KENGIC Completes Smart AS/RS Project for CRRC Zhuzhou: A 10,000 Storage Location Marvel Redefining Rail Transit Logistics

KENGIC, an end-to-end intelligent and digital solution provider for manufacturing and distribution across all scenarios, has successfully delivered a state-of-the-art Smart AS/RS project for CRRC Zhuzhou, a branch of CRRC Corporation Limited (CRRC), the world's largest supplier of rail transit equipment with the most complete product lines and leading technologies. This cutting-edge facility integrates dual-system synergy between SRMs and Pallet Four-way Shuttles, establishing new benchmarks for efficiency and resilience in industrial logistics.

CRRC Zhuzhou Dual-carbon Industrial Park

Spanning over 10,000 storage locations, the smart warehouse enables end-to-end intelligent management from raw materials to finished products, tailored to the precision demands of rail transit manufacturing. 

SRM AS/RS Warehouse

The SRM AS/RS Warehouse, housing 8,000 storage locations, features 9 laser-guided SRMs with ±2mm positioning accuracy, ensuring seamless inbound/outbound operations at 184 P/H and 172 P/H respectively—totaling 356 P/H. Moreover, the contour detection and fixed four-sided scanning systems installed at each inbound port can automatically identify barcodes, enabling the automatic binding of sub-pallets and master pallets and upload tasks instantaneously. This not only saves valuable manual time but also significantly boosts production line efficiency, effectively addressing the customer's needs for inbound/outbound operations and inventory management. Prior to inbound storage, all raw materials undergo intelligent quality inspection at a rate of 13 pallets per hour and efficient bag flipping at a rate of 16 pallets per hour, streamlining the pre-storage preparation process. Furthermore, the system incorporates an automatic palletizer that ensures a continuous and timely supply of empty pallets, thereby improving inbound efficiency to an impressive rate of 184 pallets per hour.

SRM AS/RS Warehouse

Meanwhile, a circular conveyor line is employed at the front section of the warehouse to serve as a buffer, capable of holding a maximum of 70 pallets. This accelerates the flow and retrieval of goods, catering to the material demands during peak production periods and ensuring stable support for the customer's production operations.

A breakthrough "lane relay" design eliminates traditional "lane isolation": goods in Lane 3, for example, can be transferred via Lane 2’s stacker to outbound ports, guaranteeing uninterrupted workflows.

Four-way Shuttle Dense Storage AS/RS Warehouse

Adjacent to the SRM area is the 2,500-location four-way shuttle dense storage zone, where KENGIC innovatively adopts human-machine collaborative dual-mode operation. These shuttles are engineered for versatility and flexibility:

·Capable of moving in four directions and changing layers via specialized equipment, they reach any position in    the storage system, maximizing both planar and three-dimensional space utilization.

·Their compact structure, with a small height profile, saves storage space while enabling multi-layer expansion      to increase capacity.

·High openness allows flexible connection with external equipment, facilitating smooth entry and exit of storage    units.

·Lane depths can be customized based on actual needs, supporting unmanned, high-intelligence production.

In this zone, manual picking stations handle high-frequency small items at 34 pallets per hour, while forklift AGVs directly connect to production lines for full-case material transport — a flexible design perfectly suited for multi-category, small-batch automotive production.

These two smart warehouses are equipped with the "logistics intelligent brain" as the operational core, integrating real-time monitoring (SCADA system), dynamic path optimization (WCS), and comprehensive inventory management (WMS). In case of faults, an Intelligent Emergency System activates immediately: conveyor lines reverse to bypass faulty sections, and goods are rerouted from alternate lanes (1/2/4) to ensure continuity—critical for rail transit’s strict production timelines.

"This project redefines industrial warehousing with rail transit-level reliability," said a KENGIC spokesperson. "By integrating KENGIC’s smart systems with CRRC’s production lines, we are delivering more than just goods—we are showcasing the robustness and capability of China’s intelligent manufacturing sector."

The collaboration underscores KENGIC’s expertise in tailor-made logistics solutions, reinforcing its position as a trusted partner for global heavy industries. It also highlights CRRC’s advanced manufacturing capabilities and commitment to innovation, demonstrating how collaboration between industry leaders can drive progress and efficiency in the logistics and manufacturing sectors. Together, KENGIC and CRRC are setting new benchmarks for smart, reliable, and sustainable industrial operations.