Automated Material Handling Systems
Guide for Your Warehouse

Warehouse Automation Picking Methods

In warehouse automation operations, two primary picking methods are used:
Goods-to Person and Person-to-Goods.

Three Common Automated Material Handling Systems

Across our 2,500 warehouse management customers that span a variety of industries, three Automated Material Handling Systems solutions consistently stand out: ASRS (Automated Storage and Retrieval Systems), AMR (Autonomous Mobile Robots), and Warehouse Conveyance.
Let’s take a closer look at these technologies.

What is an Automated Storage and Retrieval System (ASRS)?

ASRS (Automated Storage & Retrieval Systems) is a Good-to-Persons system where sophisticated computer-controlled technologies are designed to automatically store and retrieve inventory from defined locations within warehouses and distribution centers. These systems utilize robots or computerized mechanisms to handle items with minimal human intervention, maximizing vertical space utilization while significantly improving operational efficiency.

How Do I Use an ASRS in My Warehouse?

ASRS warehouse automation solutions support several critical warehouse operations that
enhance efficiency and accuracy throughout the facility. These core operations include:

Order Picking

ASRS systems facilitate high-speed, ergonomic order fulfillment by automatically retrieving items from storage locations and delivering them to picking stations, significantly reducing manual travel time and improving picking accuracy.

Putaway Operations

These systems optimize the storage process by automatically determining the best location for incoming inventory based on size, demand patterns, and available space, maximizing storage density and retrieval efficiency.

Replenishment

ASRS manages inventory replenishment by identifying low stock levels and automatically transferring items from reserve storage to active picking locations, ensuring continuous operations without stockouts.

Cycle Counting

These systems support automated inventory verification processes, making it easier to maintain accurate inventory records without disrupting daily operations.

Inventory Management

ASRS provides real-time inventory visibility and control, tracking item locations precisely and reducing discrepancies between physical and system inventory levels.

Goods-to-Person Delivery

Rather than workers traveling to find items, ASRS brings goods directly to stationary workstations, improving ergonomics and productivity.

Advantages of Automated Storage and Retrieval Systems (ASRS)

Space Optimization: ASRS maximizes vertical storage space by utilizing the full height of a facility, reducing the warehouse footprint by up to 85% compared to conventional storage methods.

Increased Accuracy: These systems achieve near-perfect inventory accuracy (of-ten 99.9%+) by eliminating human error in storage and retrieval processes through computer-controlled operations.

Labor Reduction: ASRS significantly decreases labor requirements by automating repetitive storage and retrieval tasks, allowing businesses to reallocate staff to higher-value activities.

Enhanced Inventory Control: Real-time tracking and integration with warehouse management systems provide complete visibility of inventory status, locations, and movements throughout the facility.

Improved Safety: By handling heavy or dangerous items and operating in extreme environments (cold storage, high racks), ASRS reduces workplace injuries and creates safer working conditions.

Increased Throughput: ASRS systems can operate 24/7 with consistent speed and efficiency, dramatically increasing picking rates and overall warehouse throughput capacity.

Better Ergonomics: These systems bring goods directly to operators at ergonomic heights (goods-to-person), eliminating climbing, stretching, and heavy lifting that cause workplace injuries.

Reduced Error Rates: Computer-controlled picking and placement virtually eliminates common human errors like incorrect item selection, misplacement, and documentation mistakes.

Scalability: Modern ASRS solutions can be expanded or reconfigured as business needs change, providing flexibility for growth without requiring complete system replacement.

Data-Driven Insights: Advanced ASRS systems collect operational data that can be analyzed to identify bottlenecks, optimize inventory levels, and improve overall warehouse performance.

What is an Autonomous Mobile Robot (AMR)?

An Autonomous Mobile Robot (AMR) is an advanced robotic system designed to navigate and operate independently within warehouse and manufacturing environments without requiring fixed paths or constant human supervision.

How Do AMRs Work?

Advantages of Autonomous Mobile Robots

Autonomous Mobile Robots (AMRs) deliver significant operational benefits to modern warehousing and logistics operations. These intelligent machines:

Automate material transportation while improving accuracy in inventory management and order fulfillment.

Navigate independently using advanced sensors and AI, allowing them to detect and avoid obstacles without requiring fixed infrastructure, and enabling quick deployment and easy reconfiguration as business needs change.

Reduce operational costs by working continuously without breaks and freeing human workers for higher-value tasks.

Adapt to dynamic environments makes them ideal for facilities with changing layouts or workflows.

By optimizing resource utilization and streamlining processes, AMRs help businesses remain agile and competitive in today's fast-paced logistics landscape.

What is Warehouse Conveyance?

Warehouse conveyance refers to the systems and equipment used to move products, materials, and goods throughout a warehouse or distribution center. These systems are essential components of modern warehouse operations, designed to improve efficiency, reduce manual labor, and increase throughput. Automated conveyor systems are typically integrated into broader warehouse management systems to create seamless material flow throughout the facility, from receiving to shipping.

How Does Warehouse Conveyance Work?

Automated conveyor systems work by creating designated pathways and mechanisms that transport items between different operational zones. The basic principle involves:

Advantages of Warehouse Conveyance Systems

Increased Efficiency: Warehouse conveyance systems dramatically boost operational efficiency by reducing manual handling, enabling continuous product flow, and minimizing travel distances between zones.

Enhanced Productivity: Modern conveyance solutions enhance warehouse productivity by freeing workers for value-added tasks, increasing capacity during peak periods, and supporting around-the-clock operations with minimal staffing.

Improved Safety: Implementing conveyance systems significantly improves workplace safety by reducing lifting injuries, decreasing dangerous forklift traffic, and minimizing product damage through controlled handling.

Space Optimization: Conveyance technology optimizes warehouse space utilization through vertical transport solutions, streamlined workflows in limited areas, and enabling denser storage configurations.

Cost Reduction: Automated warehouse conveyors deliver substantial cost savings through reduced labor requirements, decreased product damage expenses, and lower energy consumption with efficient modern systems.

Better Inventory Control: Warehouse conveyance system can enhance inventory management by providing real-time movement tracking, seamless WMS integration, and virtually eliminating lost or misplaced items.