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Getting an AS/RS system wrong costs money. A lot of it. The good news? Most problems come from missing basic planning steps, not from the technology itself. Here’s what you need to know before you start an ASRS systems integration project. Your Building Matters More Than You Think AS/RS systems are tall. Some reach 100 feet high. That means your building needs to handle the weight and the height. Start with a structural engineer. They need to check your floor’s load capacity. Concrete floors often need reinforcement. Steel buildings might need extra support columns. Older warehouses sometimes can’t support modern AS/RS at all. Don’t skip this step. We’ve seen projects delayed six months because the floor wasn’t ready. One client had to pour a new foundation. Another needed to add 12 support columns. Both could have been avoided with early planning. Your ceiling height sets your storage capacity. Every foot of height means more inventory you can store. But you also need room for fire suppression systems, lighting, and HVAC. Plan for at least 18 inches of clearance at the top. Your Current WMS Needs a Health Check An AS/RS talks to your warehouse management system constantly. Every pick, every putaway, every inventory move goes through that connection. If your WMS is old or custom-built, integration gets harder. Some older systems can’t handle the speed of automated storage. Others lack the API connections modern AS/RS systems need. Ask these questions about your WMS: Sometimes the WMS needs an upgrade before you add AS/RS. Sometimes you need WES (warehouse execution system) software to sit between your WMS and the automation. Sometimes you need both. Figure this out early. WMS upgrades can take 3-6 months. That affects your whole project timeline. Power Requirements Are Bigger Than Expected Some AS/RS systems can use a lot of power. The cranes run constantly. The conveyors never stop. The control systems need clean power without interruptions. Your electrical system needs three things: Enough capacity. A typical AS/RS uses 200-400 amps. Small warehouses sometimes need a complete electrical upgrade. Budget for it. Clean power. Control systems hate power fluctuations. You might need dedicated circuits, surge protection, or even a UPS backup system. The right locations. Power needs to reach the crane rails, the conveyor motors, and the control panels. Running new lines through an operating warehouse costs more than installing them in an empty building. Get an electrical contractor involved in month one, not month six. Fire Suppression Gets Complicated Fire codes for AS/RS are strict. Storage racks that reach the ceiling create fire hazards. Automated systems can’t evacuate themselves. Most AS/RS installations need in-rack sprinkler systems. That means sprinkler heads inside the storage structure, not just on the ceiling. The cost varies, but plan for $50,000 to $200,000 depending on system size. Your local fire marshal needs to approve the design. In some cities, this approval process takes months. Start it early. Some AS/RS designs use ESFR (early suppression fast response) sprinklers. Others use standard sprinklers with draft curtains. Your building height, product (including packaging), storage density, and local codes determine which you need. Layout Planning Takes Real Work Where the AS/RS sits in your warehouse matters. It affects everything else. Receiving proximity. Putting the AS/RS too far from receiving docks means long conveyor runs. Each foot of conveyor costs money and needs maintenance. Shipping access. Pick faces need to be close to shipping areas. Workers shouldn’t walk 200 feet to retrieve picked orders. Column spacing. Existing building columns might block the ideal layout. Sometimes you can work around them. Sometimes they force you to choose a different AS/RS. Traffic flow. Forklifts, people, and automation need to coexist. Poor planning creates bottlenecks and safety hazards. Draw it out. Use tape on the floor. Build a mock-up if you need to. Walking through the layout catches problems that look fine on paper. Product Matters Product size and shape play a critical role in AS/RS design, but it’s not just about the individual SKU. How the product is stored matters just as much — including vendor case sizes, inner packs, and the quantities you plan to hold and move through the system. Variability in dimensions, weights, and packaging can quickly limit storage density or complicate picking if it’s not understood upfront. This is why accurate product and order data is essential early in the process. Providing 12 months of outbound order history will help to establish realistic design rates for both storage and picking. That data helps determine slotting strategies, throughput requirements, and whether the system can scale with seasonal or promotional spikes. Replenishment also needs careful consideration. Replenishment should be simple, intuitive, and predictable. If the process becomes overly complex, labor-intensive, or error-prone, it’s usually a sign that the storage strategy or system configuration needs to be rethought before moving forward. Integration Time Is Real Time You can’t install AS/RS in a weekend. Even small systems take weeks. Large ones take months. Most warehouses can’t shut down for installation. That means working around ongoing operations. Night shifts. Weekend work. Phased installations. Plan for these phases: Week 1-2: Site prep. Floor reinforcement, electrical work, fire suppression rough-in, safety system testing. Week 3-6: Structural install. Rack assembly, crane installation, conveyor placement. Week 7-10: Systems integration. Control software setup, WMS connection, ongoing safety system testing. Week 11-12: Testing and training. System testing, staff training, process documentation. Week 13+: Go-live and optimization. Gradual ramp-up, issue resolution, performance tuning. These timelines assume everything goes right. Add buffer time for problems. They always happen. Staff Training Can’t Be an Afterthought AS/RS systems change how your warehouse works. Your team needs to learn new skills. Operators need to understand the control system. They monitor dashboards, handle exceptions, and troubleshoot basic problems. Maintenance staff need to know the mechanical systems. Crane maintenance is different from forklift maintenance. Supervisors need to understand the workflow changes. Pick processes are different. Put-away processes are different. Inventory management is different. Start training before installation finishes. Good vendors provide training during installation, not just after. Plan for at least 40 hours of training per

