The "Single Point of Failure": An AS/RS crane in a narrow aisle has no backup. If it breaks, that inventory is trapped. Maintenance must be predictive, not reactive.
Precision Alignment: AS/RS robots rely on lasers and rails. Software must track Rail Wear and Wheel Condition to prevent positioning errors.
The 2026 Standard: The best tools integrate with the WCS (Warehouse Control System) to track "Mission Cycles" and automate maintenance during low-volume hours.
"Crane 2 is stuck in the rack with a pallet on board. We can't access Aisle B."
Automated Storage and Retrieval Systems (AS/RS) are the marvels of modern logistics. They are fast, dense, and efficient.
But they are mechanical beasts. They have wheels, cables, lasers, and motors that wear out.
Legacy maintenance (waiting for a fault code) is disastrous. A stuck crane requires high-angle rescue and stops shipping.
In 2026, AS/RS Maintenance Software is integrated. It counts the Missions (Cycles). It monitors the Motor Current on the lift axis. It schedules downtime during the lunch break.
Here are the 5 best tools to keep your warehouse automated.
| Software | Best For... | Crane Cycle Tracking | Precision/Laser Logs | WCS Integration |
| 1. Fabrico | Unified (WCS + Maint) | Automated (PLC) | High (Digital) | Native |
| 2. SSI Schaefer (WAMAS) | SSI Systems | Best (OEM) | High | Best (Native) |
| 3. Dematic (Sprocket) | Dematic Systems | Best (OEM) | High | High |
| 4. Honeywell (Forge) | Intelligrated | High | Medium | High |
| 5. MaintainX | Manual Inspections | Low | Medium | Low |
Verdict: The best choice for warehouses with Mixed Automation (e.g., Swisslog cranes + Daifuku shuttles) that need a single maintenance view.
Fabrico connects to the PLC/WCS to treat the crane as a production asset. We track the health of the lifting and traveling motors.
Cycle-Based Maintenance: AS/RS cranes run thousands of missions. Fabrico tracks "Travel Distance" and "Lift Cycles." "Inspect Hoist Cable every 100km of travel." This prevents cable fatigue failures.
Visualizing Faults: If the crane errors out ("Position Error"), Fabrico’s Video Analysis (via onboard cameras) shows you if the pallet was wrapped poorly or if the rack was bent.
Digital Laser Checks: Laser distance meters drift. Fabrico enforces a digital calibration checklist. Technicians input the values, ensuring the crane lands perfectly every time.
Best For: Automated Cold Storage and Distribution Centers.
Verdict: The absolute standard if your high-bay is built by SSI Schaefer.
WAMAS is the WMS/WCS that runs the facility. Its maintenance module is deeply integrated.
Predictive Analytics: Uses global fleet data to predict when a wheel will fail based on load profiles.
Integrated Control: It can automatically route the crane to the "Maintenance Bay" when a service interval is due.
Brand Locked: Optimized for SSI. Less effective if you have a legacy Dematic system in the building next door.
Cost: Enterprise pricing.
Best For: SSI Schaefer installations.
Verdict: Essential for Dematic users. Sprocket is a robust EAM designed for automated distribution.
Dematic knows the specific failure modes of their Multishuttle and SRU systems.
Parts Prediction: Automatically suggests the specific spare parts needed for an upcoming PM based on the crane model.
Workflow: Strong focus on the specific workflows of distribution center maintenance.
User Interface: Can feel older and less mobile-friendly than modern SaaS apps.
Best For: Dematic-powered warehouses.
Verdict: A powerful analytics layer for Honeywell / Intelligrated systems.
Forge focuses on asset performance management (APM).
Energy Mgmt: Tracks the energy efficiency of the AS/RS system.
Alarm Management: Filters out nuisance alarms to focus maintenance on real issues.
High Level: It’s an analytics tool, often requiring a separate system to manage the actual wrench-turning work orders.
Best For: Large logistics hubs.
Verdict: The simplest way to manage the Daily Visual Inspection of the racking and crane aisles.
Even automated warehouses need human eyes. MaintainX digitizes the safety walk.
Photo Logs: Snap a picture of a bent rack upright or debris on the rail.
QR Codes: Place a code at the end of each aisle to prove the inspection was done.
Manual: It relies on the human. It doesn't connect to the crane controller to warn you of motor overheating.
Best For: Safety inspections and racking maintenance.
An AS/RS is only efficient if it moves.
If you have SSI Schaefer, use WAMAS.
If you have Dematic, use Sprocket.
If you need a Unified Platform that tracks Crane Cycles, monitors Motor Health, and uses Video to solve faults, Fabrico is the 2026 solution.
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