Common Automated Storage and Retrieval System Mistakes and How to Avoid Them

Common Automated Storage and Retrieval System Mistakes and How to Avoid Them

Overview

Automated Storage and Retrieval Systems (AS/RS) deliver substantial benefits but are complex systems combining mechanical, electrical, and software elements. Mistakes during selection, implementation, and operation can erode ROI and introduce operational risk. This guide details common mistakes and practical strategies to avoid them.

Mistake 1 — Inadequate SKU and throughput analysis

Prematurely selecting a system without deep SKU velocity and variability analysis often leads to mismatched capacity or poor performance. For example, investing in a high-density shuttle system optimized for tote storage may not be cost-effective if the SKU base contains many oversized or irregular items.

Avoidance

Perform ABC/XYZ profiling, measure peak and average throughput requirements, and model scenarios with seasonal peaks. Use discrete-event simulation to validate that the selected AS/RS can meet required cycle times.

Mistake 2 — Choosing the wrong AS/RS type

Selecting an AS/RS based on vendor preference or price rather than operational fit causes long-term inefficiencies. Unit-load cranes are powerful for pallet storage but overkill for small-parts distribution; VLMs are compact but limited for high-velocity omnichannel picks.

Avoidance

Map use cases to system strengths. Consider hybrid approaches where different AS/RS types serve distinct SKU clusters and integrate through buffers and conveyors.

Mistake 3 — Weak integration with WMS/ERP

An AS/RS without robust WMS integration leads to inventory discrepancies, order delays, and inability to leverage advanced slotting or replenishment logic.

Avoidance

Define integration interfaces early, perform end-to-end tests (including exception scenarios), and establish clear data ownership and reconciliation processes. Ensure middleware supports retries, message queuing, and priority handling during peaks.

Mistake 4 — Overlooking maintainability and spare parts

Failing to plan preventive maintenance and spare-part inventories increases downtime and repair lead times. Critical components like motors, controllers, or shuttle batteries can become single points of failure.

Avoidance

Implement a preventive maintenance program informed by vendor recommendations and system telemetry. Stock critical spares on site and establish SLAs with vendors for urgent support calls.

Mistake 5 — Underestimating change management and training needs

Operators and maintenance staff unfamiliar with AS/RS workflows or diagnostics can inadvertently cause slowdowns or unsafe conditions.

Avoidance

Provide role-based training, hands-on sessions, and clear SOPs for normal operations and exceptions. Create escalation paths and quick-reference guides for first-line troubleshooting.

Mistake 6 — Ignoring building and regulatory constraints

Many projects run into issues with floor loading, fire suppression requirements, or egress when installing high-bay AS/RS. Retrofitting solutions post-approval is costly and time-consuming.

Avoidance

Evaluate structural, HVAC, and fire protection impacts early. Engage architects and local authorities in preliminary reviews and obtain required permits before procurement commitments.

Mistake 7 — Poor slotting and replenishment rules

Static slotting that ignores demand changes creates bottlenecks. Overconcentration of fast movers can saturate a single aisle or retrieval machine.

Avoidance

Use dynamic slotting based on velocity and seasonality. Implement replenishment thresholds and balance loads across lanes to prevent hot spots.

Mistake 8 — Unrealistic ROI and payback expectations

Overly optimistic ROI assumptions (ignoring integration costs, training, and change management) can result in disappointing financial outcomes.

Avoidance

Conduct thorough TCO and ROI modeling that includes capital, integration, consulting, and recurring maintenance costs. Stress-test models with different demand scenarios.

Mistake 9 — Neglecting safety and ergonomics

Automation does not eliminate safety responsibilities. Poorly defined pedestrian exclusion zones, inadequate lockout/tagout procedures, or ergonomic neglect at operator workstations create hazards and reduce productivity.

Avoidance

Implement comprehensive safety assessments, clear signage, interlocks, and ergonomic workstation design. Train staff on emergency procedures and maintain compliance documentation.

Mistake 10 — Failing to plan for scalability and future change

Building a system that meets today’s needs but lacks modular expansion paths forces costly retrofits as demand grows or product ranges change.

Avoidance

Select modular AS/RS architectures (e.g., shuttle-based lanes) where possible, and design infrastructure (power, network, space) with headroom for future expansions.

Practical remediation and governance

If you encounter these problems mid-project, establish a governance board with cross-functional stakeholders to prioritize remediation, re-baseline KPIs, and coordinate vendor support. Run targeted pilots to validate corrective actions before full rollouts.

Example cautionary tale

A retailer implemented a high-density AS/RS without integrated WMS logic for order sequencing. The site experienced order delays during peak season because replenishment buffers were not synchronized with outbound waves. The retailer mitigated the issue by implementing middleware for real-time queue management and revising wave planning rules, restoring throughput targets within two months.

Conclusion

Avoiding these common mistakes requires rigorous analysis, realistic planning, strong integration governance, and investment in people and maintenance. With proper foresight and disciplined execution, an Automated Storage and Retrieval System becomes a resilient platform that drives efficiency, accuracy, and scalable capacity.