Systems in Motion is proud to announce that we have been named a Top Workplaces 2025 honoree by Chicago Top Workplaces.  This recognition is especially meaningful because it’s based entirely on feedback from our own team, gathered through a confidential survey conducted by Chicago Tribune partner Energage. The survey measures the core elements of a thriving workplace—feeling respected and supported, being empowered to grow, and having the confidence and clarity to execute with impact. “At Systems in Motion, we’ve always believed that our people are our greatest strategic advantage,” explains Systems in Motion President Scott Lee. “This award affirms that our commitment to fostering an inclusive, growth-driven, and collaborative culture is not only felt, but valued.” “Earning a Top Workplaces award is a badge of honor for companies, especially because it comes authentically from their employees,” said Eric Rubino, CEO of Energage. “That’s something to be proud of. In today’s market, leaders must ensure they’re allowing employees to have a voice and be heard. That’s paramount, and it pays dividends.” We couldn’t agree more. We’re grateful to our team for the passion, trust, and innovation they bring every day—and we’re honored to see that commitment reflected in this award. Click the link to learn more!

The Systems in Motion Command Center is your all-in-one hub for warehouse automation. It helps you manage, monitor, and optimize every part of your material handling system. This platform combines SCADA visualization, KOZ WCS/WES, and CCTV surveillance. Everything is in one place. Operators and managers can make fast, informed decisions that keep operations safe and efficient. Whether you run a distribution center, an ecommerce fulfillment center, or a food warehouse, the Command Center adapts. It gives you: Visibility – Real-time warehouse analytics and insights Control – Centralized access across conveyors, robotics, and automation Confidence – Tools to reduce downtime and boost throughput The Command Center supports modern order fulfillment workflows. This includes goods-to-person picking, pick and pack zones, returns management, and retail distribution. It helps improve labor efficiency, order accuracy, and overall productivity. For high-speed order picking, automated distribution centers, or microfulfillment, the SIM Command Center gives you the edge. It’s designed to support both day-to-day performance and unexpected events. View the full flyer here.    Contact us at shop.systemsinmotion.com for your command center needs

