The client turned to us for design-build delivery of an effective automated storage and retrieval system (ASRS). To consolidate the warehouse, we designed a solution that maximizes vertical space and can move multiple tote sizes, including totes up to 33 inches by 26 inches by 12 inches. This eliminates walking, manual parts storing and manual picking for most kit requirements.
All totes are managed by a warehouse control system (WCS) that provides dynamic inventory control. The WCS sequences orders based on their contents to optimize picking operations. It also reduces double‑handling by processing picks and puts within a single operating step. With the new WCS, the client can initiate a mass freeze on any product impacted by quality assurance issues. Both storage and active order totes can be locked down within the ASRS in real time.
To further improve accuracy, operator picks and puts are visually directed via various lighting systems and dynamic user interface screens. These elements physically guide and confirm completion of operator actions. This allows the system to track performance parameters for each operator by hour, day and month, while also improving safety as machine movements are initiated by strategically placed human‑machine interface points.