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Category: AS/RS

  • How Automated Cycle Counting Maximizes AS/RS Performance

    How Automated Cycle Counting Maximizes AS/RS Performance

    AS/RS cycle counting is no longer just an inventory control task. In highly automated warehouses powered by AutoStore and other AS/RS systems, inventory accuracy directly impacts throughput, order fulfillment, labor efficiency, and the return on automation investments.

    By integrating an RFID tunnel directly into the AS/RS conveyor flow, we enable continuous inventory validation without interrupting warehouse operations. Every tote that passes through the RFID tunnel is automatically identified, verified, and synchronized with the WMS through Zentup, creating a perpetual inventory environment with real-time visibility. This approach eliminates manual counting activities while increasing reliability and operational performance.

    Automated cycle counting transforms inventory from a periodic manual exercise into a continuous and autonomous process operating 24/7.

    Why traditional inventory counting limits AS/RS performance

    Despite investing millions in warehouse automation, many companies still depend on manual cycle counts to maintain inventory accuracy.

    This creates a disconnect between warehouse automation and inventory management, generating unnecessary labor costs, operational disruptions, and data integrity challenges.

    Manual counting creates hidden operational costs

    Traditional cycle counts require operators to dedicate significant time to counting and validating inventory.

    Common challenges include:

    • Labor-intensive counting processes
    • Warehouse slowdowns or shutdowns
    • Human counting errors
    • Inventory discrepancies between counts
    • Reduced confidence in WMS data

    As inventory volumes increase, these challenges grow proportionally, making manual counting progressively less sustainable.

    Periodic inventory checks leave accuracy gaps

    Most operations perform cycle counts periodically.

    The result is simple: inventory accuracy deteriorates between audits while discrepancies remain undetected for weeks or months.

    Without continuous verification, warehouses face:

    • Phantom inventory
    • Stock mismatches
    • Order fulfillment errors
    • Lower productivity in automated systems
    • Reduced operational visibility

    How AS/RS cycle counting with RFID works

    The concept is straightforward but highly effective.

    RFID tunnels are integrated directly into the AS/RS conveyor infrastructure. As totes travel through the system, every tagged item inside the container is automatically identified and compared against expected inventory information.

    RFID tunnels automate tote verification

    Each tote is routed through a dedicated RFID tunnel where:

    1. The tote identifier is captured.
    2. All RFID-tagged items inside are read simultaneously.
    3. Inventory data is validated automatically.
    4. Information is transmitted to the WMS in real time.
    5. Any discrepancy is immediately detected.

    The process occurs without operator intervention and without affecting warehouse throughput.

    Zentup synchronizes inventory data in real time

    The intelligence behind the solution is Zentup, our RFID data capture and device management platform.

    Zentup collects all RFID information, validates the data, and synchronizes inventory records with enterprise systems.

    This provides:

    • Real-time inventory visibility
    • Automated inventory updates
    • Reliable data governance
    • Seamless WMS integration
    • Continuous operational monitoring

    As a result, inventory remains permanently aligned with physical stock levels.

    RFID Shield Technology guarantees reliable readings

    One of the biggest concerns in automated environments is preventing unwanted reads.

    Our proprietary RFID Shield Technology creates a controlled RFID environment that isolates the tunnel from external signals and eliminates stray reads.

    This delivers:

    • Maximum reading precision
    • Stable performance
    • Zero cross-contamination between totes
    • Consistent results even at high throughput

    Reliable data starts with reliable reading accuracy.

    rfid tunnel for asrs systems

    The five key advantages of automated inventory counting

    Automating inventory control within an AS/RS environment creates measurable operational and financial benefits.

    1. Greater profitability from existing automation investments

    AS/RS systems represent a significant capital investment.

    When inventory accuracy decreases, warehouse performance follows the same trend.

    Automated RFID cycle counting protects that investment by ensuring inventory remains continuously accurate, allowing the automation system to operate at its full potential.

