MIT's 2026 State of Supply Chain Omnichannel Report describes a new reality for supply chains, one defined less by growth than by operational complexity: more SKUs, more channels, and greater variability to execute against. Mixed inventory is where that complexity shows up on the floor, and the ability to accommodate very different inventory profiles in one operation is becoming a requirement rather than a nice-to-have.
FlexBinsPort brings that flexibility to the workstation. It handles all AutoStore Bin heights and types at a single Port, removing a constraint that has traditionally shaped how mixed-dimension inventory is picked. This deep dive covers how it works, how it complements FlexBins™, and what it changes for the operation.
When different products call for different Bin heights, operations have typically accommodated them in one of three ways:
Dedicated workstations for each Bin height
Separate flows that are consolidated downstream
Extra workstations, buffering, and floor space to absorb the difference
Each approach works but also adds something, whether that's equipment and training, extra handling, and order dependencies. FlexBinsPort removes the need for all three by letting every Bin height come to the same station.
FlexBinsPort handles 220-, 330-, and 425-mm Bins, as well as case-handling Bins, at a single Port. As the Robot lowers a Bin onto the tray, the Port adjusts to that Bin's height within the normal delivery cycle, so switching heights doesn't slow how quickly Bins are presented.
Every Bin arrives at the same opening, in the same position, so the operator works from one place at a consistent, comfortable height. A sensor-equipped safety cover and an overweight check are built in.
In practice, that means:
One workstation type instead of several to buy, maintain, and train against
Orders spanning different Bin heights picked in one place, rather than split and consolidated later
Software can orchestrate around physical constraints, but software-based workarounds often introduce trade-offs in flexibility, productivity, and total cost of ownership. FlexBinsPort addresses Bin-height compatibility at the workstation itself.
FlexBins provides mixed-Bin flexibility in the Grid, so products can be stored in the Bin height that fits them. FlexBinsPort carries that flexibility through to the workstation. Each delivers value on its own. Together, product dimensions decide how inventory is stored without storage dictating how work is routed.
FlexBinsPort fits systems that use multiple Bin heights or whose workflows regularly may need to mix them at the same station. Existing AutoStore customers can install it, and it delivers the most value alongside FlexBins.
When Bin height matches the product rather than the workstation, less Grid volume goes to empty space in oversized Bins. That capacity is recovered inside the existing footprint, easing the pressure to expand as the business grows.
10% to 15% higher storage utilization
Used together with FlexBins, FlexBinsPort helps deliver 10% to 15% higher storage utilization by matching Bin size to each product.
On the labor side, fewer separate flows mean fewer handling, staging, and coordination steps, and a single workstation setup simplifies training. Fewer exceptions also mean fewer interruptions against throughput goals.
The benefit is largest where inventory profiles vary widely or change often.
|
Segment |
How FlexBinsPort helps |
|
3PL with multiple tenants |
New clients with different inventory profiles can be onboarded to existing stations without a workstation reconfiguration. |
|
Apparel & footwear |
Folded and boxed goods in the same order are stored in the Bin heights that fit them and picked at one station. |
|
Consumer electronics, home supplies, general merchandise |
Large SKU assortments and mixed-category orders bring products with varied dimensions to the same workstation, where different Bin heights and types can be picked. |
|
Grocery, food and beverage, healthcare |
Small units and bulky cases move through the same station, reducing the handoffs where compliance errors occur. |
|
Electronic equipment, automotive, machinery |
Wide-ranging part dimensions are stored densely without limiting which stations can retrieve them. |
Mixed inventory keeps changing. New SKUs enter the assortment, product dimensions vary, and demand shifts over time.
FlexBins lets AutoStore customers match Bin height to the product. FlexBinsPort extends that flexibility to fulfillment by bringing all Bin heights and types to one workstation.
This means workstation flows no longer need to be designed around Bin-height compatibility. Products can be stored in the Bin that fits, while operators use the same workstation setup for picking.
For operations managing a varied or changing assortment, the result is a simpler path from storage to fulfillment, with fewer handoffs, fewer constraints, and more room to adapt.
→ Discover how FlexBins and FlexBinsPort work together
→ Learn more about AutoStore's practical path to autonomous operations