Start with the total count, the number you want to keep, the outside dimensions and the usable shelf dimensions. The customer confirmed four shelves.
trolleys
ASRS PLANNING
ASRS ROI calculator
Change the yellow cells. Your results update, just like Excel.
Calculator not active in this preview. Download this HTML file and open it in Chrome, Edge or Safari, or use the hosted webpage. File previews may show the page without running the calculator. The example inputs below stay visible, but are disabled until the calculator starts. Download the Simple Excel template instead.
Example values
Simple mode uses the same size and shelf loading for current and future trolleys. Starting values are examples. Measure your actual trolley and goods.
Trolley count
Use the same counts as your Excel workbook.
What to enterYour valueGuide
Count all trolleys, including empty ones and spare ones. More than 500 were reported. The starting example uses 500.
Count all future trolleys: working, waiting, docked, empty and spare.
trolleys
Of the trolleys you plan to keep, enter how many normally carry no goods.
trolleys
Current trolley measurements
Yellow cells are editable. The outside size and the usable shelf size are separate measurements.
What to enterYour valueGuide
Choose feet, metres or millimetres. Use this unit for all trolley and shelf sizes below. Changing the unit does not convert the numbers. Enter matching measurements.
unit
Measure end to end, including any handle or part that sticks out. See the blue L arrow.
ft
Measure across the widest part, including wheels or handles that stick out. See the blue W arrow.
ft
Measure the flat shelf space inside the frame. Leave out posts, edges and handles. See the green l arrow.
ft
Measure from front to back inside the frame. See the green d arrow.
ft
Count the shelves that can hold goods. The customer has confirmed four shelves.
levels
Enter the average across every shelf and trolley. Include empty shelves as 0%. Example: half covered = 50%.
%
YOUR CALCULATION
Storage, floor space and ROI
Usable tray surface930.0 sq ftAll installed tray positions
Net floor released-313.4 sq ftThis layout needs extra floor
Work hours freed26,000 / yearTime available for other work
Cash paybackNot calculatedRequires costs and cash savings
This ASRS is smaller than the target needs. It holds 80 loaded trays; 3,441 are needed. At this size, approximately 491 trolleys are still needed. Increase capacity or check the actual inventory. The target of 100 is not yet supported.
See how your figures are calculated
Compare all three concepts
| Measure | Concept A | Concept B | Concept C |
|---|---|---|---|
| Enough storage to reach trolley target? | No | No | No |
| Usable tray positions in racks | 160 | 64 | 100 |
| Trays held at planned fill level | 128 | 51 | 80 |
| Loaded trays needed for trolley target | 3,441 | 1,155 | 3,441 |
| Rack positions needed, including free spaces | 4,302 | 1,444 | 4,302 |
| Extra rack positions still needed | 4,142 | 1,380 | 4,202 |
| Trolleys still needed with this ASRS size | 486 | 483 | 491 |
| Trolleys this ASRS size could remove | 14 | 17 | 9 |
| Floor taken by all current trolleys (sq ft) | 10,000.0 | 10,000.0 | 10,000.0 |
| Usable surface on all trolley shelves (sq ft) | 40,000.0 | 40,000.0 | 40,000.0 |
| Loaded shelf area to move into ASRS (sq ft) | 32,000.0 | 32,000.0 | 32,000.0 |
| Usable storage surface on one tray (sq ft) | 9.3 | 27.7 | 9.3 |
| Total usable tray surface in ASRS (sq ft) | 1,488.0 | 1,773.2 | 930.0 |
| Tray surface at planned filled positions (sq ft) | 1,190.4 | 1,413.0 | 744.0 |
| Floor taken by the ASRS machine (sq ft) | 406.4 | 584.3 | 278.1 |
| Crane travel floor, already inside ASRS (sq ft) | 177.8 | 279.4 | 130.9 |
| Trolley floor freed before adding ASRS (sq ft) | 280.0 | 340.0 | 180.0 |
| Extra aisle floor that can be freed (sq ft) | 0.0 | 0.0 | 0.0 |
| Extra loading and service floor (sq ft) | 215.3 | 215.3 | 215.3 |
| Net workshop floor gained (sq ft) | -341.7 | -459.5 | -313.4 |
| Net floor at target, if capacity is enough (sq ft) | — | — | — |
| Whole new test or assembly bays | 0 | 0 | 0 |
| Tray storage surface / machine floor (times) | 3.7 | 3.0 | 3.3 |
| Storage density compared with current trolleys (times) | 0.9 | 0.8 | 0.8 |
| Tray levels that fit the height | 10 | 8 | 10 |
| Calculated machine length (m) | 11.8 | 11.8 | 7.6 |
| Calculated machine width (m) | 3.2 | 4.6 | 3.4 |
| Machine height needed for these levels (m) | 4.8 | 4.8 | 4.8 |
| Hours available for other work per year | 26,000 | 26,000 | 26,000 |
| Value of saved time, before cash check (SGD) | — | — | — |
| Actual labour spending avoided per year (SGD) | 0 | 0 | 0 |
| Actual space spending avoided per year (SGD) | 0 | 0 | 0 |
| Yearly cash benefit after running costs (SGD) | — | — | — |
| Total one-off project investment (SGD) | — | — | — |
| Years to recover the investment | — | — | — |
| Five-year cash return on investment (%) | — | — | — |
| Five-year cash value at today's value (SGD) | — | — | — |
HOW TO USE IT
Measure, enter, compare.
Choose A, B or C. Change modules, bays, levels and tray size. The model counts actual usable trays and checks that the entered dimensions fit.
Open Results to see storage area, net floor, time saved and cash return. Blank money results mean more cost inputs are needed.
A trolley is the wheeled cart. A tray is the removable surface stored by the ASRS. A bay is one vertical rack column; a level is one tray height. The IO bay is the loading and unloading point. Pictures show what to measure; they are not final fabrication drawings.
KEEP YOUR WORK
Save your inputs and use Excel
Your entered values
Save a scenario to continue later or move your entries to another browser. It includes both modes and all three concepts.
The CSV contains your current inputs and calculated results for A, B and C. Open it in Excel as a calculation record.
The CSV is a record, not a formula workbook.
Formula workbooks
The Simple and Detailed Excel workbooks use the same calculations. These templates start with the example values; web edits do not change the templates.
Web interface Rev N. Calculation model and Excel templates Rev M. Values match when the same inputs and mode are used.
Continue with AETEC
Copy all Simple inputs and the A/B/C design settings into Detailed mode, then complete future trolley dimensions and engineering checks together.
Detailed cost lines must be completed separately. Copying replaces the shared and design inputs currently in Detailed mode.
Measurement photo
Add a trolley or tray photo for reference during this session. It stays on this device and does not set the dimensions automatically.