    2. Lower operating costs and reduced labor dependency

    Manual inventory checks consume valuable warehouse resources.

    RFID automation dramatically reduces the time and labor required for cycle counts while eliminating repetitive manual tasks.

    Manual inventory processAutomated RFID cycle counting
    Dedicated counting teamsFully automated process
    Warehouse interruptionsContinuous operation
    High labor requirementMinimal operator involvement
    Delayed inventory updatesReal-time updates
    Human counting errorsAutomated validation

    The result is lower operational expenditure and improved resource allocation.

    3. Higher reliability and inventory accuracy

    Inventory decisions are only as reliable as the data behind them.

    Automated RFID cycle counting delivers a highly accurate and repeatable process by eliminating human variability and continuously validating inventory data.

    Key reliability benefits include:

    • Continuous stock validation
    • Immediate discrepancy detection
    • Elimination of manual counting errors
    • Improved data consistency
    • Greater confidence in WMS information

    4. Scalability for growing warehouse operations

    Growth introduces complexity.

    As warehouse volumes increase, manual inventory processes quickly become a bottleneck.

    RFID-based cycle counting scales naturally alongside warehouse expansion because the validation process is embedded within the conveyor infrastructure itself.

    Whether an operation manages tens of thousands or hundreds of thousands of AS/RS locations, the process remains fully automated and highly efficient.

    5. Full automation and 24/7 inventory visibility

    The ultimate benefit is autonomous inventory management.

    Unlike traditional cycle counts that occur periodically, automated RFID counting operates continuously and can even run during non-operational hours without affecting picking, replenishment, or fulfillment activities.

    This enables:

    • Real-time inventory monitoring
    • Continuous validation
    • Immediate inventory updates
    • No operational disruption
    • Perpetual inventory accuracy

    Why continuous inventory accuracy matters in AutoStore environments

    AutoStore and similar AS/RS systems depend entirely on inventory precision.

    Even small discrepancies can create inefficiencies across the entire operation.

    Better picking performance starts with accurate inventory

    When inventory records match reality, warehouse systems can confidently direct picking operations.

    Benefits include:

    • Faster order fulfillment
    • Fewer exceptions
    • Reduced search time
    • Higher throughput
    • Better customer service

    Automated inventory creates a more resilient supply chain

    Real-time inventory visibility improves both operational and strategic decision-making.

    With continuous validation, companies can:

    • Identify discrepancies immediately
    • Improve stock allocation
    • Reduce inventory uncertainty
    • Increase supply chain responsiveness

    Why Clustag delivers a different approach to AS/RS cycle counting

    At Clustag, we combine three critical components into a single ecosystem:

    • Clustag RFID Solutions for high-performance automated identification
    • Zentup for RFID data orchestration and WMS integration
    • RFID Shield Technology to eliminate stray reads and guarantee reliable performance

    Together, they create a scalable solution capable of transforming inventory management from a periodic manual task into a continuous automated process.

    If you want to see how automated RFID cycle counting can improve the performance of your AS/RS operation, we invite you to contact our team or visit our Customer Experience Center. Bring your own products, test them under real operating conditions, and discover how continuous inventory visibility can unlock hidden value across your warehouse.

    Frequently asked questions

  • How an automated infeed elevates AS/RS performance

    How an automated infeed elevates AS/RS performance

    An automated infeed for AS/RS performance is the foundation of fast, predictable and error-free warehouse operations. While shuttles, cranes and high-density storage systems are essential, their real efficiency depends on the quality of inbound data. When identification, weight or volume information is incomplete, even the most advanced AS/RS struggles to perform at scale.

    By automating the inbound entry point and capturing accurate data in a single step, warehouses can improve flow, reduce exceptions and unlock full inventory visibility from the very first meter of the process.

    Why automated infeed is critical for AS/RS performance?

    Automated Storage and Retrieval Systems depend entirely on the reliability of inbound information. The infeed area generates, validates, and distributes operational data across the entire warehouse ecosystem.

