AutoStore is a robotic cube-based ASRS that employs a grid-based system where robots move on top of a storage grid and drop down within the grid columns to access and pick-up bins that are stacked directly on top of one another.
If you're not familiar with AutoStore, here's a deep dive on how AutoStore works.
Traditional shuttle systems such as case shuttles and multi-shuttles use aisles with shuttles running horizontally to retrieve cartons, bins, trays, or a combination of all.
The case shuttle system is adept at accommodating cases and larger products efficiently.
In buildings with clear heights less than 40 feet, it may struggle to match the density of AutoStore due to AutoStore bins stacking directly atop each other, eliminating air gaps. However, in structures exceeding 40 feet in height, the case shuttle excels in density, surpassing AutoStore.
While case shuttle systems provide pretty good density compared to other technologies, they require a significant investment in light goods conveyors in addition to the multi-shuttle system. It's important to note that despite their high throughput, multi-shuttle systems may require in-rack sprinkler systems per fire regulations, which can impact the overall space utilization of the system.
Case shuttle systems traditionally boast higher throughput rates, however, recent technological advancements from AutoStore (i.e. AutoCase, CarouselAI) and Kardex (i.e Kardex FulfillX, Intuitive Picking Assistant) have closed this throughput gap. In fact, in a recent AutoStore project, Kardex achieved 13,100 bin presentations per hour.
Watch the AutoStore case study featuring 13,000 bin presentations per hour.
As a result, businesses evaluating warehouse automation solutions now find themselves with a more balanced choice between the two systems, where considerations beyond throughput, such as space utilization and system flexibility, may play a more significant role in decision-making.
Operator speed is usually what limits throughput.
Your storage system can deliver bins incredibly fast, but humans can only pick so quickly. In the end, operator performance becomes the great equalizer across all automated storage and retrieval systems.
In workflows where the pick task is extremely simple and fast (typically under 7 seconds per pick) operators may pick slightly faster out of a shuttle than AutoStore. However, AutoStore paired with Kardex technologies like the Intuitive Picking Assistant. (IPA) helps speed up operator performance, ensuring consistently high throughput even in demanding environments.
Ryan Reed
Senior Logistics Consultant, Kardex
AutoStore offers an advantage in maximizing storage density and efficiency for facilities dealing with a high volume of small SKUs.
Additionally, Kardex can combine AutoStore with an existing Kardex Vertical Lift Module (VLM), all controlled through a single software platform. This hybrid approach allows operations to store both small parts (in AutoStore) and large, bulky items (in a Kardex VLM) within one unified system and workflow. It creates a more flexible storage ecosystem without forcing you to choose between technologies.
While case shuttle systems can handle a wider variety of product sizes, including large and bulky items, AutoStore's reliance on standardized bin optimizes space utilization and simplifies inventory management. This design allows AutoStore to achieve significantly higher storage capacity within a compact footprint.
In an AutoStore system, if any single robot or port encounters a malfunction, the rest of the system remains operational, ensuring uninterrupted warehouse operations. Conversely, in a case shuttle system, if an aisle goes down due to maintenance or repair any aspect of that aisle (ie., shuttle), all inventory within that aisle becomes inaccessible until the issue is resolved.
To mitigate this risk, case shuttle systems require inventory to be mirrored across multiple aisles, necessitating the duplication of stock to safeguard against disruptions in accessibility. This mitigation technique requires more storage locations, means more equipment costs and more floorspace.
Conversely, AutoStore eliminates the need for mirrored inventory, offering a more streamlined and efficient solution for maintaining reliability and minimizing downtime within warehouse operations. Inventory is able to be transported by any robot within the AutoStore system and be delivered to any port, meaning full redundancy of the system without the need for additional storage locations for mirrored inventory.
Simply put, AutoStore excels in buildings under 40 feet with high storage density due to vertically stacked bins, while case shuttles perform better in buildings that are taller than 40 feet. Case shuttles and AutoStore offer roughly the same throughput rates. AutoStore’s design minimizes downtime, costs, and space requirements.
For most facilities, AutoStore offers a stronger return on investment. Its lower implementation costs, high throughput, superior density, and built-in redundancy make it a cost-effective solution for operations seeking speed without the heavier infrastructure requirements of shuttle systems.
Here's everything you need to know about how much AutoStore costs.
However, in ultra-high throughput scenarios with simple pick tasks, shuttle systems can offer a faster payback period despite their higher initial investment. The enhanced efficiency and productivity of shuttle systems in handling large volumes of orders quickly can lead to significant operational savings and revenue generation, thereby offsetting the initial costs more rapidly.
The total cost of ownership (TCO) of robotic automated storage and retrieval systems (ASRS) includes several factors beyond the initial purchase price. Key factors that play into the TCO are:
When deciding between implementing an AutoStore system or a case shuttle system in your warehouse facility, consider all of the following factors:
When recommending AutoStore over shuttle systems, industries or warehouse scenarios with medium throughput and a focus on handling smaller parts are ideal candidates.
AutoStore excels in efficiently managing inventory with medium to very high throughput levels, making it well-suited for order fulfillment of light industrial manufacturing components, hardware pieces, plumbing supplies, sensors, electrical components, and items of similar size.
Any sector that requires the kitting and assembly of small parts can benefit from AutoStore's precision and organization. Conversely, shuttle systems may be more appropriate for industries dealing with larger items or requiring very high throughput, where the size and weight of products demand a different approach to storage and retrieval.
Above are some factors to consider, however each business case is unique and has special requirements.
To better understand the differences between AutoStore and other shuttle systems, contact an automation expert.