Goods-to-Person Without the Price Tag: How VLMs & Carousels Deliver GTP Efficiency for Real-World Operations

Why manufacturers, warehouses, and MRO teams don’t need a multimillion-dollar ASRS to compete

“Goods-to-person” is having a moment again. Everyone in the automation space is using the term because labor is expensive, floor space is tight, and speed-to-operator matters more than ever. But when most people hear “GTP,” they picture a massive, high-cost ASRS with shuttles, robots, and multi-level infrastructure.

That assumption is outdated. Vertical Lift Modules (VLMs) and vertical carousels have always been goods-to-person systems, and they deliver the same core advantages at a fraction of the cost and footprint.

The Misconception: GTP Requires a Full-Scale ASRS

There’s a widespread belief that GTP solutions require:

Seven-figure automation budgets
Major facility renovations
Months of engineering and integration
Robotics, mezzanines, and conveyor networks

Those setups can make sense for enterprise-level fulfillment operations shipping thousands of SKUs an hour. But most manufacturing, service, aerospace, and parts facilities don’t need that level of infrastructure to solve their challenges. What they need is a faster, denser, easier-to-implement system that doesn’t require rebuilding a facility or blowing up a capital plan.

The Reality: VLMs and Carousels Are Goods-to-Person Automation

VLMs and vertical or horizontal carousels deliver the exact workflow GTP is built around:

Inventory is brought directly to the operator
Travel time and walking are eliminated
Items are stored in high-density, secured space
Throughput, accuracy, and ergonomics all increase
Labor requirements and search time drop significantly

No shuttles. No mezzanines. No robots. Yet the outcome is the same: the product moves to the picker instead of the picker chasing product.

Cost-Efficient GTP for the Mid-Market

VLMs and carousels deliver goods-to-person benefits without the price tag or footprint of a full ASRS. They’re especially effective for:

Manufacturing and MRO
Aerospace and defense
Healthcare and medical device facilities
Parts departments and service centers
Distribution, kitting, and repair operations

A shuttle-based GTP system can run $1M to $4M before integration. A VLM or carousel delivers the same functional advantages for a fraction of that investment, with shorter lead times and smaller installation windows.

Faster ROI, Smaller Footprint, Easier to Deploy

With VLMs and carousels, companies gain GTP advantages without heavy infrastructure:

✅ Fraction of the cost of traditional ASRS or cubic ASRS
✅ Installation without disrupting operations
✅ Fits tight spaces and low ceilings
✅ Integrates with existing WMS/ERP systems
✅ Scales one unit at a time instead of an all-or-nothing approach
✅ Delivers ROI in months, not years

They directly address the biggest pressures driving the GTP conversation:
Space – Reclaim up to 85% of floor space
Labor – Reduce travel time and improve pick efficiency
Accuracy – Minimize human error and improve control

Why GTP Is Surging Right Now

The rise in interest is tied to real business conditions:

Reshoring and onshoring are increasing storage demands
Labor shortages aren’t easing
Building expansions are costly and slow to approve
Inventory visibility and traceability matter more
Orders are smaller, faster, and more frequent

Companies don’t have room for inefficiency. GTP solves the problem, and it doesn’t have to look like a million-dollar shuttle system to do it well.

VLMs and Carousels Aren’t “Entry-Level” — They’re the Practical Form of GTP

These systems deliver goods-to-person efficiency in a format that works for the majority of real-world operations. They make GTP achievable without the cost, complexity, or disruption of a traditional ASRS.