    An automated infeed for AS/RS performance ensures that every item enters the system with verified identification, dimensions and weight. This structured data foundation enables automated decisions downstream and prevents disruptions that are difficult to correct later in the process.

    Ensuring data consistency from the entry point

    When people capture inbound data manually or in multiple steps, they almost inevitably introduce inconsistencies. Automated infeed solutions eliminate these gaps by standardizing data capture at the source.

    Automated RFID infeed station by Clustag scanning a plastic tote on a conveyor inside a warehouse.

    Capturing inbound data in a single automated step

    One of the main advantages of an automated infeed is the ability to consolidate multiple validation tasks into a single, continuous flow. This reduces handling, accelerates inbound throughput and minimizes operational friction.

    By integrating identification, weighing and volume measurement, warehouses gain a reliable and repeatable process that supports AS/RS performance at scale.

    RFID, weight and volume capture at infeed

    Modern automated infeed systems combine RFID reading, dynamic weighing and volumetric measurement in motion. This approach removes manual checks and validates every carton, tote, or parcel before it enters automated storage.

    Improving data accuracy with Zentup from day one

    Accurate inbound data supports better inventory control, faster storage decisions and fewer exceptions. For high-volume warehouses, this level of precision is critical to maintain stable performance over time.

    Optimizing storage slotting with automated infeed for AS/RS data

    Storage slotting decisions are only as good as the data that feeds them. When AS/RS systems receive incomplete or incorrect dimensions, space utilization and system efficiency suffer.

    An automated infeed provides the dimensional intelligence required to allocate storage locations correctly from the outset.

    Enabling smart slotting decisions in AS/RS

    With verified item dimensions and identification, shuttles and cranes can automatically select the optimal storage position. This improves space utilization, reduces congestion and minimizes unnecessary relocation cycles.

    Reducing exceptions in automated storage systems

    Exceptions are one of the biggest threats to AS/RS performance. Even minor discrepancies can force automated systems to stop, reroute or require manual intervention.

    Automated infeed solutions act as a control gate, detecting inconsistencies before items enter the automated core of the warehouse.

    Preventing disruptions before they enter the AS/RS

    The system identifies issues such as unreadable tags, incorrect carton sizes, or unexpected weights early. The system diverts items that do not meet validation criteria to exception lanes, keeping automated flows uninterrupted.

    Stopping error propagation across warehouse processes

    By validating data at the source, warehouses prevent errors from cascading into storage, picking and outbound operations, where corrections are significantly more costly.

    Enhancing traceability with smart RFID intralogistics

    Beyond operational efficiency, automated infeed plays a critical role in traceability and quality assurance. Capturing item-level data at entry creates a digital record that follows each unit through the warehouse.

    This level of visibility supports compliance, auditing and service transparency across supply chains.

    Improving inventory visibility and accountability

    Smart RFID intralogistics solutions enable accurate inventory reconciliation, reduce disputes and improve accountability in both B2B and B2C environments.

    Maximizing AS/RS ROI with a reliable infeed process

    AS/RS systems represent a significant investment, and their performance depends heavily on inbound data quality. Strengthening the infeed process is one of the most effective ways to increase return on investment without major infrastructure changes.

    Supporting Scalable and Future-Ready Operations

    A robust automated infeed allows warehouses to adapt to changing product mixes, seasonal peaks and business growth while maintaining consistent AS/RS performance.

    At Clustag, we design automated infeed solutions that enhance AS/RS performance through precise data capture, Smart RFID technology and seamless system integration. Visit our Customer Experience Centre to see our solutions in action and experience the speed, accuracy, and traceability that Clustag can bring to your warehouse. To explore how our RFID solutions can be tailored to your specific needs, fill out our contact form and one of our experts will guide you through a personalized demonstration.

    FAQ

    What is an automated infeed in AS/RS systems?

