Warehouse Automation Storage & Retrieval System (ASRS)

Customer Requirements

Seamless integration with the Automation Storage & Retrieval System (ASRS) was paramount as the client sought automated solutions to streamline warehouse operations, improve stock management accuracy, and elevate safety standards.



The client, a prominent distributor in the logistics industry, faced significant operational challenges in their existing warehouse facility. The lack of organisation and haphazard arrangement of pallets resulted in inefficiencies, with difficulties in locating stock leading to unnecessary delays and increased manufacturing costs. Safety concerns arose from tall pallet stacks and incidents of forklift operators damaging racking structures.

Tall pallet stacks

System Installation

A phased approach was adopted to firstly integrate the new Automatic Guided Vehicle (AGV) system with the Automation Storage & Retrieval System (ASRS) shuttle system. This was followed by the transition of the entire warehouse inventory into the new system without interrupting ongoing operations.

AGV Deployment
The warehouse welcomed a fleet of four MAXAGVs, designed to autonomously navigate, retrieve, and precisely transport pallets (sometimes x2 high) throughout the facility.

Inventory Transition and Scanning
Existing stock was systematically moved and catalogued into the new Warehouse Management System (WMS). This process enabled accurate tracking of each item while ensuring uninterrupted warehouse functionality.

Pallet Scanning and Placement
Pallets arriving from the manufacturing area were scanned to allow the Warehouse Management System (WMS) to determine the optimal rack location for each piece of stock, enhancing storage density and accessibility.

AGV Stock Movement
The Automated Guided Vehicles (AGVs) seamlessly transport pallets to designated rack locations and command the Automation Storage & Retrieval System (ASRS) shuttle system to store items logically, in up to 22 deep rack positions maximising warehouse space utilisation.

Order Fulfilment Automation
The Automated Guided Vehicle (AGV) system facilitated autonomous order fulfilment. Upon receiving an order, the AGVs efficiently retrieved the required combination of stock types and delivered them to the outfeed area, streamlining the order process.

3D Visualisation
The new Warehouse Management System (WMS), integrated with a 3D visualisation feature enhanced warehouse navigation and could be accessed on smartphones, tablets, and laptops.

3D Visualisation of new warehouse management system

Successful Outcome

By effectively integrating a sophisticated Automated Guided Vehicle (AGV) system with an Automated Storage & Retrieval System (ASRS), the client transformed their chaotic warehouse into a streamlined and efficient operation.

The innovative solution resolved the clients initial challenges and laid the foundation for improved productivity, safety, and customer satisfaction. This case study serves as a positive testament to the power of advanced automation and integration in modern warehouse management.


Enhanced Operations
The warehouse transitioned to a 24/7 operation, significantly improving operational efficiency.

Streamlined Stock Management
The 3D visualisation feature made stock identification and retrieval simple and efficient, reducing the time taken to locate items.

Autonomous Order Fulfilment
The system enabled seamless and autonomous order processing, further expediting customer deliveries.

Optimised Space Utilisation
The AGVs and ASRS shuttle system collaboration maximised warehouse space utilisation with a gain of 2 – 3 times the volume of pallets utilising the same footprint.

Enhanced Safety
The organised storage system also reduced safety risks with tall pallet stacks no longer required and more space available, forklift-related incidents have been reduced.

Client Testimonial

“I am extremely satisfied with the efficiency and reliability of our automated warehousing solution. The after sales service and technical support provided by the RA team has been exceptional.”
Domenic Tacca – Managing Director, Tacca Industries