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.
