ASRS Goods-to-Person for High-Volume E-commerce Fulfilment
Illustrative scenario based on real deployment patterns. Not sourced from a specific company.
Warehouse Profile
- Warehouse size
- 7,500 sqm
- SKU count
- 35,000+
- Daily orders
- 2,000–3,500 per day
- Deployment type
- Brownfield or greenfield
The Situation
Manual picking cannot scale with order volume growth. Storage is at capacity. Pickers walk over 6 km per shift with low productive time. Error rates drive costly returns. Adding headcount produces diminishing returns due to aisle congestion and coordination overhead.
Automation Approach
A 3D grid-based ASRS brings storage bins to picking stations on demand. Robots retrieve the relevant bin; pickers select the correct item without moving from their station. The grid occupies 40–60% of the floor area but achieves extreme vertical utilisation, creating far more storage capacity than conventional racking in the same footprint.
Expected Outcomes
- 3–5x picking throughput per workstation versus manual picking
- 40–60% increase in storage density within the same floor area
- Picking accuracy above 99.5% — systematic error elimination
- Order volume can double without additional floor space
Is This Scenario Right for You?
- Deployment
- Brownfield viable with minimum 5m clear ceiling height
- WMS requirement
- Essential — deep integration required for slot management
- Budget range
- EUR 2M–5M
- Implementation
- 12–18 months
- Minimum volume
- 1,500+ daily orders for ROI justification at this scale
Relevant Vendor Types
AutoStore, Exotec (Skypod), KNAPP (OSR Shuttle).
Browse the Supplier Discussion GuideFrequently Asked Questions
What ceiling height is required for a grid-based ASRS?
Most grid-based systems (AutoStore, Exotec Skypod) require a minimum 4.5–5.5m clear ceiling height for economic viability. Higher ceilings (up to 10m or more) increase storage density further. The exact requirement depends on the number of grid levels specified. Some systems offer a lower-profile variant for constrained environments.
How does AutoStore compare to Exotec Skypod?
AutoStore uses robots that travel on top of a dense aluminum grid, retrieving bins from below. Exotec Skypod uses robots that climb vertical structures to retrieve bins from any height. AutoStore typically achieves higher storage density per sqm; Exotec can offer higher single-robot throughput. Both suit high-volume, high-SKU environments but have different footprint and throughput profiles.
What minimum daily order volume justifies a goods-to-person ASRS?
For B2C e-commerce, the economics typically become compelling at 1,500–2,500 orders per day. Below this threshold, a well-designed manual or semi-automated picking system may offer better ROI. For B2B with large-case picks, the threshold is lower due to higher labour cost per pick.
Readiness Considerations
- WMS must be capable of deep ASRS integration including slot management, goods-receipt routing, and picking station orchestration.
- Minimum 5m clear ceiling height required. Confirm actual available height including lighting, sprinklers, and HVAC obstructions.
- Daily order volume should be 1,500 or above for the investment to recover within a reasonable timeframe.
Supplier Questions to Ask
- QWhat is the throughput guarantee per picking station for our order profile and SKU mix?
- QWhat WMS integration interfaces are required and what does our IT team need to provide?
- QHow does the system handle peak periods above the baseline throughput design?
- QWhat is the path to capacity expansion if order volume grows by 30 to 50 percent?
Assumptions to Validate
- Current and projected order volumes. Verify 3-year growth assumptions before sizing the system.
- Picks per hour per station at your actual average items per order, not vendor reference site averages.
- Full integration and implementation timeline including WMS readiness, site preparation, and commissioning.
- Total cost of ownership including maintenance, spare parts, and software licence fees over 5 to 7 years.
When This May Not Be the Right Time
- Current order volume is below 1,500 per day. A well-designed manual or semi-automated picking system may offer better ROI.
- Clear ceiling height is below 5m without a confirmed brownfield workaround.
- WMS is not ready for ASRS integration or is scheduled for replacement.
Related Scenarios
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