Automated Storage System
Why Choose Us?
Rich Experience
Founded in 2015, Guangzhou JustBest Logistics Equipment Co., Ltd. is mainly engaged in R&D, design, manufacturing, installation and after-sales service of warehousing equipment.
Professional Technical Team
We have 20 years of experienced engineering team: more than 20 engineers-level professional service teams around the world, and many experts from the company's research institutes and design institutes as backup forces for after-sales service.
Wide Product Range
Our products include industrial products such as storage shelves, logistics trolleys, aerial vehicles, pallets, storage cages, material racks, smart racks, tool cabinets (trucks), tool cabinets (trucks), storage cabinets, roller devices, etc.
Excellent Customer Service
Whether in the quality assurance period, or more than the quality assurance period, the supply side in the receipt of the user to report within 48 hours of the notice of repair, the supply side of the maintenance of technical personnel to arrive at the scene for testing and repair, such as can not be immediately repaired, then immediately make a maintenance plan.
What is Automated Storage System?
Automated storage system are computer- and robot-aided systems that can retrieve items or store them in specific locations. The system is usually comprised of predefined locations where machines can follow established routes to get items. As long as everything is stored in its proper location, these systems help to speed up manufacturing and shipping tasks. Typically, automated storage and retrieval systems are used when high volume loads must be moved rapidly and accurately.
Advantages of Automated Storage System
Better Floor Space Utilization = Increased Storage Capacity
The most obvious benefit of automated storage system is the considerable space savings they provide. Removing the wasted aisle space shelving requires and utilizing the full ceiling height of your facility; Automated storage system technologies offer high density storage in a compact footprint. These dynamic systems utilize tightly configured totes, bins, dividers, drawers and specialty holders to organize inventory most efficiently to maximize storage capacity. Further, integrated inventory management software dynamically manages the cube space within the storage system, keeping all inventory tightly compressed.
Reduced Labor Requirements
The second most obvious advantage of automated storage systems is the labor savings. Automated storage system units deliver the required item directly to the operator via the “goods to person” concept, dramatically reducing operator walk and search time. Often workers are traveling miles during a shift (use a pedometer to check your walk times); and that walking time translates into wasted time. In a manual operation—where workers must travel to the stored items—associates frequently spend as much as 60-65% of their shifts walking.
Improved Pick Accuracy
Each step within the picking process is an opportunity for human error. The more manual the process, the greater the opportunity for error. Automated storage systems integrate with a variety of light-directed picking technologies and integrated message centers that communicate pick information to the operator for high pick accuracy. Together, these systems indicate the precise area within the carrier of the item to be picked, display the part number or description, pinpoint the exact location, direct picking (or storage for replenishment) and indicate the required quantity.
Increased Pick Throughput
In a manual operation, pickers often fill just one order at a time, translating into pick rates of approximately 50 lines per hour. automated storage system technologies utilize the goods to person delivery concept to eliminate walk and search time to double throughput. Integrating pick to light systems that direct the operator to the exact location of the pick double the throughput rates again. Using batch picking—a process that groups together orders with a common item or items—integrated inventory management software sequences the picks for completion in a single rotation (or cycle) of the unit.
Greater Inventory Control
Automated storage system solutions house inventory within a fully enclosed system; providing safe, secure and controlled inventory management. The system can be configured to permit only authorized personnel access to stored inventory through a personal login and password. This allows missing or misplaced goods to be tracked back to a specific individual. This enhanced level of accountability and security eliminates inventory shrink and its negative impact on the bottom line. Additionally, items are kept clean and protected from exposure to dirt, dust and other environmental contaminants.
Improved Ergonomics
Every item stored in an automated storage system can be delivered to the operator at an optimal ergonomic height - also called the “Golden Zone” (between a user’s shoulder and knees). Shelves, trays or bins of items are presented in easy reach, eliminating bending down to retrieve an item stored low, or stretching up to grab an item stored high. With some automated storage system units, the addition of a lift table can be necessary to achieve this ergonomic benefit. This substantially reduces the risk of worker injury, absenteeism, insurance premiums and claims for worker’s compensation.
● Unit-load ASRS – They are used for large loads such as cases of items or pallets. Unit-load AS/RS is used for loads often weighing several thousand pounds. It uses fixed-aisle and moveable-aisle cranes;
● Mini-load ASRS – They are smaller than unit-load AS/RS solutions. They are used for handling lighter loads. Mini-load AS/RS use shuttles and cranes, which makes them suitable for warehouses with narrow aisles;
● Horizontal carousels – They are used for sorting small pieces and parts. Horizontal carousels leverage bins and rotate them horizontally to deliver goods;
● Vertical carousels – They are similar to horizontal carousels. They rotate vertically, which helps maximize the use of storage space;
● Vertical lift modules – Or VLMs, are automatic inserters or extractors placed in the center of a column of trays. They help retrieve and store items in the trays.
