Mobile AS/RS
A Fully Automated Solution
What Is Mobile AS/RS?
Mobile Automated Storage and Retrieval Systems (AS/RS) are advanced automated solutions designed to improve warehouse efficiency and optimize space utilization. Unlike traditional automated storage systems, mobile AS/RS use unconstrained automated shuttles or vehicles to navigate throughout a storage system. These systems decouple storage, throughput and picking operations to provide independent scalability and redundancy based on operational needs.
By leveraging roaming robots to store and retrieve loads these systems provide the flexibility to dispatch vehicles anywhere within the system. This flexibility leads to better equipment utilization compared to traditional aisle-restricted systems, resulting in lower system costs and a higher return on investment
How Mobile AS/RS Works
Mobile AS/RS uses robotic vehicles to travel through a storage structure, retrieve inventory, and deliver it to workstations, conveyors, pallet positions, or picking zones. The system separates three major functions:
- Storage capacity, how much inventory the system can hold
- Throughput, how many loads, cases, totes, or orders the system can process
- Picking operations, how inventory is presented to people or automation
Because these functions can scale independently, facilities can add robots, storage positions, or workstations as demand changes.
Mobile AS/RS vs. Traditional AS/RS vs. Manual Storage & Retrieval
| Category | Mobile AS/RS | Traditional AS/RS | Manual Storage & Retrieval |
|---|---|---|---|
| Movement style | Uses roaming robots, shuttles, or automated vehicles | Uses fixed cranes, aisle-based shuttles, or dedicated equipment paths | Relies on forklifts, pallet jacks, or workers walking to retrieve inventory |
| System flexibility | Robots can be dispatched throughout the system | Equipment is often tied to specific aisles or zones | Fully flexible, but flexibility depends entirely on available labor |
| Redundancy | High redundancy because multiple robots can access inventory | Redundancy depends on crane, aisle, or shuttle configuration | Low redundancy; retrieval speed is limited by staffing and shift coverage |
| Scalability | Storage, throughput, and workstations can scale independently | Scaling often requires larger structural or equipment changes | Scaling typically means hiring more labor, which adds cost and training time |
| Layout adaptability | Strong fit for irregular layouts, brownfield sites, and space-constrained facilities | Best suited for layouts designed around fixed automation infrastructure | Adaptable to almost any layout, but travel distance directly impacts efficiency |
| Storage density | Supports deep storage and compact footprints | Can achieve high density, but often with more rigid system design | Lower density, since aisles must accommodate people and equipment |
| Best fit | Operations needing flexibility, phased growth, and adaptable automation | Operations with highly predictable flows, high vertical clearance, or fixed high-volume requirements | Lower-volume operations, highly variable SKUs, or facilities not yet ready for automation investment |
Benefits & Applications
The operational redundancy and storage density that mobile AS/RS provide makes this technology very attractive to support various use cases. In addition, since the technology does not require high ceiling clearance, it is well-suited for brownfield, as well as greenfield applications.
Operational Redundancy
By utilizing mobile AS/RS technology, operational downtime is mitigated through the ability of each roaming robot to access all of the loads in a system and provides high redundancy.
Scalability
Mobile AS/RS systems are designed to scale storage capacity, throughput, and the number of workstations independently, allowing tailored growth based on operational needs and makes investments future-proof.
Labor Savings
By automating the storage and retrieval of items mobile AS/RS technology reduces the labor associated with travel and provides more efficient picking operations.
Storage Density
By leveraging multiple roaming robots to maintain item delivery responsiveness mobile AS/RS systems are able to leverage deep storage density to minimize the space required for storage.
Layout Flexibility
With the flexibility of vehicle travel paths and racking design, this technology can adapt to various layout restrictions and shapes to maximize space utilization.
Tailored For Full Pallet and Goods to Person Picking
Pallet Mobile AS/RS
Automated storage of pallets and other standard unit load carriers has traditionally been accomplished using stacker cranes. While this technology remains a preferred solution for many applications, mobile AS/RS offers distinct advantages in the right scenarios—such as the decoupling of storage and throughput in system design and vehicle redundancy.
