Automated Storage Solutions

High-density automated storage and retrieval system (ASRS) with metal racking in a modern warehouse.

Storage systems determine how efficiently a warehouse uses space and how quickly inventory can be stored, located, and retrieved. Manual storage depends on operator movement and visual slot selection, which limits vertical space utilization and leads to placement errors and inconsistent put-away performance.

Toyota Automated Logistics designs storage systems that place inventory precisely where it belongs and retrieve it on demand. Our AS/RS, shuttle systems, and goods-to-person solutions eliminate wasted cube space, reduce labor requirements, and give operations teams real-time visibility into every storage location.

Overview

A worker picks an item from a divided storage bin in an automated storage system

What it is: Storage and put-away involves assigning storage locations, placing items in those locations, and maintaining accurate inventory records.

Why it matters: Manual storage systems limit effective use of vertical space, increase the likelihood of inventory inaccuracies and raise the risk of product damage while requiring significant time and effort to place and retrieve goods.

How we help: Toyota Automated Logistics evaluates how inventory moves through your facility and how the space is configured to design automated storage systems that improve density, placement accuracy, and on-demand access.

Capabilities

AS/RS Crane Systems

Unit-load AS/RS cranes handle full pallets in high-bay racking up to 100+ feet tall. These systems maximize vertical cube utilization while maintaining single-command and dual-command cycle times that support high-throughput operations.

Mini-Load and Shuttle Systems

Mini-load cranes and multi-level shuttle systems handle totes, cartons, and cases at high speeds. Shuttle systems enable simultaneous access across multiple levels, increasing throughput density compared to single-crane architectures.

Goods-to-Person Workstations

Cube storage and tote to person systems bring inventory directly to operators rather than sending workers into aisles. This approach removes unnecessary travel while improving labor efficiency and pick accuracy for each-pick operations.

Directed Put-Away Logic

Automated systems assign storage locations based on SKU velocity, dimensional characteristics, and slotting rules. Fast-moving items stay in accessible zones, while slow movers consolidate in high-density areas. The system continuously improves placement.

Cold Storage and Specialized Environments

Automated storage operates in deep-freeze, refrigerated, and controlled-atmosphere environments where human exposure must be minimized. Cranes and shuttles maintain throughput without requiring workers in harsh conditions.

Reliable Inventory Tracking

The system maintains precise awareness of SKU locations, allowing inventory to remain accurate while removing search time and supporting cycle counting without disrupting operations.

Benefits

Maximize space utilization

Automated storage systems reach heights manual methods can’t and minimize aisle requirements, increasing storage density within the same footprint.

Eliminate mislocation errors

Automated placement ensures goods go exactly where the system directs, removing the inventory inaccuracies that plague manual put-away.

Reduce labor requirements

Goods-to-person systems and automated cranes eliminate travel time, allowing fewer workers to handle higher volumes.

Accelerate put-away throughput

Automated systems maintain consistent cycle times regardless of shift, fatigue or workforce availability.

Enable real-time inventory visibility

Every movement is tracked, giving operations teams accurate counts and exact location data for any SKU at any moment.

Support operational growth

Modular systems can expand incrementally as storage requirements grow without redesigning the facility.

Comparison: Manual vs. Automated Storage

Feature	Manual Storage	Automated Storage
Vertical space	Limited to 25-30 feet	Cranes access 100+ feet
Put-away accuracy	1-3% mislocation rate	Near-perfect accuracy
Labor requirements	High - operators walk aisles	Minimal - automated handling
Throughput consistency	Variable by shift	Consistent 24/7
Inventory visibility	Delayed updates	Real-time tracking
Cold storage	Limited worker exposure	Full harsh environment operation
Scalability	Requires additional labor and expansion space	Modular systems expand as storage needs grow

Applications

Toyota Automated Logistics assesses storage and put‑away requirements across a wide range of industries, matching system design to each facility’s SKU mix, constraints, and growth plans.

Automated storage and retrieval applies wherever operations need to maximize space, maintain inventory accuracy, or support high-throughput operations without proportional labor increases.

Toyota Automated Logistics provides assessments of storage processes and put-away for a variety of industries:

E-commerce and Retail Fulfillment Centers
Food and Beverage Warehouses
Grocery and Food Retail
Manufacturing
Third-party Logistics Providers

Frequently Asked Questions

What types of automated storage systems does Toyota Automated Logistics provide?

TAL designs unit-load crane systems, mini-load systems, shuttle systems, and goods-to-person solutions, including cube storage and vertical lift modules.

How will automated storage change our current workflow?

Automated storage streamlines your operation by replacing manual put-away, retrieval, and inventory checks with coordinated, software-driven processes. Your team spends less time walking aisles or operating lift equipment and more time on value-added tasks. The result is faster, more predictable throughput with fewer bottlenecks.

What types of products can automated storage systems handle?

Automated storage systems can manage a wide range of SKUs — from small parts and cartons to totes, trays, and full pallets. Standard solutions cover most common product sizes and weights, and custom carriers, bins, or grippers can be engineered for unique items. We tailor the system to your product mix to ensure reliable handling and high storage density.

Can automated storage integrate with our existing WMS?

Yes. These systems integrate with all major warehouse management systems through standard interfaces. The automation layer communicates inventory movements and status updates in real time.

How flexible is the system if our SKU mix or order profiles change?

Modern automated storage platforms are built for adaptability. Modular hardware and configurable software allow you to adjust slotting strategies, add new SKU types, or shift between batch, wave, or real-time picking as your business evolves. Whether your assortment grows, packaging changes, or order patterns shift, the system can adapt without major redesign.

Is automated storage practical for operations with many slow-moving SKUs?

Yes. High-density cube storage and AS/RS excel at storing slow-moving inventory efficiently while maintaining quick access when needed.

Can the solution scale as we grow?

Yes. Automated storage systems are inherently scalable. You can expand capacity by adding aisles, shuttles, robots, or grid modules as volume increases. This modular growth approach helps you extend the life of your current facility and avoid premature expansion or relocation.

High-Density Automated Storage with Reliable Inventory Access