5 Strategic Considerations for Designing a High-Performance AutoStore System

As C-suite leaders evaluate warehouse automation investments, AutoStore often emerges as a front-runner—thanks to its compact footprint, scalability, and ability to drive rapid ROI.

However, successful implementation requires more than just choosing the right technology. A poorly planned system can limit throughput, complicate expansion, and waste capital.

To help you build a resilient, scalable solution, here are five key strategic considerations when designing your AutoStore system:

1. Understand Your Throughput Goals and Their Impact on Downstream Automation

Before selecting ports or robots, you must define your expected throughput; both now and five years out. This will dictate how much downstream automation is required, thereby avoiding overbuilding or underbuilding the system.

• A common misconception is that high-volume operations automatically need extensive conveyor networks or fleets of Autonomous Mobile Robots (AMRs).
• In reality, most small to mid-sized AutoStore deployments operate efficiently with minimal takeaway systems, often using simple carts that hold 8–12 orders or a compact takeaway conveyor.

Key takeaway for executives:

Don’t overspend on automation you may not need. Align your throughput forecast with your long-term business strategy to ensure your AutoStore investment remains cost-effective and aligned with your overall business objectives.

2. Build for Scalability, Even If You’re Not Scaling Yet

AutoStore systems are modular by nature; however, planning for growth during the initial implementation is significantly more cost-effective than retrofitting later.

• Consider floor remediation and fire suppression upgrades during your first installation phase. These “future-proofing” moves minimize disruption when expansion becomes necessary.
• Pre-installing future port frames enables the quick addition of new ports without requiring grid downtime.

Key takeaway for executives:

Capital invested in early infrastructure can yield substantial returns when expansion time arrives. Think beyond today’s needs to protect tomorrow’s margins.

3. Clean, Reliable Data Is the Foundation of Operational Success

Even the best automation can’t overcome poor data. AutoStore excels at handling SKU and order variability; however, the system relies on accurate historical and operational data to perform optimally.

• Inaccurate SKU velocity, dimensions, or order profiles can lead to reconfiguration needs after going live, which drive up costs and impact service levels.

• Warehouse data accuracy, particularly regarding SKU slotting and order frequency, ensures that bins are stored and retrieved with maximum efficiency.

Key takeaway for executives:

Invest in a rigorous data audit before implementation. The upfront effort will eliminate downstream friction and increase the speed-to-value time.

4. Design With Port Ergonomics and Workforce Efficiency in Mind

AutoStore ports, especially carousel ports, offer height customization during installation, from 35.5″ to 42.5″, but this choice is fixed once implemented.

• Consider workforce ergonomics to avoid fatigue and injury. Think through walking distances created by additional pick positions or carts.
• Efficiently managing empty tote return flows is also vital to maintaining productivity. Mishandling tote logistics can add hidden labor costs.

Key takeaway for executives:

Don’t let seemingly small design choices lead to systemic inefficiencies. Prioritize ergonomics and labor utilization as strategic levers for performance.

5. Your Software Will Define Day-to-Day Efficiency and Long-Term Agility

While the AutoStore hardware handles movement and bin storage, your software orchestrates operations. From order prioritization to labor coordination, software is the brain behind the system.

• Choose a Warehouse Execution System (WES) that is robust, configurable, and capable of scaling with your operation.

• KPI Solutions’ Opto Software Suite offers advanced functionality tailored for high-volume, high-speed fulfillment environments, enabling real-time insights, predictive workflows, and seamless integration with upstream systems.

Key takeaway for executives:

The right software not only supports current operations—it unlocks growth, adaptability, and innovation over time.

Final Thought: Strategic Design = Operational Resilience

An AutoStore system can dramatically improve space utilization, order accuracy, and labor efficiency, but only if designed with strategic foresight.

By aligning throughput, data, infrastructure, ergonomics, and software into a cohesive strategy, you set the foundation for an operation that thrives today and scales tomorrow.

Partner with a trusted integrator like KPI Solutions to turn your AutoStore vision into a competitive advantage. Contact KPI Solutions today!