The two primary technologies for automated pallet mobile AS/RS are:
· Multi-Dimensional Shuttle Systems
· Automated Very Narrow Aisle (AutoVNA) Systems
Multi-Dimensional Shuttle Systems
Multi-Dimensional Shuttle Systems utilize deep lane storage to achieve high storage density. They rely on sophisticated software to synchronize vehicle movements, enabling high throughput. These systems are particularly valued for their design flexibility and scalability, making them adaptable to a wide range of operational needs.
AutoVNA Systems
AutoVNA systems offer the traditional benefits of manual VNA setups, including high storage density due to narrow aisles and single-deep storage selectivity. The Jungheinrich AutoVNA system is the perfect aisle-changer and can go up to 40 ft. These vehicles are powered via busbars located within the storage aisles, allowing for continuous charging and uninterrupted operation.
Tailored For Case and Each Picking
Tote Mobile AS/RS
Automated storage of totes and cases has traditionally been accomplished using stacker cranes and dedicated aisle shuttles. While this technology remains a preferred solution for many applications, mobile AS/RS offers distinct advantages in the right scenarios—such as the decoupling of storage and throughput in system design and vehicle redundancy.
The two primary technologies for automated mini load mobile AS/RS are:
· High Reach & Transport (HRT) Systems
· Climber Systems
High Reach & Transport (HRT) Systems
HRT Systems leverage a combination of high reach automated mobile robots (AMRs) and low profile transport AMRs. By leverage high reach AMRs to storage and retrieve items from the shelving and transport AMRs to deliver items to workstations, these systems are able to provide very economical solutions in case and each picking applications.
Climber Systems
Climber Systems use a robust automated mobile robots (AMR) that both transports items to racking, as well as, climbs the racking to storage/retrieve items. These systems are well suited for higher throughput applications that require the travel path flexibility that can be achieved with climber AMRs.
Our Tailored Solutions
HaiPick Systems
Hai Robotics
Modular & scalable automated storage and retrieval solutions designed to enhance warehouse efficiency through advanced robotics. The core components include Autonomous Case-handling Mobile Robots (ACRs) and Autonomous Mobile Robots (AMRs). These systems are engineered to integrate seamlessly with existing Warehouse Management Systems (WMS) or Warehouse Execution Systems (WES), facilitating smooth operations and rapid deployment.
HaiPick offers three distinct system configurations to address various operational needs:
-System 1: Ideal for high-density vertical storage.
-System 2: Combines ACRs with Heavy-Duty Companion AMRs to handle both bulk and palletized goods alongside totes.
-System 3: This system achieves ultra-high storage density, accommodating up to 43 totes per square meter, and is designed for rapid order fulfillment in high-throughput environments.
Each HaiPick system is tailored to meet specific operational requirements, offering flexibility and scalability to optimize warehouse performance.
Automated Very Narrow Aisle Solution
Jungheinrich AutoVNA
Jungheinrich’s Automated VNA Storage systems are designed to enable extremely efficient and dense warehousing in constrained spaces. Their EKXa trucks are built specifically for VNA environments, allowing safe and reliable storage and retrieval of pallets at heights up to about 13,000 mm and with load capacities up to around 1,600 kg. The systems can be installed in entirely new warehouses or retrofitted into existing narrow-aisle racking, using features like pallet detection, clearance sensing, and 360° safety systems to ensure safety and precision.
These systems also include flexibility in how they’re deployed: they can work in “open” systems (with pedestrian access, but with rigorous safety systems in place) or in more enclosed setups. Integration with higher-level control software ensures smooth routing, order management, and process tracking. Through use of wire guidance, RFID or inductive technology, and seamless warehouse-control integration, Jungheinrich aims for high reliability, minimal empty runs, and strong safety performance.
