Solutions: Automated Storage/Retrieval Systems (AS/RS)

Optimise space and efficiency with automated storage and retrieval systems

Warehouses, distribution centres and manufacturing facilities often face challenges managing high volumes of inventory and meeting customer expectations for speed and accuracy, specifically when handling a wide range of item sizes. Automated storage and retrieval systems (AS/RS) streamline storage and retrieval, offering a fast, accurate and cost-effective approach to inventory management and order fulfillment.

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AS/RS for high capacity, throughput and performance

Automated storage and retrieval systems are ideal for increasing operational performance without increasing your building footprint. Inventory accuracy and reduced shrinkage make these ideal solutions for high-volume inventory. The optimised flow of material and just-in-time replenishment eliminates unnecessary inventory, reducing your total cost. Automated storage and retrieval systems also work well in ambient, chilled or freezer environments and are ideal for a variety of industry segments and applications for manufacturing and distribution.

An automated storage and retrieval system is a material handling solution that uses a racking or grid structure to store bins or totes. Shuttles or robots navigate through or above the structure to retrieve items and deliver them to a goods-to-person station for order fulfillment. An automated vertical storage system combines automation and warehouse software to manage inventory and maximise storage efficiency. An automated storage and retrieval system contains:

Tote or case racking and storage
Automated shuttles or robots
Controlling and inventory software
Goods-to-person stations

Available for small, mid and large loads, AS/RS solutions can be customised to a best-fit solution that can reduce labour-intensive work. At the same time, it improves productivity and order fulfillment time. Automated storage and retrieval systems can take advantage of current facility capacity and automate manual processes, from shuttles to goods-to-person stations to automated vertical storage lifts and carousels.

Types of AS/RS solutions

Like many solutions for warehouse operations, there are various types of AS/RS solutions, each designed to meet a specific need or challenge. From the smaller mini-load automated storage and retrieval system to the pallet-based storage systems, each solution can bring a particular advantage to a unique industry or vertical.

Understanding the types of AS/RS solutions available, how they can impact your operations, and how flexible and scalable they are is critical to operational success and excellence.

AutoStore grid and robots

AutoStore cube-based
High-density storage
Mini-load
Carousel-based
Shuttle
Vertical, horizontal and robotic vertical lift module (VLM)
Micro-load
Vertical sequence systems (VSMs)
Unit-load
Mobile robot (AGVS and AMRs)
Temperature-controlled

Key benefits of automated storage and retrieval systems

Utilises vertical space and reduces footprint.
Maximises cubic storage capacity.

Minimises human error.
Enhances order picking – up to 99.9% accuracy.

Reduces retrieval and put-away time.
Accelerates order processing and fulfillment.

Reduces dependency on manual labour.
Reallocates labour to high values tasks.

Real-time inventory tracking.
Improves demand planning.

Streamlines workflows and reduces bottlenecks.
Ensures consistent performance for all levels of demand.

Minimises human interaction with inventory.
Reduces risks of accidents and/or injuries.

Modular systems that can grow with your business.
Adapts to changing SKU profiles and demand patterns.

Lowers labour, space and energy costs.
Drives ROI thru increased productivity.

Optimises energy.
Reduces waste.

Moen AutoStore automated storage and retrieval system - FORTNA

Customer Success Case Study

How Moen Transformed Its Distribution Operations with FORTNA

Discover how Moen optimized supply chain operations by consolidating facilities and automating distribution to boost efficiency and reduce labour costs by 60%.

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The FORTNA difference

The FORTNA data-driven, consultative approach sets us apart by turning operational data into actionable insights that drive measurable results. We don’t just recommend solutions—we analyse your unique operational metrics, workflows and demand patterns to identify the most impactful opportunities for improvement. Our consultative process combines advanced analytics with robust supply chain expertise to design strategies tailored specifically to your facility needs, whether that is optimising throughput, improving labour efficiency or increasing storage utilisation. This fact-based methodology ensures decisions are grounded in evidence, not assumptions, delivering long-term value and a clear return on investment for your warehouse operations.

FORTNA Distribution Optimization Framework Lifecycle Performance Services supports a diverse portfolio of MHE and software implementations worldwide

FORTNA Framework

FORTNA can help optimise business-critical operations with the FORTNA Framework™

The FORTNA Distribution Optimisation Framework^TM (FORTNA Framework) leverages proprietary processes, tools, and algorithms to design and deliver solutions using best-fit automation technologies and intelligent software.

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FORTNA's experience enables us to develop solutions for industry-unique challenges and cross-pollinate best-in-class strategies and solutions.

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FAQs

Automated storage and retrieval systems (AS/RS) are material handling solutions that use a racking or grid structure to store bins or totes. Shuttles or robots navigate through or above the structure to retrieve items and deliver them to a goods-to-person station for order fulfillment. An automated vertical storage system combines automation and warehouse software to manage inventory and maximise storage efficiency.

AS/RS solutions support operations with high inventory volume, limited space, labour challenges and/or the need to improve the speed and accuracy of order fulfillment. If your organisation experiences frequent picking errors, rising labour costs or space constraints, an AS/RS solution can provide measurable improvements in efficiency, throughput and storage density.

A FORTNA data-driven operational assessment can determine suitability.

The best-fit AS/RS solution depends on your product size, weight, order profiles and throughput demand.

AutoStore cube-based AS/RS is ideal for high-density and high-throughput, goods-to-person piece picking.

Unit-load systems are ideal for heavy inventory or pallet storage.

Mini-load systems work well for smaller totes or cases.

Shuttle systems provide high-speed, flexible retrieval for dense storage environments.

Vertical Lift modules (VLMs) or carousels are well-suited for small parts.

A FORTNA technology assessment can help identify the appropriate solution for your organisation.

ROI will vary but is often achieved within 2 to 5 years, depending on labour savings, space utilisation and productivity gain expectations. The initial capital investment can be significant, but long-term savings include reduced labour costs, enhanced space utilisation, fewer picking errors and increased throughput.

AS/RS solutions are highly modular and can scale as your business grows. You can expand storage aisles, add grid modules, add shuttles or lifts, or integrate additional picking zones as demand increases.