7 Tips for Choosing an Automated Storage and Retrieval System

MHI reports that 55% of firms plan to increase technology investment. That number sounds promising, but investment without clear goals creates expensive confusion. Define the target first: higher throughput, better accuracy, safer lifting, or reduced travel time. Set measurable figures, such as 120 order lines per hour and 99.8% inventory accuracy. Keep the goal practical.

Audit your inventory before reviewing system designs. Record dimensions, weights, turnover rates, and seasonal peaks. Map every movement from receiving dock to shipping lane. Check ceiling height, floor strength, fire protection, and available power. Small building limits can change the entire solution.

Choosing an AS/RS starts with the load, not the equipment label. Heavy pallets need strong storage positions and stable retrieval controls. Small cartons may suit tote-based systems with dense vertical storage. Irregular items require clearances that standard bins cannot provide. Measure weight, dimensions, fragility, and packaging variation across real inventory.

Study the SKU profile carefully. A few fast-moving items may need direct access and short travel paths. Thousands of slow movers may benefit from higher density. Track daily receipts, picks, replenishment tasks, and peak-hour demand. Average throughput can hide serious congestion. It often does. Order patterns matter too. Single-line orders favor rapid presentation, while mixed orders require coordinated buffering and sequencing.

Test at least three operating scenarios. Include normal demand, seasonal peaks, and unexpected SKU growth. A system that performs well today may struggle after a modest volume increase. Review equipment speed, aisle capacity, software response, maintenance access, and recovery procedures. Simulation is useful, but its assumptions must reflect actual work. One warehouse review showed that poor slotting reduced performance more than mechanical speed. That lesson is easy to miss. Validate the design with historical orders, operator feedback, and a clear measurement plan before committing.

Ask vendors to show validated space-saving benchmarks from comparable installations. Look beyond advertised percentages. Check the original aisle width, rack height, tote size, access requirements, and safety clearances. Density should include usable inventory volume, not only the system’s external footprint. Request calculation sheets and challenge every assumption.

Map your current workflows before comparing equipment.

Tip one: record storage locations, order peaks, travel distances, and manual handoffs. Tip two: verify WMS and WES integration through a live test environment. Confirm inventory updates, task releases, exception messages, and recovery after a network outage. Ask for interface documentation. Do not trust a polished demonstration alone.

Tip three: inspect safety standards and certification records for the target region. Check guarding, light curtains, emergency stops, access doors, and maintenance procedures.

Tip four: observe a controlled fault test, not just normal operation. Operators need clear alarms and safe restart instructions. Small details matter, such as whether a blocked aisle can be cleared without entering danger zones.

I have seen projects underestimate training time. That mistake is expensive.

Tip five: review cybersecurity architecture. Separate operational networks, restrict remote access, require strong authentication, and log administrator actions. Tip six: ask how software patches are tested and approved. A rushed update can interrupt fulfilment.

Tip seven: model scalability using realistic growth, seasonal peaks, product sizes, and staffing limits. Check whether storage modules, lifts, or software licenses can expand without rebuilding the entire system. Request performance data from comparable operating conditions. Claims without measurable assumptions deserve questions.

The best choice may still involve compromises, and those should be documented before purchase.