FREQUENTLY ASKED QUESTIONS

ASRS (Automated Storage and Retrieval System) has long been associated with stacker cranes. Before 2018, pallet automated storage solutions were limited to stacker crane warehouses. Today, four-way shuttle systems represent a new generation of ASRS that achieves fully automated storage and retrieval while overcoming many technical limitations of traditional stacker cranes. ASRS is no longer exclusive to stacker crane systems.

Modern battery technology enables high-capacity energy storage and efficient charging. The four-way shuttle is a fully electric intelligent pallet-handling robot that can carry 1,000 kg pallets and move in all four directions within racking systems. It communicates with the server via industrial-grade high-power wireless base stations, ensuring reliable WiFi connectivity for real-time coordination.

We serve multiple industries across Malaysia, Singapore, China, and beyond:

• Manufacturing — Siemens, Qisda
• Logistics & Courier — DHL, Sinotrans, Kuehne+Nagel
• Cold Chain & Food — Starbucks, Qinglian Food
• Electronics — Qisda, Innolux
• E-commerce — JD.com

The four-way shuttle can reach 2.5 m/s when unloaded. When carrying pallets, we typically set a slower speed ranging from 0.8—1.2 m/s, especially for taller pallets, to ensure safety and stability.

Storage capacity depends on available space. Four-way shuttle systems achieve the highest storage density — up to 30% more than traditional stacker crane ASRS, and 60% more than VNA (Very Narrow Aisle) systems.

Multi-floor capability is a key advantage of four-way shuttle systems. If you have a multi-story warehouse, the shuttle system can be deployed across all floors, with shuttles traveling between levels to create a unified multi-floor operation.

Battery Charging: 1.5—2 hours for full charge.

Runtime: Approximately 8 hours of operation.

The shuttle automatically detects when battery falls below 30% and goes to the charging station. Once fully charged, it returns to work — no manual intervention required.

Batteries are rated for 2,000 charging cycles by the supplier. With daily charging, this translates to approximately 5-6 years of operation.

Real-world example: Our Sinotrans project has been running for over 6 years with original batteries still operating normally.

We have two key requirements:

1. Standard Size — Pallets used on racking must be uniform in size
2. Sufficient Strength — Pallets must not sag in the middle over time. Serious warping affects four-way shuttle operation.

Use a Master Pallet solution.

Before warehousing, stack different-sized pallets onto a Master Pallet. This allows:

• Mixed supplier pallet sizes to be stored
• Uniform storage interface for the shuttle system
• Flexibility at receiving dock

WCS (Warehouse Control System) is our proprietary software that controls all hardware devices in the warehouse:

• Four-way shuttles
• Pallet lifters (elevators)
• Conveyors
• Pallet stacker/de-stacker machines
• All other automated equipment

iWMS vs WCS:

• iWMS — The "brain" — connects to ERP, manages inventory, handles order picking
• WCS — The "hands" — executes iWMS commands, controls all hardware

Both are in-house developed software systems.

Yes, integration is essential. The system architecture is:

Customer orders flow from your system through iWMS to WCS, which then coordinates all hardware to retrieve/store pallets automatically.

WCS monitors every shuttle's position in real-time. If one fails:

• Dashboard immediately shows the fault
• Other shuttles automatically detour around the stopped unit
• Operations continue — single failure doesn't stop the system

Minor issues (network disconnection, etc.):

• WCS can reset the shuttle remotely
• No manual intervention needed

Serious malfunctions (unresponsive):

• Personnel use maintenance ladders and walkways to access the shuttle
• All racking systems include built-in maintenance access

Our four-way shuttles are now in their 5th generation (6th generation in development). Each generation addresses safety issues found in previous versions.

Every shuttle is equipped with over 10 sensors serving various safety functions:

• Obstacle detection
• Collision prevention
• Load positioning
• Edge detection
• And more

Continuous iteration ensures we deliver the safest, most reliable product to customers.

Maintenance is a major advantage of shuttle systems over stacker cranes.

Stacker Cranes:

• Massive equipment requiring high-altitude maintenance
• Can only be serviced during scheduled plant shutdowns
• If one stacker stops, its entire aisle becomes inaccessible
• Higher maintenance costs due to shutdown timing (typically holidays)

Four-Way Shuttles:

• Compact (300-400 kg) — no high-altitude work needed
• Can be called to maintenance station anytime
• Individual shuttles can be serviced while others continue operating
• No production disruption — warehouse stays fully operational

In principle, we can design the racking height based on your warehouse building height. However, each project requires technical assessment to ensure structural integrity and operational efficiency.

To date, our tallest installation is 32 meters.

No. Once installed, the rack structure is bolted to the floor and all footings are grouted with concrete. It is a permanent structure and cannot be reconfigured.

Yes. If upgrading an existing operational warehouse, a full shutdown is required and all materials must be temporarily relocated. This is typically the greatest challenge in brownfield projects.

Standard shuttle capacity is 1,500 kg. Custom shuttles for higher loads are available upon request.

Typically ≤ 5 mm. Plastic pallets are generally manufactured within this tolerance. A profile checker at the inlet verifies pallet dimensions — non-conforming pallets are automatically rejected.

The tallest pallet dimension determines the rack design. Specific levels can be dedicated to taller pallets — e.g., Levels 1–2 for 1.9 m pallets, Levels 3+ for standard 1.5 m pallets. However, different heights cannot coexist on the same level unless the racking is physically separated.

System availability (MTBF): 99.2%

Mean Time To Repair (MTTR): < 30 minutes

A key advantage of four-way shuttle systems is that maintenance does not require system downtime — the overall system remains operational during maintenance.

Every 3–6 months, depending on operational intensity. No planned downtime is required — the system continues operating during maintenance activities.

Throughput is fixed at system design. However, if the system was intentionally over-designed with additional lifters during installation, throughput can be scaled up by adding more shuttles. Otherwise, increasing lifter capacity involves significant structural work.

The pallet lifter is the primary bottleneck. Throughput planning revolves around lifter capacity.

The ASRS delivers full pallets to the picking station. Operators pick cartons per iWMS instructions; the remaining pallet is automatically returned to storage. For full-pallet picks, a forklift or AMR removes the pallet from the station.

Dedicated workstations with operating terminals are required.

All strategies are supported and configurable via iWMS.

In practice, pallet weights vary across all operations, and the system handles this as standard.

Lifter failure does not halt overall operations. Maintenance personnel access the affected lifter directly. The system continues operating with remaining lifters at reduced efficiency.

Yes. For example, in a system with 10 lifters and 20 shuttles, individual equipment failure does not halt the system. It continues operating as a whole, but at reduced efficiency until the failed component is restored.

Dual-server deployment is available — one server acts as a redundancy node with real-time data synchronization.

Slotting is managed by iWMS — every inbound pallet's storage location is determined automatically.

Routing is managed by WCS, using smart algorithms to assign the shortest and fastest routes to each shuttle while preventing collisions.

Implementation cost is directly tied to warehouse scale. Unlike selective racking, there's no fixed "price per pallet position." Larger systems have lower per-pallet costs, while smaller warehouses have higher unit costs.

As a reference, clients can estimate RM 800-1,000 per pallet position, though this varies significantly based on project scope.

Project timeline depends on scale and complexity. Typically, implementation takes 6-10 months from design to commissioning.

Simulation is available upon request, but will incur additional cost.