Kardex Remstar Blog | Elevate Your Warehouse

AutoStore vs Competitors: A Comparative Analysis of Robotic ASRS

Written by Brandon Hochstedler | 11/4/24 7:03 AM

In the evolving landscape of automated storage and retrieval systems (ASRS), robotic solutions have emerged as powerful alternatives to traditional systems. These advanced technologies are reshaping how warehouses manage inventory, optimize picking processes, and maximize storage space.

 

While traditional shuttle systems have long been the standard for reliable automation, robotic ASRS solutions offer enhanced flexibility, speed, and scalability that cater to the needs of modern businesses. In this post, we’ll delve into various robotic ASRS solutions, comparing their capabilities and benefits. 

 

For a deeper understanding of how AutoStore vs. shuttle systems compare and where traditional shuttle systems fit into the broader automation landscape, we have explored these aspects in detail in another post.

 

 

Topics covered in this blog:


 

 

Popular Types of Robotic ASRS

 

When selecting the right Automated Storage and Retrieval System (ASRS) for your warehouse, understanding the various types of robotic solutions available is crucial. Each system offers unique benefits and is tailored to address specific challenges in different operational environments.

 

In this section, we’ll explore the most popular types of robotic ASRS, from the high-density cube-based systems like AutoStore to more flexible options such as Movable Rack AMRs and Aisle-Based Robotic Shuttles. By comparing these systems, supply chain directors can better assess which solution aligns with their warehouse's needs, space constraints, and long-term growth strategies.

 

 

1. Cube-Based Systems

 

Cube-based systems, such as AutoStore, utilize a high-density grid structure where bins are stored in vertical stacks within a cubic framework.

 

Robots move along the top of the grid to access and transport bins to workstations for picking or replenishment.

 

This design maximizes storage capacity by utilizing vertical space and eliminating the need for aisles. Cube-based systems offer high storage density, scalability, and energy efficiency. They are ideal for operations with limited floor space that require a high degree of automation, such as in e-commerce, pharmaceuticals, and small parts storage.

 

 

2. Moveable Rack AMR

 

Movable Rack Autonomous Mobile Robot (AMR) systems involve robots that autonomously navigate the warehouse floor to retrieve and transport entire shelves or racks of goods to picking stations.

 

These types of systems do not require fixed racking as the racking is inherently movable. This can result in a short implementation timeframe; however, these systems do not use vertical space effectively, so they require a larger footprint for similar cubic storage capacity.

 

Movable Rack AMR systems are flexible and easily scalable, making them suitable for various industries including e-commerce, retail, and manufacturing.

 

 

3. Autonomous Case-Handling Robot (ACR)

 

Autonomous Case-Handling Robots are designed to manage and transport individual cases or totes within a warehouse.

 

These robots can handle tasks such as picking, sorting, and transporting cases to designated areas for further processing or shipping.

 

They often work alongside conveyor systems and other automation technologies to streamline the movement of goods.

 

 

4. Aisle-Based Robotic Shuttles

 

Aisle-Based ASRS with mobile robots combines traditional aisle-based storage with advanced robotic technology.

 

In this system, mobile robots travel along designated aisles to retrieve and deliver items from storage racks.

 

The robots can either move vertically to access different levels of the racks or work in conjunction with vertical lifts. This system enhances efficiency while maintaining a familiar aisle-based layout.

 

 

 

Comparing AutoStore ASRS and Alternative ASRS

 

 

1. Performance and Speed

 

When evaluating automated storage and retrieval systems (ASRS) for modern warehouse operations, speed and throughput are often at the forefront of decision-makers’ minds. These factors can greatly impact efficiency, order fulfillment rates, and overall operational performance. With a variety of robotic ASRS solutions on the market—from shuttle-based systems to fully integrated cube storage technologies—understanding how they stack up in terms of speed and throughput is essential for choosing the best fit for your business. 

 

Cube-Based Systems:

 

AutoStore, a common cube-based system, excels in performance and speed due to its highly efficient cube-based design. Robots move quickly across the top of the grid, retrieving and delivering bins in a streamlined manner. This system is known for its high throughput and rapid order fulfillment capabilities.

 

Movable Rack AMR:

 

Movable Rack AMRs offer flexible performance, as they can transport entire shelves to picking stations. However, their speed can be limited by the need to navigate through storage aisles and other robots, making them slightly slower in dense environments compared to cube-based systems.

 

Autonomous Case Handling Robot:

 

These robots are designed for high-speed operations, efficiently handling individual cases and totes. Their performance is impressive in environments requiring precise and quick case-level handling, often surpassing traditional manual methods but potentially lagging behind AutoStore in overall throughput as well as storage density.