Customer demand has driven Ecommerce and Fulfillment Industries to offer 24/7 delivery with few to no mistakes. And without 24/7 technical help, equipment failures often result in disappointed customers and lost income. Here’s how a preventative maintenance plan helped Spreetail, an Ecommerce Acceleration company A year ago, this ecommerce company experienced frequent operational disruptions, resulting in 9 emergency service calls. With average technician time exceeding 2.5 hours per incident (including travel), total downtime approached 24 hours across the year. Estimated revenue losses were over $100,000, and even more when considering customer dissatisfaction. Now, with a Preventative Maintenance program in place, they’ve experienced 0 downtime, 0 emergency calls, and a look-forward strategy that identifies problems before they happen. Ray Goins, Director of Engineering & Facilities at Spreetail, appreciates the customized program, saying “Systems in Motion was the first company to think outside the box and support us the way we needed, with a unique and tailored program.” Ray elaborates, “Two things stand out with Systems in Motion. They came to the table to listen to us, to hear our concerns and work with us to deliver what we needed, not a packaged program. And they are extremely accessible. It feels like they care as much about our business as we do, and it’s obvious they want us to succeed.” What did Systems in Motion deliver? A Strategic Partner Approach: Expert-level audits to catch failures before they escalate Custom dashboards for operational decision-making Preventative protocols to increase uptime and reduce total cost of ownership What is preventive maintenance?A unique check-in and check-up program designed for each customer. For our ecommerce client that meant: 1. Understanding their equipment’s real lifecycle – when and where failures could happen – and scheduling repairs and/or replacements before failure. Experts who provide: a. Visual inspectionsb. Wear component replacementc. Sensor calibrationd. Debris removale. Functional testing of motors, belts, rollers, and air systems 2. Creating an annual maintenance budget – not an unknown repair bill 3. A strategic partner that provides timely data-driven maintenance forecasting: a. Emergency service history and trendsb. Preventative maintenance logsc. Labor tracking and service hoursd. Parts usage and inventory demand forecasting These insights helped company leadership justify an investment in maintenance and visualize ROI in real time.

Shop.SystemsinMotion.Com — Your New Destination for Conveyor and Material Handling Equipment Parts HytrolParts.com has a new website address and contact information, but one thing hasn’t changed — we’re still the same dedicated team helping you get the right conveyor parts quickly, accurately, and without the hassle.  We’re excited to announce that you can now browse, chat, and shop online at shop.systemsinmotion.com. For questions or direct support, use live chat or email shop@systemsinmotion.com.  But that’s not all — we’ve expanded our e-commerce offerings beyond OEM parts for Hytrol conveyors. You can now view pricing and order flexible conveyor parts from FMH online, and we’re continuing to add more OEM brands by request, so ask if you can’t find something.  Our goal remains simple: to keep your operation moving with reliable parts, dependable service, and a team you can count on.  Thank you for being part of our journey. We look forward to serving you in new and improved ways at shop.systemsinmotion.com.  Contact us at shop.systemsinmotion.com for your conveyor parts.

As summer comes to a close and our extra help heads back to school, Systems in Motion would like to take a moment to express our heartfelt appreciation to the talented interns and office support team members who joined us. Over the past few months, we’ve had the opportunity to share our knowledge and experience—from Engineering to Project Management, Marketing to Office Support. In return, you brought fresh ideas, energy, and dedication that made a real impact on our work. From the start, our summer interns and office help played an important role in supporting teams across the organization: Engineering – Assisting with designs, documentation, and problem-solving that helped keep projects on track. Project Management – Helping coordinate schedules, organize tasks, and ensure that details didn’t fall through the cracks. Marketing – Contributing to campaigns, content creation, and research that amplified our brand and outreach. Office Support – Keeping our daily operations running smoothly with a positive attitude and a willingness to jump in wherever needed. You brought valuable skills, but you also brought a fresh perspective and enthusiasm that inspired our team. It’s always exciting to see how quickly you adapt, learn, and contribute to real-world projects. For many of you, this internship may have been your first step into the professional world. Meanwhile, for us, it was an opportunity to learn from your new ideas and see challenges through a different lens. Ultimately, we hope your time at Systems in Motion has been as rewarding for you as it has been for us. Looking ahead, we’re excited to see all that you accomplish—and perhaps welcome you back in the future. From all of us at Systems in Motion—thank you for making this summer one to remember!  

With peak season approaching quickly, Systems in Motion wants to make sure that you are ready for the most important season of the year.  The Aftermarket Services team is ready to offer qualified equipment health assessments to prevent conveyor failure during peak season on a wide variety of conveyor systems.  A few of the options we have available for you are: Preventative maintenance visits Custom-made aftermarket preventative maintenance packages Readily available technicians for emergency service calls or scheduled visits Assist with decreasing down time during your busy season Assist with preventing conveyor failure Download your Systems in Motion Equipment Checklist here Times and services are beginning to fill up quickly for preventative maintenance and assessments so make sure to book yours soon.  Please feel free to contact Aftermarket Services at ams@systemsinmotion.com and schedule your assessment today.  Or call 800-687-9091.