Designed to maximize the efficiency of any warehouse, cubic ASRS offers industry-leading storage density, picking accuracy and speeds, and reduced labor costs.
Also referred to as ‘grid-based ASRS’, ‘robotic cube storage’, ‘hive storage’ or ‘cASRS’, these systems consist of:
- A fixed structure: A sturdy, modular metal framework leveraging the vertical and horizontal space within a warehouse to its fullest potential, allowing for the storage of stock bins in an exceptionally dense, uniform manner
- Picking robots: Instead of using Storage Retrieval Machines (SRMs, common in pallet unit-load ASRS) or shuttles that move along rails between racks (used in shuttle ASRS), cubic ASRS employs multiple computer-controlled robots that navigate the top layer of the grid, picking items or bins. Removing the need for aisles or rails within the grid significantly increases storage density.
While cubic ASRS is just one type of automated storage and retrieval system, we believe it represents the pinnacle of ASRS technology—offering the highest throughput, densest storage and greatest scalability in a vast number of applications. That’s why we chose cubic ASRS for our own Ocado warehouses, now in operation worldwide.
What are the benefits of cubic ASRS?
Vertical storage density
Cubic ASRS maximizes warehouse space by utilizing the building's height, which is often underused in traditional storage. This efficient use of vertical space allows for much higher inventory capacity within the same or smaller footprint, reducing real estate costs and enhancing operational efficiency through quicker retrieval and better inventory management. OIA’s OSRS solution offers 4x better space utilization than manual racking and 2x better than a shuttle ASRS solution.
Reduced fixed costs
Storing more products within the same footprint can eliminate the need to purchase additional warehouse space, lowering associated fixed costs. Our OSRS solution goes a step further, enabling in-grid buffering of completed orders, reducing the need for external racking to store outbound bins and packages.
Enhanced scalability
The uniform nature of cubic ASRS means it can be easily expanded or reconfigured to accommodate changing inventory levels and product assortments, simply by adding more grid and/or more robots. This flexibility is particularly beneficial to businesses experiencing rapid growth or seasonal fluctuations in demand, enabling them to maintain operational efficiency and customer satisfaction.
No single point of failure (SPOF)
Because robotic cube storage is exactly that—a collection of lots of cubes and lots of robots—there is no single point of failure. If a robot or section of the grid encounters an unrecoverable issue, the rest of the grid is unaffected—keeping downtime at an all-time low. This is a significant differentiator between cubic ASRS and other types of ASRS such as shuttles, where a single robot malfunction can block access to entire sections of storage.
Safe and secure
Each bin in the cubic storage system is distinctly separated from the others, and the bin above acts as a natural lid—preventing access to the contents below while they are stored in the grid. It’s also stored far more safely than in traditional racking, reducing the risk of falling items to zero while stored in bins. This is especially important in seismic regions; OIA offers a seismic grid currently in use in Tokyo. We’ve also significantly raised the bar in fire safety and asset protection in launching our Metal Bins—the result of five years of research and testing.
Picking accuracy and speed
Cubic storage and retrieval systems are G2P (Goods-to-Person) systems that can quickly identify the optimal path to retrieve items, minimizing travel time and reducing the likelihood of picking errors. In Ocado’s own warehouses employing OSRS, high accuracy and reliability enables 99% of orders to be dispatched on time. And while a typical manual warehouse might achieve 220 units picked per hour (UPH) on a good day, our warehouses typically operate at around 450 UPH—a 104% uptick in productivity.
Data-driven approach
Due to their uniform structure, cubic ASRS grids lend themselves to the integration of sophisticated software and real-time data analytics. In fact, the software orchestrating the grid—and its use of real-time data—is often the greatest differentiator in throughput and overall efficiency. For instance, the OSRS warehouse execution system (WES) software dynamically adjusts the storage locations of high-demand items to minimize retrieval times based on real-time data from each robot, further enhancing operational efficiency. We call this revolutionary approach to warehouse slotting ‘smart putaway’.
Contributing to sustainability
By maximizing storage density and reducing the need for additional warehouse space, businesses can minimize their physical footprint and associated energy consumption. Furthermore, the automation and efficiency gains provided by cubic ASRS systems lead to lower energy usage and reduced waste. For example, robots in a cubic ASRS system consume significantly less energy than traditional forklifts, conveyors and other manual handling equipment. These sustainability benefits align with many of our customers’ corporate social responsibility goals.
Who uses cubic ASRS?
Cubic ASRS is growing in adoption across various industries beyond traditional retail and ecommerce. Sectors such as pharmaceuticals, automotive, and manufacturing are increasingly leveraging robotic cube storage to enhance their supply chain operations. Here are just some of the industries utilizing the unique benefits of cubic ASRS today:
Healthcare and Pharmaceuticals
Healthcare and pharmaceutical supply chains demand stringent capabilities for product integrity, temperature controls, and last-minute fulfillment—all while navigating ever-changing legislation and customer demand. Cubic ASRS offers an ideal solution for storing and processing pharmaceutical orders, organizations need to recognize that not all robotic cube storage solutions are the same; they’ll need one that provides the traceability and secure storage of high-value, misuse-prone or dangerous pharmaceuticals while meeting strict regulatory standards is key for healthcare brands.