 

Aisle-based ASRS with Mobile Robots:

 

This system offers solid performance with robots efficiently retrieving items from storage racks. However, their speed is generally constrained by the aisle layout and the need to move vertically and horizontally within defined paths. The throughput within a single aisle is very high, but multi-aisle systems require complex conveyor routing between aisles and/or SKU redundancy across aisles.

 

 

2. Flexibility and Scalability

 

Flexibility and speed are key attributes that can set apart one automated storage and retrieval system (ASRS) from another. Whether you're navigating seasonal demand spikes, managing diverse inventory types, or responding to unexpected operational shifts, an ASRS that balances flexibility with speed can be a game-changer. 

 

— Cube-Based Systems:

 

AutoStore is highly scalable, allowing businesses to start with a small setup and expand as needed.

 

AutoStore is one of the easiest ASRS solutions to expand with minimal downtime, as oftentimes there is no need to extend or relocate inbound and outbound conveyor systems when scaling up. Adding more robots or grid modules can be done seamlessly without the necessity of adding additional ports when expanding aisles, making it a cost-effective and flexible solution for growing businesses.

 

— Movable Rack AMR:

 

Movable Rack AMRs are also very flexible and scalable. New robots can be added to the system easily, and the layout can be adjusted without significant downtime. This makes them suitable for dynamic environments where flexibility is key.

 

Autonomous Case Handling Robot:

 

These systems are designed for scalability and can be expanded by adding more robots. Their ability to handle various case sizes and types adds to their flexibility, making them suitable for diverse and evolving warehouse operations.

 

— Aisle-based ASRS with Mobile Robots:

 

This system offers decent scalability but may require more significant infrastructure changes to expand compared to AutoStore and AMRs. Flexibility is moderate, as the system is somewhat constrained by its aisle-based design.

 

 

3. Cost and ROI

 

In the realm of automated storage and retrieval systems (ASRS), understanding the balance between cost and return on investment (ROI) is essential for making informed decisions. While some ASRS solutions come with a higher price tag, their long-term benefits, including labor savings, increased efficiency, and enhanced space utilization, can often justify the initial expense. On the other hand, more cost-effective options might offer a quicker payback period but come with trade-offs in terms of scalability or advanced capabilities. 

 

— Cube-Based Systems:

 

AutoStore offers significant cost advantages by eliminating the need for extensive conveyor systems to route inbound and outbound cartons. Since the ports in an AutoStore system are directly connected, even manual picking operations can be streamlined, simplifying outbound processes. This system is particularly advantageous for smaller setups unlike other providers who may not cater to small projects.

 

— Movable Rack AMR:

 

These systems generally have lower initial costs compared to AutoStore. The ROI can be realized quickly due to lower operational costs and improved efficiency. However, the overall storage density may not be as high as AutoStore.

 

— Autonomous Case Handling Robot:

 

These robots offer a balanced cost structure with moderate initial investment and quick ROI through enhanced productivity and reduced labor costs. They are particularly cost-effective for operations with high throughput requirements.

 

— Aisle-based ASRS with Mobile Robots:

 

The initial investment for these systems can be significant, particularly if substantial modifications to existing infrastructure are required. ROI depends on the scale and complexity of the implementation but can be favorable with improved efficiency and labor savings.

 

 

Applications and Industry Use Cases

 

Most robotic ASRS solutions are geared towards the storage of small parts and items since they are stored in standard totes.

 

Cube-based systems, like AutoStore ASRS, excel in environments where high-density storage is essential, making it an ideal choice for storage of items such as:

 

  • Light industrial manufacturing supplies
  • Hardware components
  • Plumbing supplies & valves
  • Electrical components & sensors
  • Medical supplies for kitting
  • Automotive parts & pieces
  • Non-bulky clothing (i.e. inefficient to store full-length winter puffer coat)

 

AutoStore is effective in managing peak periods, urgent orders, and variable demand through sophisticated software. However, AutoStore is limited to handling items that fit within a single bin size, making it unsuitable for odd-shaped, long, or heavy items.

 

The Movable Rack AMRs may have a little bit more flexibility in terms of storing a variety of product sizes as they can oftentimes pick up and carry pallets of cases.

 

In scenarios where all SKUs have similar demand, AutoStore ASRS, like other ASRS systems, can face challenges, although other robotic solutions may handle this situation slightly better.

 

Nonetheless, AutoStore's ability to store diverse range of small items in such dense locations makes it valuable for many industry applications.

 

 

Key Features of the AutoStore

 

AutoStore systems offer several key features that make them a popular choice for automated storage and retrieval:

 

 

1. High Storage Density

AutoStore systems are designed to maximize the use of available space. By stacking bins vertically and employing a compact grid structure, these systems can significantly increase storage capacity compared to traditional shelving or even other robotic ASRS technologies.

 

2. Scalable

One of the major advantages of AutoStore is its modular design. This allows businesses to start with a small system and expand it incrementally as their storage needs grow. Additional robots and ports can be added without disrupting ongoing operations. The grid can be expanded while the existing system continues to run.