    An automated infeed in AS/RS systems is the process where inbound items are automatically identified, weighed and measured before entering automated storage. It ensures accurate data capture at the entry point, enabling efficient storage, sequencing and retrieval operations.

    Why is automated infeed important for AS/RS performance?

    Automated infeed is critical for AS/RS performance because automated storage systems rely on precise inbound data. Accurate identification, weight and volume information reduce exceptions, prevent disruptions and allow AS/RS equipment to operate at full capacity.

    How does automated infeed reduce exceptions in AS/RS environments?

    Automated infeed reduces exceptions by validating inbound items before they enter the AS/RS. Incorrect dimensions, unreadable tags or unexpected weights are detected early and diverted to exception handling areas, preventing system interruptions.

    What data is captured during an automated inbound process?

    During an automated inbound process, systems typically capture item identification using RFID, along with accurate weight and volume measurements. This data is used to optimize storage allocation and improve overall warehouse efficiency.

    Can automated infeed improve ROI on existing AS/RS systems?

    Yes, automated infeed improves ROI on existing AS/RS systems by enhancing data quality without major infrastructure changes. Better inbound data increases throughput, reduces downtime and extends the operational lifespan of automation assets.

  • Order preparation AS/RS for faster and more accurate warehouse picking

    Order preparation AS/RS for faster and more accurate warehouse picking

    Efficient order fulfilment is one of the biggest challenges in modern automated warehouses. Companies rely on Automated Storage and Retrieval systems to optimize space utilization and accelerate the movement of goods. Order preparation AS/RS systems deliver precision, speed, and automation throughout the picking process. Even the most advanced setups benefit from smart verification tools. That’s where RFID technology makes the difference. By integrating RAIN RFID-based verification into order preparation AS/RS, warehouses can achieve complete accuracy, real-time visibility, and smooth operator workflow that eliminate costly errors and inefficiencies.

    With warehouses managing thousands of SKUs and hundreds of orders per hour, every second counts. rfid solutions such as those developed by Clustag bring intelligence and automation to the picking stage, ensuring that every item is correctly identified, validated, and tracked in real time. The result is a fully reliable and efficient order preparation process that enhances both productivity and accuracy.

    What is order preparation in AS/RS systems?

    Order preparation is a crucial part of warehouse operations, especially in Automated Storage and Retrieval Systems (AS/RS). In these environments, orders are fulfilled from storage bins automatically delivered to picking stations, where operators select the items required for each order. Autostore systems often serve as the backbone of such setups, ensuring seamless bin delivery.

    While AS/RS systems automate the transport and retrieval of goods, manual unit picking can still be prone to errors if verification is not automated. Misplaces, missing, or incorrect items can compromise both inventory accuracy and customer satisfaction.

    Adding RFID verification during order preparation AS/RS eliminates this weak point. Each item is identified instantly and validated against the digital order, preventing discrepancies and ensuring that the right product reaches the right customer every time.

    How RFID enhances order preparation AS/RS

    RFID technology seamlessly integrates with AS/RS picking stations to bring full transparency and automation to the process. By using RAIN RFID tags for unit-level identification, warehouses can improve speed, accuracy, and visibility at every stage of order preparation.

    Operator no longer need to rely solely on manual barcode scanning or visual checks. RFID-enabled workstations automatically recognize items, confirm correct solutions, and send real-time updates to warehouse management systems. This results in fasters workflows and dramatically fewer picking errors.

    Key benefits of RFID in order preparation AS/RS

    Integrating RFID into order preparation AS/RS delivers measurable operational improvements that go far beyond speed alone. From minimizing errors to empowering operators with real-time insights, RFID technology transforms the picking process into a smarter, more efficient, and fully traceability workflow. Autostore integration further streamlines order fulfillment by reducing manual handling.

    AS/RS delivers bins automatically

    The system retrieves the bins containing required SKUs and brings them to the picking station, eliminating unnecessary operator movement.

    Operator picks items at the RFID workbench

    The operator removes the indicated items and places them on a RFID-enabled workbench for automatic validation.

