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In today’s fast-paced logistics and manufacturing environments, a well-organised and automated warehouse is no longer just an advantage it’s a necessity. With the advent of e-commerce and evolving supply chain demands, companies must manage inventory, demand, and order fulfilment with precision and efficiency.
Implementation of ASRS System is crucial in helping businesses meet these challenges, offering a dynamic way to store materials of varying sizes from large and heavy items to small, intricate parts.
The rise of e-commerce has dramatically increased daily order fulfilment requirements, and manual operations are struggling to keep up. As companies scramble to stay ahead of the curve, they are eager to select a system that aligns perfectly with their operational “sweet spot.” This sweet spot is defined by two main objectives: increasing storage capacity and improving picking throughput.
Pre-requisites for Implementation of ASRS System
Data is the Foundation, and Analysis is the Key Driver
The backbone of a successful implementation of ASRS System is data both historical and projected. A deep dive into your inventory data is crucial, encompassing SKU velocity classification, order trends, and storage requirements. This data needs to be analysed to predict future needs, ensuring the system is scalable and can handle projected growth.
Moreover, product mix, order rates, minimum order quantities, and fulfilment processes must be considered during the design phase. These factors will dictate the size, configuration, and throughput capabilities of the ASRS Systems. Without thorough data analysis, you risk over or under-engineering the system, leading to inefficiencies down the line.
System Configuration
One of the first decisions you’ll need to make is about the configuration of your ASRS System. This includes both the electrical and software setup to ensure seamless operation. The system must be robust enough to handle the demands of modern manufacturing or fulfilment processes.
Beyond software, it’s critical to establish the physical input and output points for storage and retrieval tasks. These points should be strategically placed in central locations to optimise workflow efficiency and minimise travel time for materials.
Operational Clarity
Not all materials are created equal, and the way they are handled will vary based on their nature. Whether you’re dealing with full pallets, mixed pallets, cases, cartons, or kitting operations, each comes with distinct storage and retrieval needs. You will need to assess how implementation of ASRS System will impact the entire material flow—from upstream manufacturing to downstream shipping processes.
For instance, kitting operations may require different handling procedures compared to large pallet storage. Knowing how each material type interacts with the system is essential to maintaining a streamlined process.
Material Handling Components
Before implementation of ASRS System, it’s important to identify the ancillary materials that will work alongside the ASRS, such as carrier boards, slip sheets, totes, and pallets. Determine if these materials will be captive in the system or introduced at another point in the process. This decision will affect how the implementation of ASRS System is configured and how efficiently it can run.
Addverb’s Crane ASRS efficiently loads and unloads heavy items, ensuring precise storage.
Facility Evaluation
Will your existing facility accommodate the new ASRS System, or are modifications required? Many businesses underestimate the importance of ensuring that their building can house a storage and retrieval system, especially if it involves vertical lifts or cranes.
If a new building or renovation is necessary, compliance with regulations and building codes is essential. This becomes especially critical when integrating the ASRS System into an already existing facility where space constraints and infrastructure challenges may arise.
Customisation and Technology Selection
Customisation is a key advantage of implementation of ASRS System, allowing it to fit the unique needs of your operation. It’s essential to evaluate whether you need a unit load ASRS crane system or a unit-load shuttle system. Additionally, determining whether AGVs (Autonomous Guided Vehicles) or conveyors will assist with material movement is crucial to the system’s overall efficiency.
Further considerations should include the type of picking operations (e.g., piece picking or batch picking) and technologies (such as RFID or Pick-to-Light) that will complement your AS RS.
Software Integration
Implementation of ASRS System with existing warehouse management systems (WMS), warehouse control Systems (WCS), warehouse execution Systems (WES), and enterprise resource planning (ERP) is crucial. These software systems need to work in harmony to ensure seamless operations, and the ASRS System must be able to communicate effectively with these platforms for accurate data exchange and smooth material handling.
Avoiding Pitfalls
Implementation of ASRS System can bring incredible benefits, it’s important to be aware of potential pitfalls. Light-duty systems, for example, may not be well-suited for your operation if they lack the robustness to handle the physical demands of a busy warehouse. These systems can experience frequent breakdowns, causing major disruptions.
Such issues can lead to severe losses, including downtime, lost revenue, and diminished workforce morale. For small- and medium-sized businesses, these disruptions can be especially costly, so it’s important to invest in a well-engineered AS RS that minimises vulnerabilities.
Get Set, Go!
Once you’ve gone through the above checklist and addressed all the potential challenges, you’re ready to move forward with implementation of ASRS System. Remember, the key to success lies in identifying the processes that need automation, evaluating the potential efficiency gains, and understanding the disruptions that may come with the transition.
By addressing each of these pre-requisites, companies can avoid common mistakes and ensure a smooth, successful implementation of the Storage and Retrieval system. This approach not only boosts productivity but also enhances operational resilience and scalability.
FAQ
What is an ASRS system?
An Automated Storage and Retrieval System (ASRS) is a technology-driven solution designed to automate the process of storing and retrieving goods in a warehouse with precision and efficiency.
Why are pre-requisites important for implementation of ASRS System?
Pre-requisites help ensure that the system is correctly planned and integrated with the existing warehouse infrastructure, leading to smoother implementation and optimized performance.
How does warehouse layout impact implementation of ASRS System?
A well-planned warehouse layout ensures that the ASRS can operate efficiently, making full use of vertical and horizontal space while maintaining proper workflow.
Why is integration with WMS critical for ASRS success?
Seamless integration with Warehouse Management Systems ensures smooth coordination between storage operations, inventory management, and order fulfillment processes.
How can staff readiness influence implementation of ASRS System?
Proper training and readiness of staff are essential for adapting to the new technology, ensuring minimal disruption in operations, and maximizing system efficiency.
Founded in 2016, Addverb offers complete robotics solutions for warehouse and industrial automation, with a strong global presence through its subsidiaries worldwide. The company provides a range of in-house automation products, including Autonomous Mobile Robots, ASRS, and sorting technologies. It serves over 350+ clients, including well-known companies such as Coca-Cola, Amazon, and DHL.
