Automatisches Kleinteilelager (AKL)
Also: AKL, Automatisiertes Kleinteilelager, Automatisches Kleinteilelager, Behälterlager automatisch, Automatiklager Kleinteile
AI-generated
The Automated Small Parts Warehouse (AKL) is a fully automated storage system for totes, trays and small parts, in which storage and retrieval operations are performed without manual intervention by stacker cranes or shuttle systems.
Key facts
- An AKL fully automates the storage and retrieval of small parts and totes via stacker cranes or shuttle systems.
- The goods-to-person principle in an AKL reduces travel times for pickers and improves ergonomics at the workplace.
- Shuttle-based AKL systems are more scalable and resilient than classic single-mast stacker crane systems, but are generally also more capital-intensive.
- Integration into a Warehouse Management System (WMS) and upstream ERP systems is a critical success factor for operation.
- The suitability of an AKL depends heavily on the product range — products with high turnover frequency and compact dimensions are particularly well suited.
What is an Automated Small Parts Warehouse?
An Automated Small Parts Warehouse, or AKL, is a fully automated high-bay storage system designed specifically for storing small parts, piece goods and containers. Unlike manual warehouses, machines — typically stacker cranes (SRM) or shuttle systems — handle all transport movements within the racking structure. Goods are stored in standardized totes or on trays, which the system automatically delivers to picking or transfer stations. Control is managed by a Warehouse Management System (WMS) or a higher-level Warehouse Control System (WCS) that administers storage locations, transport orders and inventory data in real time.
How does an AKL work in practice?
During inbound storage, a filled tote is identified at the entry point — typically via barcode or RFID — and assigned a free storage location by the system. The stacker crane or shuttle carrier independently transports the tote to the designated aisle and rack position. During retrieval, the WMS calls up the required tote, which is then presented at a workstation according to the goods-to-person principle. Pickers no longer need to move through the warehouse, significantly reducing travel times and improving ergonomics.
AKL systems can broadly be divided into two types:
- Single-mast stacker cranes (classic AKL): One SRM per aisle handles all storage and retrieval operations. This Solution is well-established and suitable for medium to high throughput requirements.
- Shuttle systems: Multiple autonomous shuttles travel on each level and share a common lift. They offer greater flexibility and scalability, as performance can be increased by adding more shuttles.
What matters when making a selection?
Several factors are critical when designing an AKL. Article structure plays a central role: AKL systems are particularly well suited to items with high access frequency and small to medium volumes. Items that are too large or too heavy are generally not suitable. Peak performance is also important — that is, how many storage and retrieval operations the system must handle per hour. Stacker cranes and shuttle systems differ considerably in this regard.
You should also factor the following points into your planning:
- Redundancy and availability: If an SRM fails, the entire aisle is at a standstill. Shuttle systems are more resilient in this respect, as a defective vehicle can be replaced by others.
- Scalability: As the product range grows, shuttle systems are easier to expand than classic SRM-based systems.
- Integration: The AKL must communicate seamlessly with the existing WMS, ERP and any upstream conveyor systems. Interfaces and data exchange should be clarified at an early stage.
- Capital and operating costs: An AKL is capital-intensive. The return-on-investment calculation should take into account not only the number of storage locations, but also savings in personnel costs, error rates and space efficiency.
Whether an AKL is the right Solution depends heavily on the individual product range, throughput requirements and long-term growth strategy. A comparison with alternative concepts such as manual tote storage or hybrid approaches is recommended.
Related terms
- ABC-Analyse
ABC analysis is a method for classifying items, vendors, or processes into three priority classes (A, B, C) based on their economic significance. It forms the basis for differentiated decision-making in warehousing, inventory management, and procurement.
- AGV
AGV (Automated Guided Vehicle) refers to driverless transport vehicles that automatically move goods in warehouses and production environments. They follow predefined or sensor-controlled routes without a human driver.
- AMR
AMR (Autonomous Mobile Robot) is a driverless, self-navigating transport robot that moves goods within a warehouse without any fixed installed infrastructure. It orientates itself independently using sensors and digital maps, and dynamically avoids obstacles.
- Akustische Kommissionierung
Acoustic order picking is a paperless picking method in which warehouse employees receive pick instructions via voice and confirm each step using spoken responses. Both hands remain free throughout the actual picking process.
- Artikelstammdaten
Item master data refers to the permanently valid base data of an item – such as dimensions, weight, packaging units, hazardous goods classification, and best-before date relevance. It forms the foundation for all logistical, procurement-related, and system-driven processes along the supply chain.
- Auslagerung
Retrieval refers to the physical process by which goods or load units are removed from a storage area and transferred to a downstream process – such as picking or shipping.
- Automatiklager
An automated warehouse is a fully or partially automated storage system in which the receipt, retrieval, transport and management of storage units are carried out without manual intervention, using conveyor technology, storage and retrieval machines, and a higher-level control software.
- Hochregallager
A high-bay warehouse is an automated storage facility with racking from approximately twelve meters in height, where stacker cranes automatically store and retrieve pallets.
- Kommissionierung
Order picking is the process of assembling individual items from warehouse stock to fulfill a specific customer order — the most labor-intensive step in the warehouse.