While ASRS comes in many configurations, a vertical ASRS (such as a Vidir Vertical Lift Module) offers unique advantages. By storing inventory in a high-density vertical column, vertical ASRS maximize cubic space, minimize floor footprint, and deliver goods at an ergonomic height, reducing strain and improving throughput.
Lean Manufacturing: A systematic approach to eliminating waste and creating value through continuous improvement.
ASRS (Automated Storage and Retrieval Systems): High-density storage solutions that automatically deliver goods directly to the operator.
5S Lean Manufacturing Methodology: A Lean workplace organization system designed to improve efficiency, safety, and consistency. Lean organizations follow five steps: Sort, Set in Order, Shine, Standardize, and Sustain. Several of these steps align directly with how ASRS addresses the 8 Wastes, which we’ll explore below.
ASRS Turns the 8 Wastes into Measurable Operational Gains
The Lean “8 Wastes” framework identifies the most common sources of inefficiency that can erode productivity, profitability, and employee morale. ASRS tackles each of these wastes head-on, improving flow, protecting quality, and freeing up valuable space and labor capacity.
Downtime is the enemy of any Lean operation. Every minute lost to defects, waiting, or inefficiency chips away at your productivity and profits. Warehouse automated storage and retrieval systems tackle each of the 8 Wastes and flips them from pain points to measurable wins.
1. Defects
The challenge: Damaged goods and picking errors undermine quality and customer satisfaction, often leading to costly returns or rework. Mispicks alone can cost companies as much as $390,000 annually.
The solution: ASRS reduces mispicks by over 90% and minimizes manual handling, cutting waste from rework or scrap and reducing damage to goods.
2. Overproduction
The challenge: Producing or picking more than is needed ties up working capital and clogs valuable space.
The solution: ASRS integrates with demand-driven systems to deliver only what’s required for the next stage, keeping processes lean and inventory tight.
3. Waiting
The challenge: Idle time while operators wait for materials or parts disrupts workflow and delays shipments. In fact, an Intermec study found that 18% of the most efficient workflow is in picking and inventory control.
The solution: ASRS brings items directly to the operator in seconds, eliminating the downtime (and errors) of manual searches.
4. Non-Utilized Talent
The challenge: Skilled employees are bogged down by repetitive, physically demanding tasks. This is especially problematic amid today’s record-high skilled labor shortages.
The solution: ASRS automates low-value work, freeing staff to focus on problem-solving, continuous improvement, and other high-value activities that engage and retain talent.
5. Transportation
The challenge: Excess material movement eats up time and increases the risk of product damage.
The solution: ASRS centralizes inventory in a compact footprint, reducing internal transport distances and simplifying material flow.
6. Inventory
The challenge: Overstocking creates clutter, limits cash flow, and consumes costly warehouse space. Many manufacturers and warehouses attempt to solve these challenges by expanding their footprint, often through leasing additional space, which grew 14.6% year-over-year – an expensive band-aid rather than addressing the root cause.
The solution: ASRS supports just-in-time principles, keeping only what’s needed close at hand and maximizing cubic storage. A Vidir VLM, for example, can reduce your storage footprint by up to 85%.
By ensuring every item has a designated, efficient location, this directly supports the Set in Order step of 5S Lean manufacturing.
7. Motion
The challenge: Unnecessary walking, bending, and reaching adds fatigue and slows productivity. These kinds of repetitive motions are common causes of workplace injuries.
The solution: Goods-to-person retrieval eliminates wasted operator motion, improving ergonomics and throughput. In fact, 70% of warehouse operators report automation reduces physical strain on workers.
By promoting clean, orderly, and safe workspaces that reduce risk and inefficiency, this directly supports the Shine step of 5S Lean manufacturing, making it a natural extension of Lean practices.
8. Extra Processing
The challenge: Redundant handling or inspections add no value and slow order fulfillment.
The solution: Automated delivery and integrated scanning ensure accurate, one-touch processing.
Standardizing these processes also connects to the Standardize and Sustain steps of 5S, reinforcing consistent practices and ongoing adherence to them.
Lean Manufacturing succeeds when obstacles are removed, allowing the principles to be put into action every day. ASRS addresses all eight wastes, ensuring your warehouse stays efficient, organized, and competitive. When paired with 5S Lean manufacturing methodology, it keeps processes disciplined and sustainable.
If you’re ready to see how this could work in your facility, talk to a vertical ASRS specialist today.
