AI GeneratedOPS & AUTOMATIONInsight

The Hidden Gaps in Your ASRS: Why Size Alone Doesn't Guarantee Peak Performance

Jun 15, 2026

Adversarial AI Pipeline

Key Takeaway

Daifuku Intralogistics America built an ASRS for Peterbilt Motors that buffers full truck bodies between assembly and paint — a process step most operators handle with sprawling outdoor yards or floor staging. Using vertical ASRS storage for components this large reclaims floor space and decouples assembly throughput from paint booth availability, eliminating the single biggest sequencing constraint in heavy-vehicle production.

Our Take— Mike Sanders, Founder

“We see this as proof that the buffer between two unbalanced process steps is where the P&L lives — paint booths typically run at 70-85% utilization in heavy truck manufacturing, and every hour of forced idle time on a $200K+/day assembly line is pure margin loss.”

The Hidden Gaps in Your ASRS: Why Size Alone Doesn't Guarantee Peak Performance

From the Source

"This ASRS was built by Daifuku Intralogistics America for Peterbilt Motors Company to store truck bodies in between assembly and painting."

— Is this the largest ASRS you've ever seen?

Key Takeaways

01Daifuku built an ASRS for Peterbilt that stores entire truck bodies — not pallets or totes
02Buffer location is between two of the most expensive process steps: assembly and paint
03Decoupling assembly from paint scheduling removes a major throughput constraint
04Vertical storage of large bodies reclaims significant floor space vs. ground staging
05ASRS scope keeps expanding — from small parts to full vehicle bodies