Movu Atlas For Pallet AS/RS
Movu Robotics
The Movu Atlas Pallet Shuttle is a high-density Automated Storage and Retrieval System (AS/RS) designed to optimize warehouse space and streamline pallet handling. Utilizing self-powered robotic shuttles, the system transports pallets weighing up to 3,307 lbs (1,500 kg) within deep storage lanes of multi-level racking systems. By minimizing the need for wide driving aisles, the Atlas system maximizes vertical storage, achieving heights up to 150 feet (45 meters)
Mobile AS/RS In Motion
Watch this video to see a prime example of how mobile as/rs can enhance efficiency in a warehouse or fulfillment center. For personalized advice, contact us for a consultation to discover the most suitable solution for your business.
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Life Cycle Services
It takes expertise in technology and processes to optimize and implement automation into a facility’s operations – the same is required for the maintenance and optimization of those systems. With our extensive industry knowledge and diagnostic approach, we offer services to meet your unique needs, ensuring that your automated storage and retrieval system remains a strategic asset throughout its entire life cycle. Discover how our end-to-end solutions can revolutionize your warehousing operations and drive sustainable growth.
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Frequently Asked Questions
How is Mobile AS/RS different from traditional AS/RS?
Traditional AS/RS often uses fixed cranes or aisle-based shuttles. Mobile AS/RS uses roaming robots or automated vehicles that can move more flexibly through a storage system. This can improve redundancy, equipment utilization, scalability, and layout flexibility.
How does Mobile AS/RS compare to manual storage and retrieval?
Manual storage and retrieval relies on workers using forklifts or pallet jacks to move and retrieve inventory, which means speed and consistency depend on staffing levels and shift coverage. Mobile AS/RS automates this process with roaming robots, which can improve retrieval speed, storage density, and scalability while reducing the labor required to move inventory throughout the facility.
What are the main benefits of Mobile AS/RS?
The main benefits of Mobile AS/RS include higher storage density, reduced labor travel, improved operational redundancy, flexible layouts, scalable throughput, and better support for goods-to-person picking.
Can Mobile AS/RS work in an existing warehouse?
Yes. Mobile AS/RS can be a strong option for brownfield facilities because it does not always require high ceiling clearance or a fully redesigned building layout. Its flexible vehicle paths and modular design can help adapt automation to existing constraints.
What types of inventory can Mobile AS/RS handle?
Mobile AS/RS can handle pallets, totes, cases, cartons, and each-pick inventory depending on the system design. Pallet Mobile AS/RS is used for unit loads, while Tote Mobile AS/RS supports case, carton, and individual applications.
What is Pallet Mobile AS/RS?
Pallet Mobile AS/RS is a robotic storage and retrieval system for pallets or unit loads. It can use multi-dimensional shuttle systems or automated very narrow aisle systems to improve dense storage, retrieval efficiency, and system redundancy.
What is Tote Mobile AS/RS?
Tote Mobile AS/RS is an automated system for storing and retrieving totes, cartons, cases, or smaller inventory units. It is commonly used in goods-to-person picking, ecommerce fulfillment, retail distribution, and high-SKU environments.
What are Multi-Dimensional Shuttle Systems?
Multi-Dimensional Shuttle Systems use robotic shuttles that move through deep-lane storage systems to store and retrieve inventory. They are often used for dense storage and scalable throughput in pallet or unit load applications.
What are High Reach & Transport Systems?
High Reach & Transport Systems use high-reach automated mobile robots to retrieve goods from shelving and lower-profile transport robots to move inventory to workstations. This design can support cost-effective case and each picking.
How does Mobile AS/RS improve labor efficiency?
Mobile AS/RS reduces the need for workers to travel long distances to find, pick, or move inventory. Instead, robots retrieve goods and bring them to workstations, allowing labor to focus on higher-value picking, packing, replenishment, and exception handling.
Is Mobile AS/RS scalable?
Yes. Mobile AS/RS is designed to scale storage capacity, throughput, and workstations independently. Facilities can add robots, expand storage, or increase workstation capacity as operational demand grows.
What software does Mobile AS/RS require?
Mobile AS/RS typically requires integration with warehouse software such as a Warehouse Management System, Warehouse Execution System, or Warehouse Control System. These systems coordinate inventory data, task execution, robot movement, and workstation activity.