Third Party Logistics (3PL)
Cubic ASRS systems, with their compact and highly scalable design, efficiently manage diverse inventory types, aiding 3PLs in optimizing operations and meeting client demands with precision. Their scalability allows cubic ASRS to adapt to both planned and unexpected changes in operational demand, and to expand as client needs evolve.
Fashion & Consumer Packaged Goods (CPG)
The increased storage density of cube-based storage enables both B2C and D2C fashion and CPG companies to stock a greater range of this season’s must-haves. Inventory is constantly optimized to facilitate rapid retrieval of the fastest moving items. This optimization occurs naturally in some robotic cube storage solutions, while OSRS uses smart putaway algorithms to ensure stock is always in its most reachable position. This enables CPG brands and distributors to meet both seasonal and unexpected surges in demand, reduce labor costs and streamline logistics for timely delivery of customer favorites.
Industrial & OEM Parts
Managing intricate industrial supply chains involving numerous suppliers, parts, and components demands precise inventory control and efficient logistics. Automotive manufacturers can use ASRS to manage a vast array of components and accessories, ensuring timely and accurate assembly or repair processes.
Grocery
With inventories spanning hundreds of thousands of SKUs, grocery companies need a storage system that can efficiently store and retrieve a wide variety of items. From cases of cola cans to frozen items and fragile perishables, items must be handled delicately and precisely, yet with the speed required of a high-throughput grocery operation. Cubic ASRS offers benefits such as First In, First Out (FIFO), ensuring perishable items are sold before their expiration dates—reducing waste and maximizing freshness. As you read this, Ocado cubic ASRS systems are fulfilling grocery orders all over the world.
What do I need to consider in replacing conventional racking with cubic ASRS?
The implementation of cube-based ASRS requires careful planning and coordination to ensure seamless integration with existing warehouse operations. Businesses must consider a number of factors, including:
Cubic ASRS installations vary widely in size, component count, and building requirements, and can take some time to specify, manufacture and assemble.
Typically, OIA completes an OSRS project from contract to handover in 9-18 months.
This should be factored into your automation plans; we offer our Chuck AMR solution as a plug-and-play stop-gap while the cubic ASRS is being constructed.
A clear limitation of cubic ASRS compared to traditional racking is in the size and weight of stock stored within each bin, which is significantly less than a pallet.
Within OSRS, bins have a maximum payload capacity of 30kg, while stock cannot exceed 60cm along its longest side. Companies looking to exclusively store heavy, palletized items may wish to explore alternatives—such as unit-load ASRS.
Denser storage is naturally heavier, and the vertical columns of the grid present some large point loads.
The concrete floor slab (and ground beneath it) must be capable of meeting the calculated weight of a full grid. Similarly, due to the uniform nature of the grid structure, cubic ASRS has specific tolerances for level and flatness.
OIA recommends a minimum slab thickness of 200mm.
Cubic ASRS generally enables far higher construction than more traditional racking methods.
OSRS, for example, can be stacked up to 21 bins high— which would require a 10.5m (34.4ft) ceiling height. This must be maintained across the entire building and is measured from the floor slab to the underside of the warehouse eaves (including haunches).
Of course, a lower ceiling height is entirely possible, though it means fewer bins can be stacked vertically.
The individual elements of a cubic ASRS system have varying power requirements. While the grid framework itself is generally unpowered, charging solutions for robot batteries and other auxiliary systems such as sensors and cameras require a robust power supply.
Similarly, reliable data communications should be considered, especially in the case of robotic cube storage solutions such as OSRS which require a constant, resilient connection to the cloud.
It’s also important to consider that not all ASRS solutions are created equal.
Alongside the benefits we’ve listed above (the increased fire protection offered by our Metal Bins, and the unique software benefits of smart putaway and in-grid buffering), OSRS is also the only single-cell robot solution on the market.
This greatly reduces the effort required for robots to pass each other uninterrupted.
Cubic ASRS enables businesses to meet growing customer demands
Cubic ASRS represents a transformative approach to warehouse management and logistics, offering unparalleled advantages in storage density, efficiency, and flexibility. By leveraging vertical space and advanced automation technology, businesses can significantly enhance their operational capabilities and meet the growing demands of their customers.
While it’s important to recognize the initial investment and implementation considerations involved with adopting cubic ASRS, the long-term benefits make them a compelling choice for businesses seeking to maximize warehouse throughput and future-proof their fulfillment operations.
If you’d like to learn more about what makes OIA’s OSRS such a groundbreaking cubic ASRS solution, please get in touch.
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