    Automatic RFID verification

    The workbench instantly verifies that all items correspond to the digital order, ensuring perfect accuracy before proceeding.

    Real-time feedback and confirmation

    The system provides instant confirmation or alerts, allowing operators to correct errors immediately and maintain workflow continuity

    Continuous and traceable process

    Every item picked is logged in real time, creating a fully traceable and auditable process that supports quality control and performance tracking

    This streamlined workflow not only improves productivity but also enables warehouses to maintain precise inventory data and ensure customer satisfaction through perfect order execution

    Flexible and scalable solutions

    One of the key advantages of RFID technology is its flexibility. It can be adapted to any order preparation AS/RS environment, whether upgrading existing infrastructure or designing a new warehouse. RFID-enabled workbenches and readpoints can be customized to fit each client’s operational layout, allowing seamless integration with AS/RS ports and business systems like ERP, SAP or WMS. Autostore solutions are particularly effective in multi-level setups for high-density storage.

    This adaptability makes it possible for warehouses across industries; retail, fashion, healthcare, and manufacturing, to benefit from the same level of automation, accuracy, and efficiency.

    Real-time operator support with workflow integration

    The Zentup Workflow, part of the Zentup suite, provides operators with real-time guidance during order preparation AS/RS, helping reduce human error and streamline picking operations. Keyfeatures include:

    • Instant EPC-level validation of every item picked
    • Real-time visualization of order progress, showing:
      • Expected items
      • Missing items
      • Unexpected items
      • Excess items
    • User-friendly UI/UX for intuitive operation
    • Seamless integration with client systems such as ERP, SAP, or WMS

    By combining RFID verification with Zentup Workflows, operators receiv step-by-step assistance and real-time feedback, ensuring every order is accurate, traceable, and efficiency processed. This integration maximizes speed, reliability, and overall operational confidence.

    Measurable impact on warehouse operations

    Integrating RFID into order preparation AS/RS has a tangible impact on warehouse efficiency and reliability:

    • Faster picking: reduce preparation time per order and increase throughput
    • Fewer errors: minimize returns and rework due to picking mistakes
    • Full traceability: track every item in real time for improved inventory accuracy
    • Optimized workforce: let operators focus on higher-value tasks while RFID handle validation

    With these advantages, RFID transform order preparation AS/RS into a streamlined, data-driven process that enhances speed, accuracy, and operational confidence. Warehouses adopting this technology position themselves to meet growing customer demands with efficiency and reliability.

    Discover firsthand how RFID technology can transform your order preparation AS/RS operations. Visit our Customer Experience Centre to see our solutions in action and experience the speed, accuracy, and traceability that Clustag can bring to your warehouse. To explore how our RFID solutions can be tailored to your specific needs, fill out our contact form and one of our experts will guide you through a personalized demonstration. Don’t miss the opportunity to optimize your warehouse processes and take your order preparation to the next level.

  • How to optimize inventory with cycle count AS/RS

    How to optimize inventory with cycle count AS/RS

    In highly automated intralogistics environments, automated storage and retrieval systems (AS/RS) operate continuously. Consequently maintaining accurate inventory, traceability, and operational efficiency becomes a major challenge. To address this, companies implement a Cycle Count AS/RS process using Clustag’s RFID technology. This solution not only ensures real-time inventory control but also eliminates manual workloads and minimizes human errors.

    By combining AS/RS systems with Clustag’s RFID solutions, companies can enhace warehouse efficiency, achieve seamless traceability , and optimize storage process across complex operations.

    Understanding cycle count in AS/RS environments

    Cycle counting is a method of auditing inventory on a continual basis, rather than performing full physical inventories. In automated warehouses, this process must be fully integrated with AS/RS systems to avoid disrupting the flow of goods.