● Cube-based storage – This is a cutting-edge robotic picking system designed to operate in a cubical storage grid;
● Shuttles – Shuttles are often found in warehousing and manufacturing facilities that handle cartons, trays, and totes.
Application of Automated Storage System
Long-term Storage
One of the primary benefits of AS/RS is its ability to store product in a way that makes the most efficient use of available space, especially over the long term. By implementing AS/RS, an operation can automate their long-term storage of raw material or product and retrieve what they need when they need it. By integrating the AS/RS with their Warehouse Execution Software (WES) they can intelligently auto-rotate stock as new product/materials are delivered so that older product is always used first, reducing waste and spoilage (especially when it comes to handling food or pharmaceuticals).
Managing Buffer Storage
In a typical warehouse or factory, different processes take different amounts of time to complete. If these discrepancies are not properly managed, then all it takes is a poorly-timed machine breakdown in one stage of production to bring an entire operation to a standstill. Buffering aims to prevent such a breakdown by ensuring that enough supplies/product are always on hand in different stages to keep an operation running.
Staging Orders for Shipping
The impact of e-commerce and omni-channel delivery on the order fulfillment process can not be overstated. Customers are now able to shop and place orders around the clock, and they want their product delivered fast and on time. But even if an operation accepts and processes orders 24/7, there are often constraints to shipping windows: Due to worker shifts, for example, or exorbitant night and weekend delivery fees.
Goods-to-Person for Order Picking and Packing
Picking and packing product for orders can be some of the most time-consuming tasks in the order fulfillment process. In fact, the process of walking and manually picking orders can account for more than 50 percent of the time associated with picking. AS/RS offers an alternative to this through the use of Goods-to-Person (G2P) order picking. In a Goods-to-Person order picking system, the worker does not physically move from product location to product location to pick an order.
Components of Automated Storage System
The Pallet Racking
The storage shelving is comprised of standardized, easily extensible racking that’s been modified to operate with the AS/RS system. These racks allow material heights of 65 inches (165 cm) on the lower racks with a maximum height of 84 inches (213 cm) on the uncovered top racks delivered on standard pallets.
The Infeed & Outfeed
Getting materials into and out of the AS/RS system can be accomplished with several infeed and outfeed configurations, from automated conveyor lines to simple locations where a forklift can deliver a pallet. The infeed/outfeed can be integrated into an existing conveyor or other transfer process configuration.
The Shuttle
The shuttle is responsible for moving materials in and out of the system as well as retrieving and storing these materials in the racking. It travels on a ground-mounted track under servo power to the positions necessary. The shuttle’s dimensions are noticeably more compact than similar fork trucks, allowing the entire system to take up less overall square footage.
The Control System
The electronic control system is the brain of the system. Operated through a touchscreen interface, the control system provides easy-to-use access to the system. An operator uses the provided HMI to summon materials from the system or command the system to store pallets for use later. The rest of the operation is automated, including selecting available storage locations to physically move the pallets or materials.
● Replenishment Overload – If workers are spending just as much time replenishing as they are picking you’re wasting time – consider automation!
● Extensive Travel Time – If workers are wasting time traveling several miles during a shift to access inventory – consider automation!
● Excessive Search Time – If, upon arrival at a picking destination, workers must spend time visually search for the correct item and match up part numbers – consider automation!
● Rising Picking Errors – If picking errors are on the rise, wasting money and risking your company reputation – consider automation!
● Struggling Throughput – If you’re struggling to keep up with order cut-off time, or hiring seasonal workers to keep up with demand – consider automation!
● Damaged Items – If valuable inventory is often found damaged and unusable – consider automation!
● Misplaced Inventory – If inventory is frequently misplaced or temporarily lost – consider automation!
● Pilfered Product – If inventory is often unexplainably missing – consider automation!
● Facility at Max Capacity – If you’re building is bursting at the seams and there’s no room for growth – consider automation!
● Risk of Operator Injury – If workers are at risk of injury – consider automation!
Automated Storage System Technologies
Vertical Carousel Modules (VCMs)
A series of carriers traveling bi-directionally in a vertical loop around a track, vertical carousels deliver stored items safely and quickly to an ergonomically positioned work counter at the operator’s command.
Horizontal Carousel Modules (HCMs)
Highly dense storage bins mounted on an oval track which rotates horizontally to deliver product storage locations to an operator, for quick order fulfillment.
Vertical Lift Modules (VLMs)
These enclosed automated storage and retrieval systems consist of two columns of trays with an inserter/extractor in the center delivering trays of stored items to an operator as needed.
Crane Based Mini Load AS/RS
With a single, crane-mounted load handling device dedicated to each extremely dense storage aisle, mini-loads handle loads in cases, totes or trays.
Vertical Buffer Modules (VBMs)
A cost effective, tote handling system consisting of an enclosed shelving system with a movable mast in the center. It stores and retrieves totes, delivering them to an ergonomic picking station or automatically delivering them via an outbound conveyor.
