7 Ways Shuttle Storage Systems Improve Order Picking

These systems use shuttles that operate at one level at a time. They are ideal for high-throughput operations and can be expanded with multiple shuttles.

Equipped with lifts and multiple shuttles, these systems handle goods at various levels within the racking structure, improving efficiency in high-density storage environments.

Designed for heavy-duty palletised goods, these systems transport entire pallets to and from deep-lane storage or multiple-deep storage, which optimises bulk storage.

These shuttle systems are extremely efficient and ideal for e-commerce and small-item order fulfilment where the shuttles are needed to move bins and totes to the pick stations quickly.

G2P systems use shuttles, other automation technology such as conveyors or more widely, Autonomous Mobile Robots to bring stored individual items directly to workers at ergonomic picking stations, reducing travel time and increasing picking accuracy.

Shuttle systems drastically reduce the time required to locate and retrieve items. By automating the retrieval of goods from the racking, they eliminate unnecessary travel time for workers and ensure that products reach picking stations far more quickly. This speed is needed to achieve reduced order fulfilment times and support pressured delivery requirements that enhance customer satisfaction. This contributes significantly to cost savings by reducing operation time.

Errors in manual picking can lead to incorrect shipments and costly returns. Shuttle systems use advanced tools such as barcode scanning and warehouse management software (WMS) integration to ensure the correct item is always picked, leading to near-perfect order accuracy.

Traditional methods for storage and order-picking require space such as wide aisles for forklifts to safely move to collect and replenish goods. Shuttle systems, however, utilise compact storage systems and high-density storage by operating in compact spaces, maximising both vertical and horizontal storage capacity within the available footprint of the actual warehouse, without compromising accessibility. This improved storage density is a key benefit.

Manual picking requires significant manpower and is physically demanding and repetitive. By automating the retrieval process, shuttle storage systems reduce the dependency on a large workforce, leading to lower labour costs and potential for injury, while allowing employees to focus on higher-value tasks such as quality control and customer service. Integrating advanced technology also provides an opportunity for staff to learn new skills to programme, operate and maintain the shuttle systems.

As businesses grow, so does the demand for efficient storage. Shuttle systems can be easily scaled by adding additional shuttles and pick stations, or expanding the racking systems, ensuring they accommodate increasing order volumes quickly and efficiently, without major changes to the existing infrastructure.

Multi-shuttle systems can operate simultaneously at different levels, drastically increasing order throughput. They also facilitate continuous picking and replenishment, reducing the potential for bottlenecks and boosting overall warehouse productivity.

Shuttle systems are integrated with advanced WMS software (often with integrated Artificial Intelligence) that provides real-time visibility of stock levels. This reduces the risk of stockouts, prevents costly and inefficient overstocking, and enables accurate demand forecasting which ultimately optimises inventory control. This is a crucial element of efficient picking.

Retail & E-Commerce efficiently handles fast-moving SKUs, seasonal inventory, and high-order volume fulfilment. Ideal for clothing, electronics, home goods, and personal care products such as cosmetics and health & wellbeing items, shuttle storage systems optimise storage and retrieval.

Food & Beverage is perfectly suited to managing cold storage, frozen food, dairy, and packaged goods, ensuring the rapid retrieval of goods while maintaining optimal storage conditions and product integrity.

Pharmaceuticals must adhere to strict regulations, requiring secure, accurate, and timely access to medications, medical devices, and laboratory supplies, where precise order picking, as well as tracking and traceability, are essential.

Automotive & Manufacturing is ideal for storing and retrieving spare parts, tools, and components for just-in-time production, reducing downtime and improving the speed and efficiency of the overall supply chain.