/WCS).
Its core features include:
(1) High space utilization
Utilizing automated racking, storage density is 3-5 times higher than traditional warehouses;
(2) Fully automated operation
Unmanned operation reduces human error;
(3) Intelligent scheduling
Optimizes inventory management and inbound/outbound routes through AI algorithms.
Mini Automated Storage and Retrieval System Solution
for a Mechanical Parts Processing Factory
Project Background and Customer Needs
A mechanical parts processing factory faced the following warehousing problems:
(1) Raw materials and finished products were piled up haphazardly, occupying 40% of the production space;
(2) Manual material retrieval took an average of 15-20 minutes per retrieval;
(3) Inventory accuracy was only 75%, frequently resulting in production stoppages due to material shortages;
(4) Warehousing management required two full-time employees, resulting in high labor costs;
(5) Material damage rate reached 3%, causing direct economic losses.
The factory urgently needed to maximize storage capacity within limited space, achieve precise material management, improve inventory accuracy to over 98%, reduce reliance on manual labor, lower operating costs, and seamlessly integrate with existing production processes.
Based on our extensive experience and technical expertise, our factory undertook this project, providing the customer with a customized solution to help them achieve system upgrades.
Project Implementation Process and Technological Innovations
Key implementation milestones included:
(1) On-site surveying: Precise measurement of the site and design of the layout plan
(2) Foundation construction: Ground leveling and electrical wiring
(3) Equipment installation: Structural assembly and equipment debugging
(4) System integration: Software deployment and integration with ERP system
(5) Trial operation: Material migration and operation training
(6) Formal launch: Full system switchover and optimization adjustments
Technical Highlights
(1) Space Optimization Design
–Vertical space utilization: Utilizing the factory’s 4.2-meter clear height, compared to only 2 meters used by traditional shelving
–Modular structure: Using bolt connections for easy future expansion
–Double-deep storage design: Some storage locations use double-deep storage, increasing capacity by 20%
(2) Low-Cost Automation Solution
Domestic core components: Using domestically produced servo motors and controllers, reducing costs by 40%
(3) Intelligent Management System
–Barcode scanning integration: Interfacing with the existing ERP system through an interface
–Intelligent allocation algorithm: Automatically allocating storage locations based on material usage frequency
(4) Safety Protection Design
Infrared anti-collision device, cargo overload detection, emergency stop button, sound and light alarm system
Project Results and Customer Feedback
Project Results
(1) Improvement in Spatial Efficiency
Warehouse footprint reduced by 65%;
Storage capacity increased by 120%;
52㎡ of production area freed up for a new production line.
(2) Operational Efficiency Improvement
Material retrieval time reduced from an average of 18 minutes to 3 minutes;
Inventory accuracy increased from 75% to 99.5%.
(3) Management Benefits
–Refined management: One-to-one item tracking and batch traceability;
–Visual monitoring: Real-time inventory visualization to support decision-making;
–Standardized operations: Standardized material flow processes;
–Data-driven: Optimized procurement plans based on historical data.
Customer Feedback
(1) Company Head’s Evaluation:
“As a small company, we never imagined we could afford an automated storage and retrieval system, but this mini-solution perfectly matches our needs and budget. The biggest surprise is the freed-up production space, which allowed us to add a small production line, directly resulting in additional output.”
(2) Warehouse Manager’s Feedback:
“Previously, I had to walk over 20,000 steps a day to find materials, but now I only need to operate on the touchscreen, and the system automatically retrieves them. The error rate has been greatly reduced, and the workload has also been significantly reduced.”
(3) Production Supervisor’s Evaluation:
“The timeliness of material supply has significantly improved, and production line downtime due to material shortages has virtually disappeared. The accuracy of material delivery has increased, and product quality is also more stable.”
FAQ
Q: My factory building has limited (or very high) ceiling height. Is a mini-load AS/RS system suitable?
A: Mini-load AS/RS systems are very flexible, with heights typically ranging from 5 to 25 meters. For heights below 12 meters, we recommend using shuttle cars; for ultra-high spaces above 15 meters, lightweight stacker cranes offer better cost-effectiveness and vertical stability.
Q: How much more storage capacity can an AS/RS system provide compared to traditional shelving?
A: Under the same footprint, the storage density of an intelligent AS/RS system is typically 2.5 to 5 times that of traditional beam-type shelving, as it significantly reduces forklift aisle width and utilizes vertical height.
Q: What is the approximate payback period?
A: Considering savings in labor costs (typically replacing 3-5 picking workers per shift), land rent savings (3-5 times higher storage density), and reduced error rates, the average payback period is between 2.5 and 4 years.
Q: Is it easy to expand the AS/RS system if business volume increases later?
A: Shuttle car systems have excellent scalability; you only need to add more vehicles and shelving. Stacker crane systems require pre-planning to reserve aisles during the initial design phase.
Q: Can it operate in cold storage or cleanroom environments?
A: Yes. There are currently mature AS/RS solutions specifically designed for cold chain applications (withstanding temperatures below -25℃), and systems compliant with Class 100 cleanroom standards (an environment where the number of particles greater than or equal to 0.5 micrometers (µm) per cubic foot of air does not exceed 100, or less than 3.5 particles per cubic meter).
Q: Can it handle different sized boxes? Or does it require standard plastic containers?
A: Current gripping mechanisms (clamp-type or telescopic forks) are compatible with various sizes of original packaging cartons and plastic returnable containers. As long as the carton quality meets compression strength standards, the system can achieve mixed storage and retrieval without the need for additional standard pallets.