Robotic Cube Storage
In a Robotic Cube Storage System, all inventory is placed into bins and stacked inside a cube. Smart robots work at the top of the cube to shuffle, sort and retrieve bins and deliver them to a workstation (port) as needed. This type of goods-to-person automated storage system can deliver increasingly higher throughput based on the number of independently moving robotic shuttles inducted into the system.
Floor Robots (AGVs/AMRs)
AGVs & AMRs store inventory on portable storage shelving that is retrieved and transported from storage to an operator access area by a fleet of autonomous, mobile robots.
How Much Do Automated Storage System Cost?
As with most warehouse automation systems, the cost of an automated storage systems can vary widely. The cost is dependent on several factors but can range from $70K for one standalone vertical carousel to more than $5 million for a fully integrated mini-load system that manages tens of thousands of SKUs.
Some of the factors that influence the final cost of an AS/RS system include:
● The cost of the AS/RS equipment itself
● Overall size and weight of products to be handled
● Storage space
● Operating environment (AS/RS systems for climate controlled and cleanroom environments cost much more)
● Special handling requirements
● Required throughput
● The complexity of the software and machine controls
● The cost of customizing and reconfiguring the equipment and your facility to maximize benefits
● Cost of shipping, delivery and installation of the system
● Integration with existing processes
Aside from the high purchasing costs, the operating and maintenance costs of an AS/RS system is considerable. What’s more, — estimates show that a high-tech automated storage system will achieve measurable ROI in approximately 5 years, much longer compared to alternative automation solutions like collaborative mobile robots.
Workflow in Automated Storage System Equipped Warehouses
Goods receiving: The warehouse process starts when goods arrive at the receiving dock. Each item is checked, logged into the Warehouse Management System (WMS), and labeled with barcodes or RFID tags that enable tracking throughout its stay in the warehouse.
Preparation for storage: Before being stored, items undergo quality checks and sorting based on type, size, and storage needs. This sorting ensures that items are stored in a manner that optimizes space and accessibility, adhering to specific storage requirements (like temperature or humidity control).
Storage: Once the items are processed, the AS/RS takes over. Based on instructions from the WMS, the AS/RS transports items to their designated locations in the storage area. This is typically a high-density setup that maximizes vertical and horizontal space. The system places items in locations that optimize retrieval efficiency, often based on the frequency of access and the nature of the goods.
Retrieval: When an order is placed, the WMS communicates with the AS/RS to retrieve the required items. The system identifies the most efficient route to pick all items from their storage locations and delivers them to the order fulfillment area. This automation minimizes the retrieval time and enhances the accuracy of order processing.
Order assembly: In the order fulfillment area, workers or automated systems assemble orders. This might involve picking additional items not handled by the AS/RS, combining items into shipping containers, and performing final checks for order accuracy.
Packing and shipping preparation: Completed orders are then packed, labeled with shipping information, and staged in the loading area. The packing process ensures that items are securely prepared for transit to prevent damage.
Shipping: The final step involves loading packed orders onto transport vehicles according to the shipping schedules managed by the transportation management system (TMS). This system optimizes delivery routes and schedules to ensure timely deliveries.
The Considerations for Buying Automated Storage System
The right automated storage system must have well-designed software to support seamless scheduling of storage and retrieval operations. All the instructions to the automated storage system will be passed through this software, so make sure it is reliable, easy to use, and without technical glitches.
The right automated storage system must occupy a minimal footprint (to maximize the floor space) and feature various speed options that can manage picking and order fulfillment operations comfortably during peak demand. For e-commerce operations, systems with a high-speed buffer for quickly moving high-load volumes in or out of the storage will be best.
While you can customize automated storage systems to handle practically any item, some systems are excellent for specific products. Systems must be able to take the maximum weight per unit load for your operations. Mini-load and shuttle systems are designed for managing smaller loads (cases, totes, etc.). In contrast, unit load systems are the best option for heavier weights (drums, large totes, pallets, etc.). The vertical length should be equivalent to your facility’s overhead space. The higher you construct your automated storage system, the less expensive (per standing foot) it’ll be.
The ability to get quick, professional help is crucial to the company’s reputation and bottom line. Hence, you must always buy an automated storage system from a vendor that offers prompt, reliable, and satisfactory customer service. In case of any technical issue, a non-operating automated storage system can generate a domino effect of obstacles, unfulfilled orders, and reduced productivity that can significantly disrupt supply chains and lead to a dissatisfied customer base.
Our Factory
Founded in 2015, Guangzhou JustBest Logistics Equipment Co., Ltd. is mainly engaged in R&D, design, manufacturing, installation and after-sales service of warehousing equipment. As a promoter of logistics storage solutions, we provide customers with the highest quality products and warehousing solutions. We have 20 years of experienced engineering team: more than 20 engineers-level professional service teams around the world, and many experts from the company's research institutes and design institutes as backup forces for after-sales service.
Ultimate FAQ Guide to Automated Storage System
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