Can 108 AMRs + 46 ACRs Replace Manual Picking? High-Density ASRS Automation Case Study

This case study presents a large-scale high-density ASRS warehouse system using 108 AMRs and 46 ACR robots to achieve over 129,000 storage locations, transforming traditional manual picking into fully automated goods-to-person logistics.

Traditional warehouse operations face critical limitations:

7.1 Manual picking inefficiency and high labor cost
7.2 Workers spending excessive time searching for goods
7.3 Low storage density and poor space utilization
7.4 High error rate in order fulfillment
7.5 Difficulty managing large SKU complexity
7.6 Limited scalability of traditional warehouse systems
7.7 Rising operational cost and labor instability

This ASRS system solves these problems through:

8.1 Deployment of 108 AMRs for horizontal transport automation
8.2 46 ACR robots for high-density vertical picking operations
8.3 Goods-to-person picking model replacing manual searching
8.4 Fully integrated WMS + MES system coordination
8.5 Dynamic warehouse slotting optimization
8.6 Multi-level storage architecture design
8.7 Real-time task allocation system
8.8 Automated inbound and outbound logistics flow

9.1 Goods are received and scanned into WMS system
9.2 ACR robots store goods into high-density racks
9.3 AMRs transport goods between zones
9.4 System assigns tasks based on real-time demand
9.5 Workers receive goods directly at picking stations
9.6 WMS coordinates inventory tracking and optimization
9.7 MES synchronizes warehouse with production demand
9.8 Finished orders are sent to outbound logistics

12.1 This project demonstrates a next-generation ASRS warehouse system
12.2 It replaces manual picking with fully automated goods-to-person logistics
12.3 The system is designed for high SKU, high throughput warehouse environments

• 13.1 AMRs handle horizontal logistics movement
• 13.2 ACR robots handle vertical storage and retrieval
• 13.3 System enables fully automated picking workflow
• 13.4 High-density design maximizes warehouse space
• 13.5 WMS ensures real-time inventory control
• 13.6 MES connects warehouse with production demand
• 13.7 Automation significantly reduces labor dependency

14.1 Warehouse capacity and SKU analysis
14.2 AMR + ACR system architecture design
14.3 Rack structure engineering (8.6m high-density layout)
14.4 WMS and MES system integration
14.5 Robot fleet deployment and calibration
14.6 Dynamic routing algorithm configuration
14.7 System testing and simulation
14.8 Full warehouse commissioning and optimization

15.1 Significant reduction in manual labor dependency
15.2 Massive improvement in picking efficiency
15.3 Higher warehouse space utilization rate
15.4 Improved order accuracy and traceability
15.5 Scalable system for large warehouse expansion
15.6 Reduced long-term operational cost
15.7 Higher logistics performance stability
15.8 Strong ROI for large-scale automation investment

16.1 AMR + ACR hybrid ASRS systems represent the future of warehouse automation
16.2 They enable true goods-to-person logistics at industrial scale

If you are planning a warehouse automation project, we can support you with:

16.3 ASRS system design and engineering
16.4 AMR + ACR integration planning
16.5 Warehouse layout optimization
16.6 Investment cost estimation (USD 800K–3M+)
16.7 ROI analysis and feasibility study
16.8 Turnkey project delivery

Can 108 AMRs + 46 ACRs Replace Manual Picking? High-Density ASRS Automation Case Study

This case study presents a large-scale high-density ASRS warehouse system using 108 AMRs and 46 ACR robots to achieve over 129,000 storage locations, transforming traditional manual picking into fully automated goods-to-person logistics.