Case Study 1 – Automation Equipment
High-Density AS/RS Implementation for Footwear Industry
A comprehensive automated storage and retrieval system combining four-way shuttle robots, vertical lifts, and AGVs for maximum efficiency and throughput.
Project Overview
This project focused on implementing a high-density automated storage and retrieval system (AS/RS) for a footwear industry warehouse handling a large SKU count, frequent order movement, and high throughput requirements.
The primary objective was to improve storage density, order handling efficiency, and system scalability while supporting a top storage and bottom picking operating model. The solution combines four-way shuttle robots, vertical lifts, and AGVs into a unified and highly coordinated automation system.
System Configuration
Automation Equipment
35 Four-Way Shuttle Robots
Four-way shuttle robots manage horizontal pallet movement within each rack level, enabling flexible longitudinal and lateral movement.
13 Vertical Lifts
Vertical lifts enable rapid and precise pallet transfers between floors, supporting seamless multi-level operations.
1,400 lb Maximum Pallet Weight
System designed to handle heavy loads with high positioning accuracy for reliable storage and retrieval.
28 ft Total Warehouse Height
Maximizing vertical space utilization with efficient multi-level storage configuration.
17,000+ Pallet Storage Capacity
High-density storage solution providing exceptional space utilization for large-scale operations.
Performance & Technical Excellence
Performance & Throughput
- • System throughput: up to 450 pallets per hour
- • Priority-based multi-vehicle scheduling ensures optimal task allocation across shuttles
- • Intelligent path planning minimizes congestion and maximizes system-level efficiency
This performance level supports large-scale inbound replenishment and outbound order fulfillment, even during peak seasonal demand common in the footwear industry.
Technical Highlights
- • High positioning accuracy for reliable pallet storage and retrieval in dense racking
- • Four-way shuttle design enabling flexible longitudinal and lateral movement
- • Advanced scheduling logic to balance workload across multiple robots
- • AGV integration for seamless material handling beyond the racking system
- • System architecture designed for scalability, allowing future capacity expansion with minimal disruption
Project Outcome
The automated warehouse solution successfully supported large-scale delivery operations and exceeded customer-defined trial operation milestones. The system demonstrated stable operation, high throughput, and efficient space utilization, making it a strong fit for footwear industry warehouses requiring speed, flexibility, and high storage density.