Automated Storage and Retrieval Systems

WHAT IS AN AUTOMATED STORAGE AND RETRIEVAL SYSTEM (AS/RS)?

Automated Storage and Retrieval Systems, also known as AS/RS, is a broad category of warehouse automations. Most AS/RS are used in GTP (Goods-to-Person) environments, where operators remain in one location, and technology and machines bring them the items that they need.

STORAGE & RETRIEVAL

AS/RS systems are built to automate two core functions: storing inventory efficiently and retrieving it on demand.

	WHAT IT DOES	WHY IT MATTERS
STORAGE	Stores inventory in a dense, organized structure at any stage of fulfillment (including buffer storage for WIP, partial orders, or completed orders).	Increases capacity, improves organization, and helps maintain control until the next process step is ready.
RETRIEVAL	Automatically retrieves the required tote, tray, case, or pallet and routes it to a workstation, conveyor, packing area, or downstream automation.	Reduces manual picking labor and travel, while improving throughput, accuracy, and batching/sequencing efficiency.

ENGINEERING THE RIGHT AS/RS STRATEGY FOR YOUR OPERATION

Implementing AS/RS isn’t just a technology choice; it’s a redesign of how your warehouse stores, sequences, and delivers inventory. The wrong configuration can limit throughput, reduce flexibility, or inflate total cost.

Maveneer designs vendor-agnostic AS/RS solutions based on your SKU velocity, order profiles, facility constraints, and WMS/WES architecture. From modeling and simulation to systems integration, we build the right automation backbone, whether that’s unit-load, mini-load, shuttles, VLMs, AMRs, or a hybrid approach.

The result is higher density, faster retrieval, and a system that scales with demand.

HOW AS/RS WORKS (STEP-BY-STEP)

An Automated Storage and Retrieval System combines software, storage structures, and automated handling equipment to move inventory efficiently from storage to fulfillment. A typical AS/RS workflow follows these steps:

Inventory Induction. Products are received, scanned, and assigned a storage location within the AS/RS structure based on size, velocity, and system logic.
System-Directed Storage. Cranes, shuttles, robots, or lifts automatically place the inventory into high-density racking or tray systems, updating the WMS in real time.
Order Release. When an order is triggered, the WMS/WES determines the optimal retrieval sequence based on priority, batching rules, and downstream capacity.
Automated Retrieval. The AS/RS equipment locates and retrieves the required tote, tray, case, or pallet without manual travel.
Delivery to Workstation or Conveyor – Retrieved inventory is delivered to a picking station, conveyor system, or downstream automation for processing.
Inventory Update & Return. Remaining inventory is automatically returned to storage, and system data is updated to maintain accurate, real-time inventory visibility.

By eliminating manual travel and standardizing storage logic, AS/RS systems increase throughput, improve accuracy, and maximize warehouse density.

Best for: High-density pallet or tote storage

Handles: Full pallets (unit-load) or totes/bins (mini-load)

Why it’s used: Computer-controlled cranes automatically store and retrieve loads from high-bay racking, making this ideal for large facilities that require high throughput and vertical space optimization.

Best for: High-throughput pallet storage

Handles: Pallets

Why it’s used: Robotic shuttles move pallets quickly across multiple rack levels, increasing storage density and reducing manual handling in high-volume environments.

Best for: Small parts and high-value inventory

Handles: Trays

Why it’s used: Enclosed vertical systems deliver trays directly to operators at ergonomic picking windows, maximizing vertical space in compact footprints.

Best for: High-mix, smaller-item storage

Handles: Shelved SKUs

Why it’s used: Rotating shelves bring inventory directly to the operator, improving picking accuracy and reducing walking distance in moderate-volume environments.

Best for: Flexible, modular deployments

Handles: Totes, carts, pallets (depending on system)

Why it’s used: AMRs navigate autonomously without fixed infrastructure, making them ideal for facilities that require scalable automation without major structural changes.

Best for: Heavy or bulky inventory

Handles: Stacked crates or pallets

Why it’s used: Ceiling-mounted gantries transport loads above the floor, improving safety and freeing valuable warehouse space.

HOW ARE AUTOMATED STORAGE & RETRIEVAL SYSTEMS USED?

COMMON APPLICATIONS

AS/RS are used as buffer storage, meaning they’re used to store individual products, partially packed shipping orders, completed orders, or parts until they’re ready to be shipped or to move to the next part of the process. This allows for continuous order fulfillment, even when operators aren’t able to ship products or complete assembly from start to finish.

