ESI Group designed a multilevel warehouse with an automated storage and retrieval system (AS/RS) for pick-to-belt and pick-to-pallet activities within that footprint. This approach allows the operator to combine fast and slow movers in the same system by doing replenishment with the AS/RS for fast movers.  It also allows the warehouse owner to maximize overhead clearance in its existing facility, allowing for further cost amortization. This system is said to have reduced forklift labor by 90%, and improved sortation and queuing for pick-to-belt items, resulting in a 30% increase in order selection and consolidation productivity. It was designed with the capability to fully automate 80% of the total master case throughput of the facility.

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