Automated Storage/Retrieval Systems Limits Risks for Warehouse Workers

Safer Handling

Among the most prominent ways that sophisticated technology has helped make warehouses safer for workers is the emergence of Automated Storage/Retrieval Systems (ASRS). An ASRS is a combination of equipment and controls that handle, store and retrieve materials under a defined degree of automation. Systems vary from relatively simple, manually controlled order‑picking machines operating in small storage structures to extremely large, computer‑controlled storage/retrieval systems totally integrated into a manufacturing and distribution process.

PHOTO PROVIDED BY AUTOSTORE

The types of ASRS technologies include categories such as horizontal carousels, vertical carousels, vertical lift modules and robotic storage retrieval systems. Not only are all the systems developed with operator safety in the foreground, but they also provide key safety benefits that improve the working experience of warehouse team members.

Because of the variety of systems that fall into the ASRS category—and the wide variety of raw materials and products that the systems handle in warehouses—the safety benefits of the solutions can also vary. Regardless of their form factor, these advanced systems combine both equipment and controls to handle, store and retrieve materials as needed with precision, speed and accuracy. Across the board, by automating tasks traditionally performed by workers, ASRS solutions can reduce the risk of accidents and help maintain a safe working environment.

“One of the biggest benefits is that they minimize the need for employees to perform physically demanding or risky tasks, like climbing ladders, reaching for high or awkwardly placed items, or driving forklifts in busy aisles,” said Valentina Cecchi, marketing director for MHI member Modula. “These systems bring goods directly to the operator, which really limits unnecessary movement and reduces exposure to common warehouse injuries like strains, trips and falls.”

ASRS consolidates storage vertically, which helps to keep pathways clear and to create a safer, more organized working environment, said Cecchi, who serves as vice chair of MHI’s ASRS Industry Group.

“It’s something we hear often from customers—not just improvements in efficiency, but real, noticeable changes in how safe their team feels day to day,” Cecchi said.

Mark Hasler, consulting alliance director for MHI member AutoStore and chair of the MHI ASRS Industry Group, said automated retrieval also reduces human handling of flammable or hazardous materials, minimizing accidental spills or ignition, and some ASRS systems are built with reinforced racking that is better suited to withstand seismic activity than conventional shelving.

“Traditional storage setups often have wide aisles and scattered inventory, increasing fire spread risk,” Hasler said. “ASRS systems have compact storage, reducing airflow and limiting fire spread.”

In addition, with automated picking and retrieval, workers spend less time searching for items, reducing their frustration and mental fatigue—thus making them less prone to making risky mistakes, Hasler said.

Of course, the safety benefits of ASRS will be limited in isolation—they need to be properly integrated into a warehouse operation.

Click here to read the full article.