Secure/Controlled Storage Environment: AS/RS are often used for sensitive material that needs to be stored securely, or needs to be stored under specific circumstances. Because they utilize vertical space, AS/RS are able to store inventory securely and out of reach with safeguards on the WMS. The environments inside closed storage units like VLMs or vertical carousels are also able to be closely controlled and monitored for factors like humidity or temperature, making them ideal for a variety of uses, like the pharmaceutical industry.

COMMON INDUSTRIES

Some form of automated storage and retrieval systems are used in most industries. Some of the most common industries where AS/RS is used are:

Automotive
Chemical
eCommerce and Retail
Manufacturing
Mechanics & Parts
Pharmaceutical
Third-Party Logistics
Warehouse and Distribution

REAL-WORLD AS/RS-DRIVEN CAPACITY EXPANSION: CANADIAN TIRE

Canadian Tire partnered with Maveneer to expand distribution capacity and improve service levels while operating near full facility utilization and managing rapid SKU and volume growth.
Challenge: Distribution centers were approaching capacity, with increasing SKU counts, rising outbound volume, and labor-intensive picking processes limiting throughput.
Solution: Implemented high-density storage strategies including AutoStore GTP automation and very narrow aisle racking, combined with a phased retrofit approach to increase capacity without disrupting ongoing operations.

Results:

+50% increase in SKU capacity
+36% increase in outbound volume capacity
Avoided $2M in annual labor costs and $50M in transportation costs
Enabled scalable growth without expanding facility footprint

AS/RS can be very expensive. They take extensive infrastructure to implement and an effort to maintain. AS/RS must be integrated with existing warehouse technology (WMS). Operators will need initial training, as well as continual updates and assessments to make sure they are using the systems correctly. However, the return is worth the investment for most facilities.

Some benefits of AS/RS include:

Reduced Floor Space: AS/RS optimizes vertical space, allowing more storage in less floor area and reducing the need for additional real estate.
Increased Efficiency: Automated picking reduces manual labor, speeds up retrieval times, and decreases human error, leading to higher throughput and lower labor costs.
Improved Accuracy: Automation ensures precise picking, reducing mistakes and returns, which improves customer satisfaction and operational efficiency.
Higher Throughput: With faster, automated systems, AS/RS can handle high volumes of products quickly, increasing capacity and meeting growing demand.
Customizable Design: AS/RS systems are flexible and can be tailored to fit various warehouse layouts, making them suitable for different industries and operational needs.
Safety: By reducing manual handling, AS/RS systems minimize the risk of workplace injuries, creating a safer work environment.
Scalability: AS/RS systems are easily adaptable and can grow with your business, accommodating changes in product types, inventory volume, or warehouse layout.

If you’re experiencing any of the challenges below, an Automated Storage and Retrieval System may be worth evaluating. AS/RS is often the right fit when operational constraints are limiting growth, service levels, or efficiency.

Signs You Should Consider AS/RS:

You’re running out of floor space. Your inventory footprint is expanding faster than your facility can support, and adding racking or expanding the building isn’t a practical option.
Order accuracy is slipping. Picking errors, mis-slots, and inventory discrepancies are increasing, especially during peak periods or when onboarding new labor.
Labor costs are rising or are hard to control. Overtime is becoming routine, productivity depends on walking and manual travel, or labor costs are climbing faster than volume.
Throughput can’t keep up with demand. You’re hitting capacity limits during daily operations or peak season, and your current process can’t scale without adding headcount.
Labor availability is constrained. Hiring and retaining warehouse labor is difficult, and operational performance is increasingly impacted by turnover or staffing shortages.

QUICK RULE OF THUMB

If your operation is constrained by space, labor, or throughput, AS/RS can often unlock performance without linear growth in labor or footprint.

AUTOMATED STORAGE AND RETRIEVAL SYSTEMS

WHAT IS AN AUTOMATED STORAGE AND RETRIEVAL SYSTEM (AS/RS)?

STORAGE & RETRIEVAL

WHAT IT DOES

WHY IT MATTERS

STORAGE

RETRIEVAL

ENGINEERING THE RIGHT AS/RS STRATEGY FOR YOUR OPERATION

HOW AS/RS WORKS (STEP-BY-STEP)

TYPES OF AUTOMATED STORAGE & RETRIEVAL SYSTEMS

HOW ARE AUTOMATED STORAGE & RETRIEVAL SYSTEMS USED?

COMMON APPLICATIONS

COMMON INDUSTRIES

REAL-WORLD AS/RS-DRIVEN CAPACITY EXPANSION: CANADIAN TIRE

BENEFITS OF AUTOMATED STORAGE & RETRIEVAL SYSTEMS

IS AN AS/RS RIGHT FOR YOUR FACILITY?

QUICK RULE OF THUMB

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