Think before you act: Benefits of ASRS integration in your new factory

Modern innovations and technologies have revolutionized the way a factory works. Labor-intensive manual processes have given way to automated ones with minimal or no human intervention. Computerized automation systems are part of every value chain throughout the production chain, as are the various application-based software to manage them, resulting in higher levels of production at faster speeds and lower costs in a modern factory.

Warehouse or storage is an area of ​​a factory where automation and technology made relatively late and moderate inroads. However, given the scope and predicted value creation throughout the production chain, the use of automated systems and technologies has increased significantly.

Automated Storage and Retrieval System (ASRS) is one such essential part of a modern warehouse. ASRS primarily includes storage racks, stacker cranes and a warehouse management system (WMS), which is a software application. An evolution of traditional storage and retrieval equipment in a warehouse such as AGVs, the ASRS system is programmed to operate according to the load dimensions and delivery speed for a specific load type. ASRS sends information related to cargo movement to the warehouse management systems, which process the data and direct automated warehouse control systems (WCS) that maneuver other warehouse equipment in tandem.

Traditional material handling systems require manpower or small machinery to move and store the products in a warehouse using pallets stored using single or double deep racking. This procedure is extremely tedious as it requires a large amount of data to be maintained manually about the location and quantity of the products stored. A large investment in resources is required to maintain the traditional material handling system; Also, it takes a lot of time, resulting in a slow process chain in the warehouse.

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Advantages over conventional systems:

• Traditional forklifts and battery forklifts offer increased capacity resistance, while ASRS provides the same workload at all levels of the storage system.

• ASRS systems are self-manoeuvrable and therefore do not require an operator throughout the movement of the equipment.

• As electrical equipment, no battery charge times or backup batteries are required, therefore ASRS offers 24/7 availability.

• ASRS is able to move both standard and special loads in a uniformly large volume (container, pallet, etc.).

Factory owners are quick to implement ASRS for their warehouses. However, if you are setting up a new factory for your company, integrating ASRS into the warehouse can actually be a very beneficial and prudent decision, as you can reap the benefits of cost-efficiency and ease of integration better than retrofitting an existing warehouse with ASRS.

Benefits for the entire supply chain management in the new factory:

• ASRS require a small operating island and are a very dense system that minimizes space consumption and maximizes storage capacity and density.

• ASRS helps reduce costs by minimizing the amount of unnecessary parts and products in inventory

• ASRS reduces labor in operations, reducing total cost of ownership and increasing security

• ASRS helps model and manage the logical representation of physical storage facilities

• It seamlessly connects with order processing and logistics management to pick, pack and ship products inside or outside the facility

• ASRS generates data on the movement of loads (tracking where products are stored, which suppliers they come from and how long they are stored) to help companies better manage inventory.

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• It enables total production efficiencies in raw materials, packaged goods and finished products, eliminating the possibility of production downtime.