How to Plan an AutoStore System – Answers from the even Webinar with AutoStore

In a nutshell: Skilled labor shortages, rising personnel costs, growing product ranges – the pressure on small-parts warehouses is real. But when does an AutoStore actually make sense? And how do you get from raw data to a concrete system design? Jörg Wolf, Senior Solution Consultant at AutoStore, demonstrated live during the Webinar how a submitted case can be turned into an initial grid design in just a few minutes – including the number of bins, ports, robots, and a 3D view.

Missed the Webinar? Click here for the full recording. 

During the Webinar with Jörg Wolf, it quickly became clear how much interest there is in concrete planning fundamentals. We have compiled the most important questions and answers from the live session here for you.

When does an AutoStore actually make sense?

Jörg: The basic requirement is straightforward. As long as your items fit into one of the bins, the system is fundamentally an option. AutoStore offers three bin sizes, all sharing the same footprint of 600 x 400 millimeters, differing only in height. What really matters then are your individual goals – such as space savings, throughput increases, or headcount reduction. That is exactly why a thorough analysis of your own requirements is worthwhile before making a decision.

What key figures do I need, and how clean does my data have to be?

Jörg: In the first step, we look at the static picture: How many SKUs do I have, and how many fit into the bins? Then we add the dynamic dimension – how fast do individual items turn? This also determines what should actually go into the system. Very fast-moving items are sometimes stored more efficiently outside. If you provide us with well-prepared key figures, the process moves significantly faster. If you don't have complete master data, we help out with industry-specific benchmarks from comparable projects. The last bin doesn't have to be accounted for exactly.

Does my ABC structure need to follow a specific ratio?

Jörg: No. AutoStore handles any order structure. With a more evenly distributed spread, the robots need to dig a little deeper, which may mean a few more robots. We simulate this in advance and can show precisely how different structures affect the outcome. The system also learns over time – frequently needed bins migrate to the top and remain easily accessible.

Does it make sense to use different bin sizes within one grid?

Jörg: In principle, yes. You can set up different zones for different bin heights to optimize space efficiency. However, this introduces more complexity. Whether it's worthwhile depends on the actual cost driver of the project. If it's throughput, then robots and ports are the main cost factors, and better bin utilization saves less there than throughput optimization would. This is always a project-specific trade-off.

How does the planning process work in practice?

Jörg: Once the key figures are established, we start in the Grid Designer – the same tool that later controls the real system. We draw the grid based on the number of bins and the available storage height, position the workstations for goods receipt and goods dispatch, and add robots, charging stations, and access points. During the Webinar, we ran through this live for an industrial customer who wants to store and ship spare parts – around 30,000 bins, 400 bin presentations per hour in picking and 40 per hour for replenishment, spread across two shifts. As a starting point for the number of robots, we use an empirical benchmark value; the simulation then refines this and later also serves as the basis for the performance test at go-live.

Three real cases: How different AutoStore systems can look

During the Webinar, Jörg used concrete real-world examples to show how varied AutoStore systems can be depending on requirements. Three cases were covered; a fourth unfortunately didn't fit within the time available. Anyone who wants to dive deeper can find all the details directly at AutoStore:

• Alza – a massive increase in throughput and speed in e-commerce. An example of how the system scales with growing demands.
• Bergfreunde – ROI in two years and a 288% efficiency gain. A compelling business case for anyone still weighing whether the investment is worthwhile.
• Martini Sportswear – a compact entry point with clear impact. The sportswear manufacturer automated its logistics with AutoStore and streamlined operations significantly.

What does a system like this cost?

Jörg: A blanket figure says very little. What matters far more is the business case behind it. What are your current costs for staff, errors, and inefficient processes? Only in comparison to those does an investment figure make sense. We are happy to share budget pricing in a direct conversation, together with our integrators who can then also price the overall project.

Is there a rental model?

Jörg: Yes. Both AutoStore and our integrators offer financing models that allow the investment to be shifted from CapEx to OpEx. We are happy to clarify which model fits best on an individual basis.

Conclusion: From data to design – faster than you'd expect

The Webinar demonstrated that an initial, reliable AutoStore plan doesn't require months of groundwork. Anyone who knows their key figures – or is willing to share raw data – can quickly get a concrete picture of whether the system suits their requirements. The decisive step is an honest analysis: what are my drivers, and what do I really want to achieve?

Missed the Webinar?

👉 Here is the full recording.

👉 Here is the even profile for AutoStore.