3. Energy Efficient

AutoStore robots are designed to be energy-efficient, where a system with 10 robots consumes the same amount of energy as a vacuum cleaner.

 

4. Speed

By using multiple robots that can work simultaneously, AutoStore systems can achieve high throughput rates where it typically takes an average of 2 to 10 seconds between bin deliveries to a port during normal steady operations.


5. Flexibility

AutoStore systems are highly adaptable to various types of inventory and workflows. It can handle a wide range of products, making it suitable for diverse industries including e-commerce, retail, pharmaceuticals, and manufacturing. Understanding how AutoStore manages inventory effectively is key to appreciating its optimized storage and picking processes that enhance overall efficiency. This adaptability and advanced inventory management make AutoStore an invaluable solution for businesses seeking streamlined operations and increased productivity.

 

 

Is an AutoStore ASRS the right solution?

 

Customization and Integration with Existing Systems

 

When it comes to customization and integration with existing systems, AutoStore offers significant flexibility compared to alternative robotic ASRS solutions.

 

Unlike aisle-based systems that require straight lines and uniform layouts, AutoStore can be configured in various shapes, accommodating irregular spaces and optimizing existing warehouse footprints without the need for extensive reconfiguration. This adaptability makes it easier to integrate AutoStore into diverse warehouse environments.

 

AutoStore can seamlessly increase throughput by simply adding more robots or installing additional ports, which can typically be done within a couple of days.

 

One area where AutoStore may face limitations is in maintenance access; since AutoStore robots operate on top of the grid and bins are stacked vertically, it can be more challenging to perform maintenance compared to AMR solutions, which operate on the warehouse floor and are more easily accessible for service and repairs.

 

Despite this, AutoStore maintains the highest proven uptime rate in the industry (99.7%) and maintenance does not slow down operations, as the system is designed to allow maintenance activities to be carried out without significant disruption to ongoing processes.

 

Future-Proofing: Adaptability and Expansion in ASRS Systems

 

Future-proofing warehouse operations with ASRS systems requires adaptability and ease of expansion, and AutoStore ASRS excels in these areas.

 

Its modular design allows businesses to start small and scale up effortlessly as their needs grow.

 

Adding additional robots or ports to increase throughput is straightforward and causes minimal disruption, with new ports being installable in just a day or two.

 

Unlike aisle-based ASRS systems that must adhere to straight-line configurations, AutoStore's flexible design can be tailored to fit unconventional spaces, providing a significant advantage for warehouses with unique layouts.

 

This flexibility not only maximizes current space utilization but also ensures that future expansions can be accommodated without major structural changes.

 

 

Summary

 

The world of automated storage and retrieval systems (ASRS) is constantly evolving, offering a range of solutions to meet the diverse needs of modern warehouses. From aisle-based ASRS with mobile robots to cube-based systems like AutoStore, each option brings its own set of advantages in terms of scalability, cost, and flexibility. AutoStore stands out for its high storage density, scalability, energy efficiency, and adaptability to various inventory types and workflows. As businesses look to future-proof their operations, the adaptability and expansion capabilities of ASRS systems like AutoStore are crucial. Whether you are considering implementing ASRS for the first time or looking to upgrade your existing system, exploring the features and benefits of AutoStore could be the key to optimizing your warehouse operations. Engage further with industry experts to explore how AutoStore can revolutionize your storage and retrieval processes.

 

 

Key Takeaways:

 

  • Types of Robotic ASRS: Cube-based systems like AutoStore use a high-density grid structure to maximize storage space capacity, making them ideal for operations with limited floor space and high automation needs. Movable Rack AMR systems offer require little infrastructure changes to implement and can store larger goods. Autonomous Case-Handling Robots handle boxes or containers that hold goods. They can pick up, transport, and place cases on shelves. Aisle-Based Robotic Shuttles utilize robots that operate within aisles and climb the racking solution.
  • Flexibility vs. Storage Density: AutoStore not only excels in maximizing storage density in space-constrained environments but also offers a robust, scalable solution. While some ASRS solutions like Movable Rack AMRs may provide quicker initial setup, they fall short in delivering the high storage capacity and space optimization that AutoStore offers.
  • Scalability Across Systems: Both AutoStore and other robotic ASRS systems are scalable, but AutoStore's modular design allows for easier, disruption-free expansion compared to more infrastructure-dependent solutions.
  • Cost and ROI Considerations: AutoStore's elimination of extensive conveyor systems reduces implementation costs, while other systems may offer lower initial investments but compromise on storage efficiency and long-term ROI.
  • Ideal applications: AutoStore excels in space-constrained warehouses that require high throughput and scalability. Technologies like Movable Rack AMRs can be better suited for storing larger SKUs or pallets.