AutoStore ASRS Boosts Throughput 177%

Warehouse Automation Success: 177% Throughput Growth in Six Months

Addressing Distribution Center Challenges

Balluff Inc. faced significant operational constraints at its Kentucky distribution facility. The industrial automation provider needed enhanced storage capacity and faster order processing. Moreover, the solution required scalability to support expanding operations across the Americas region.

Strategic Partnership Selection

Balluff conducted comprehensive market evaluation before choosing Kardex as their automation partner. This decision leveraged previous successful implementations at European facilities. Consequently, the established relationship minimized project risks and ensured technical compatibility.

Accelerated Implementation Timeline

The AutoStore deployment achieved full operational status within six months. The installation included 20,110 storage bins and seven autonomous robots. Importantly, this rapid implementation occurred without disrupting ongoing distribution operations.

Innovative Engineering Approaches

The project featured several groundbreaking design solutions that optimized space utilization. These included cross-facility installation through structural walls and advanced seismic bracing systems. Additionally, integrated service grids extended into administrative areas while minimizing infrastructure impact.

Measurable Performance Gains

The automated system delivered exceptional operational improvements, including 177% throughput increase. This performance enhancement eliminated previous bottlenecks while dramatically improving storage density. Furthermore, the modular design supports future expansion as business needs evolve.

Workforce Integration Success

Employee adaptation to the new system proved remarkably smooth. Staff reported high satisfaction levels with system usability and reliability. The intuitive interface reduced training requirements while improving working conditions through ergonomic enhancements.

Industry Impact and Applications

This project establishes new benchmarks for warehouse automation in existing facilities. The innovative approaches provide valuable insights for organizations facing similar spatial constraints. Therefore, it demonstrates the transformative potential of modern automation solutions.

Strategic Collaboration Results

“Kardex demonstrated exceptional project management capabilities,” stated Steve Duncan, Balluff’s Quality Assurance Manager. “They delivered all commitments within budget and schedule parameters. This successful collaboration establishes a strong foundation for future automation initiatives.”

Expert Analysis: Automation Implementation

This case study demonstrates how established partnerships accelerate automation projects. The previous Hungarian implementation provided valuable lessons that streamlined the Kentucky deployment. Such continuity between projects often yields significant time and cost savings.

Implementation Scenario: Spatial Optimization

Consider traditional warehouses with limited expansion possibilities. The cross-building installation approach enables automation without facility modifications. This strategy proves particularly valuable for organizations operating in constrained industrial spaces.

Frequently Asked Questions

What operational benefits does AutoStore provide?

AutoStore delivers superior space utilization through high-density storage and robotic retrieval. The system optimizes both vertical space and processing efficiency simultaneously.

How was the rapid implementation achieved?

Comprehensive pre-planning and modular architecture enabled accelerated deployment. Previous implementation experience also contributed to the efficient timeline.

Does the system support future expansion?

The scalable design allows seamless integration of additional components. This includes more robots, processing ports, and storage capacity as needed.

What were the key technical innovations?

Cross-building installation and space-optimized seismic solutions represented major advancements. These approaches benefit facilities with spatial limitations.

How did employees adapt to the new system?

The intuitive design and comprehensive training resulted in excellent adoption rates. Staff reported improved working conditions and operational confidence.

Project Achievement Summary

• 177% throughput capacity increase
• Six-month implementation timeline
• 20,110 storage bin capacity
• Seven autonomous robot system
• Zero operational disruption during installation
• High employee satisfaction and adoption

About the Companies

Balluff provides advanced sensor and identification solutions for industrial automation applications worldwide. The company has operated since 1921 with global presence.

Kardex specializes in automated storage and retrieval systems. The company delivers innovative logistics solutions that optimize warehouse operations and material handling efficiency.