    Key principles

    A Cycle count AS/RS ensures that selected bins or totes are counted at regular intervals without halting warehouse operations. By using RFID technology, each unit within a bin can be read instantly and automatically, guaranteeing precision and reliability. This main principles include:

    • Continuous inventory verification
    • Automated data capture
    • Integration with WMS and ERP systems
    • Minimization of human intervention

    Common challenges in manual cycle counting

    Without automation, cycle counting is prone to errors caused by human handling, mislabeling, and misplacement. These errors can lead to inaccurate stock levels, delayed shipments, and increased operational costs. By automating the process within an AS/RS, these challenges are minimized. Autostore solutions can further reduce these errors by automating bin handling and transport.

    How Clustag enhances cycle count in AS/RS

    Clustag integrates the MOT S24 Slim RFID station directly into the AS/RS conveyor system. As a result, Cycle Counting occurs without interrupting operations and maintains maximum reliability.

    Step 1: Bin selection and transport

    The AS/RS system identifies bins scheduled for auditing based on a predefined cycle count schedule. These bins are automatically transported to the MOT S24 Slim Station, ensuring smooth and continuous workflow.

    Step 2: Automated RFID readings

    Once the bins arrive at the station, the system instantly scans all items using Clustag’s RFID technology. Thanks to patented shielding technology, it avoids cross-reading errors and eliminates the need for manual handling.

    Step 3: Real-time synchronization

    RFID data captured by the MOT S24 Slim is transmitted via Zentup. Clustag’s middleware platform. Zentup ensures seamless integration with ERP and WMS systems, providing real-time updates and full inventory traceability.

    Step4: Continuous operation

    The system operates 27/, including off-hours. This ensures that cycle counting is performed continuously without impacting other warehouse processes.

    Key benefits of cycle count AS/RS with Clustag

    Implementing a cycle count AS/RS with Clustag provides measurable operational advantages:

    Automated inventory management

    The system performs inventory counts automatically, which reduces the need for manual labor and minimizes human errors.

    Continuous warehouse operation

    By integrating RFID scanning into the AS/RS, the system conducts inventory audits without stopping workflows, thus maintaining productivity and efficiency

    High accuracy and reliability

    Clustag solutions achieve up to 99,96% RFID reading rates, ensuring accurate stock levels at all times.

    Rapid ROI

    Automation reduces labor costs and optimizes inventory management, delivering a fast return on investment.

    Scalable and flexible

    The system, can handle up to 1000 boxes per hour and accommodates various bin sizes, making it suitable for warehouses of all sizes. Autostore setups in particular allow scaling to very high-density storage environments.

    Best practices for implementing cycle count AS/RS

    To maximize the benefits of cycle counting with an AS/RS, consider the following strategies:

    Process standardization

    First establish clear schedules and procedures for cycle counting. Then, automate bin selection, transport, and data capture to maintain consistency.

    Staff training and oversight

    Even in automated environments, trained staff should monitor processes to address exceptions and ensure system efficiency.

    Continuous monitoring

    Use Clustag’s Zentup to track cycle count results in real-time. This enables rapid reponse to discrepancies and ensures continuous process improvement.

    Integration with enterprise systems

    Connect RFID data to your WMS and ERP for synchronized stock updates, accurate reporting, and comprehensive inventory traceability.

    Real-world results with Clustag

    Clustag’s Cycle Count AS/RS implementations have shown significant results across various industries

    • Throughput: up to 1.000 boxes per hour
    • RFID reading rate: up to 99,96%
    • Inventory accuracy: near 100%
    • ROI: less than 12 months through labor optimization
    • Continous operation: uninterrupted cycle counting even during off-hours

    Integrating Clustag’s RFID solutions into AS/RS systems tranforms cycle counting into a fast, accurate, and fully automated process. Companies gain operational visibility, minimize human errors, and optimize warehouse performance while ensuring complete inventory traceability

    Discover how Clustag can help your warehouse implement Cycle Count AS/RS with efficiency and precision. Contact our experts to design a solution tailored to your operations and to visit our customer experience centre to see in action.