Automated Storerooms: Boosting Efficiency with VLM and Vertical Carousels

Automated storerooms are rethinking how manufacturers and warehouses organize, protect and distribute parts and supplies, replacing sprawling shelving with compact, automated retrieval systems that cut travel time and errors. For Blue Sky Robotics’ audience in manufacturing, warehousing and automation, improving automated storeroom efficiency unlocks faster fulfillment, higher inventory accuracy and better use of floor space. As demand for just-in-time production and lean operations grows, these systems are becoming essential capital investments rather than optional conveniences.

Vertical Lift Modules (VLMs) and vertical carousels are the technologies at the center of this shift, delivering high storage density while reducing pick times through automated tray retrieval and controlled access. When integrated with ERP and WMS platforms, they enable real-time inventory tracking, automated replenishment triggers and smoother workflows across production and distribution. Next, the article examines how VLMs and vertical carousels function, how software integration amplifies their value, and what to consider when evaluating deployment, beginning with an overview of Vertical Lift Modules and vertical carousels.

The Evolution of Storeroom Automation

Storeroom management has moved from paper ledgers and bin cards to barcode scanning and full warehouse management systems, and the most recent step in that progression is storeroom automation. Early digitization eliminated much of the manual counting and misplacement risk, but the real leap came with mechatronics and robotics that automate retrieval and delivery , systems that physically bring parts to the operator rather than relying on human search. Key milestones include the commercial adoption of vertical carousels and Vertical Lift Modules (VLMs), which combined compact, vertical storage with automated pick delivery to dramatically increase density and reduce travel time, a trend noted in industry coverage of automation advances Automation World.

Today’s storeroom automation emphasizes three measurable gains: space savings, speed, and pick precision. Modern VLMs and carousels are commonly integrated with ERP and WMS platforms so inventory levels update in real time and replenishment triggers and pick workflows are automated, turning static storerooms into dynamic, data-driven hubs that support just-in-time operations. Ongoing developments in robotics (robotic pick arms, goods-to-person shuttles) and improved control software continue to push throughput and accuracy, making storeroom automation an essential strategy for operations seeking higher efficiency and lower carrying costs.

How Vertical Lift Modules and Carousels Work.

Vertical Lift Modules (VLMs) and vertical carousels use different mechanical approaches to deliver a goods-to-person workflow that drives automated storeroom efficiency. VLMs are enclosed, vertically stacked trays that an inserter/extractor unit moves to present the correct tray at an ergonomically positioned access opening; vertical carousels rotate carriers on a horizontal loop to bring items to the picker. Both systems rely on coordinated motors, sensors and control software so the right tray or carrier is presented quickly and repeatably, while onboard intelligence can measure item height and suggest tray assignments to maximize usable volume.

That sensor-driven optimization translates directly into faster picks and denser storage: automated height measurement, tray optimization algorithms and dynamic slotting reduce wasted vertical space and enable tighter packing of SKUs, while the goods-to-person design eliminates walking time and supports efficient batch or wave picking. Safety and ergonomic features, such as adjustable access heights, light curtains, interlocks, and weight sensing, protect operators and maintain throughput, and native integration with ERP/WMS platforms provides real-time inventory visibility and automated pick instructions that further reduce cycle times and errors. Together these capabilities make VLMs and vertical carousels foundational components of an automated storeroom strategy designed to increase storage density and accelerate fulfillment.

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Integrating Automated Storerooms with ERP/WMS for Real-Time Inventory and Workflow Automation

Connecting automated storerooms, especially systems built around Vertical Lift Modules (VLMs) and vertical carousels, with an organization’s ERP or warehouse management system (WMS) transforms static storage into a real-time inventory platform. When VLMs and carousels report transactions (picks, returns, replenishments) directly to the ERP/WMS, stock levels update instantly, reducing manual cycle counts, minimizing stockouts, and improving order accuracy while preserving the storage density and pick efficiency these systems provide. Vendors and system integrators commonly provide built-in interfaces or standardized APIs to enable this level of synchronization and ensure that the automated storeroom becomes a visible, auditable part of the broader supply chain Kardex.

On the technology side, integration typically relies on a mix of RESTful APIs, middleware, and event-driven messaging so that each VLM or carousel action triggers workflow updates, replenishment triggers, and downstream processes like kitting or shipping. That tight coupling also enables advanced automation, such as pick-to-light guidance, automated replenishment alarms, and prioritized order staging, so teams realize quicker cycle times and measurable KPI improvements (throughput, picks per hour, and inventory accuracy). By combining the vertical storage density of automated storerooms with real-time ERP/WMS visibility, organizations gain both the space savings and the operational control necessary for scalable, modern inventory management.

Final Thoughts

In conclusion, the advancements discussed provide a clear pathway toward greater efficiency and innovation. Embracing these changes will not only enhance productivity but also open new opportunities for growth and development. It is essential to remain adaptable and forward-thinking as the landscape continues to evolve.

Looking ahead, the integration of emerging technologies promises to reshape industries and everyday experiences alike. Staying informed and proactive will ensure that individuals and organizations can fully benefit from these transformative trends. Ultimately, the future holds considerable potential for those willing to engage with the possibilities ahead.