Automated Storage/Retrieval Systems - Explained

A simple and clean presentation on AS/RS, generally used in Manufacturing Systems.

1. AUTOMATED STORAGE / RETRIEVAL SYSTEMS C GAUTAM REDDY M VENKATA KRISHNA

2. What is this? Excess inventory Lost or damaged product Inaccurate records Endless searching Climbing Bending Frustration Cluttered aisles

3. Definition AS/RS is a system designed to transport, store , retrieve, and report on every item in any industrial inventory with up-to-the minute accuracy. AS/RS provide dense inventory storage to maximize floor space.

4. Quick Glance When & why to use? If you are suffering from cluttered storage. Where to use? Fields of manufacturing, pharmacy, retail and wholesale industries. How to use? Generally this system is integrated with software like WES or WCS .

5. Todays’ Agenda Introduction AS/RS Components and Terminology Types of AS/RS Type of layouts in AS/RS Design of an AS/RS

6. Structure of an AS/RS

7. Video

8. Components & Terminology Storage Space It is the three-dimensional space in the storage racks used to store load. Storage Racks This structural entity comprises storage locations, bays and rows . Generally made of steel and aluminium Bay It is the height of the storage rack from floor to the ceiling. Row It is a series of bays placed side by side.

9. Components & Terminology… Aisle It is the spacing between two rows for the machine operations of AS/RS. Aisle Unit It encompasses aisle space and racks adjacent to an aisle. Storage/Retrieval Machine It is used to move items in and out of inventory. An S/R machine is capable of both horizontal and vertical movement. A rail system along the floor guides the machine and a parallel rail at the top of the storage structure is used to maintain its alignment.

10. Components & Terminology… Storage Modules These are the unit load containers used to hold the inventory items. These include pallets, steel wire baskets and containers, pans and special drawers. These modules are generally made to a standard base size capable of being stored in the structure and moved by the S/R machines. Pickup and Deposit (P/D) Stations P/D stations are where inventory is transferred into and out of the AS/RS. They are generally located at the end of the aisles to facilitate easy access by the S/R machines. The location and number of P/D stations depends upon the origination point of incoming loads and the destination of output loads.

11. Types of AS/RS Unit Load Mini Load Deep Lane Man on Board

12. Unit Load AS/RS Consists standard sized containers Over 250 kg loads One component per one rack Most used system

13. Mini Load AS/RS More than one component per storage space Such a system is applicable where the availability of space is limited . E.g.: Tools

14. Deep Lane AS/RS Useful for storing large quantities of stock Up to 10 items in a single rack (one behind another) Principles (LIFO & FIFO)

15. Man on Board AS/RS Human operator rides on the carriage of the S/R machine to pick up individual items from a rack I ndividual items to be picked directly at their storage locations . E.g.: Less than unit load quantities

16. Types of Layouts Horizontal Carousel Rotary Carousel Vertical Carousel Vertical Lift Module (VLM) Fixed Aisle (F/A) Storage Retrieval Systems

17. Consists of a fixed number of adjacent storage columns or bays that are mechanically linked to an oval track which rotates horizontally, on an overhead or floor mounted drive mechanism. Horizontal Carousels

18. Consists of a fixed number of adjacent storage columns or bays that are mechanically attached to a rotary positioning stage . Rotary Carousels

19. Consists of a number of horizontal shelves, trays or bins that are mechanically linked to an oval track which rotates vertically Vertical Carousels

20. A storage system that consists of two parallel columns. A container is inserted, extracted and transported between storage levels and picking locations via an elevator-like device with an automatic shuttle that travels up and down within the space between the storage columns.  The storage container is presented to a fixed P/D station.   Vertical Lift Modules (VLM )

21. Consists of one or more long, narrow aisles framed on both sides by a steel or extruded aluminium storage rack structure from which loads are automatically stored and retrieved under computer control. Fixed-Aisle (F/A) Storage Retrieval Systems

22. Advantages of AS/RS Utilization of maximum floor space, thus recovering the space for manufacturing facilities Increasing the efficiency of storage capacity Increasing the stock rotation Improved customer service Improved control over inventories Reducing labour cost in storage operation Reducing pilferage and improving security

23. Process Activity Identify the layout Ans : VLM

24. Process Activity Identify the layout Ans : Vertical Carousel

25. Process Activity Which one is more efficient when you have less floor space? A) Horizontal Carousel B) Vertical Carousel C) Rotary Carousel C) Vertical Lift Ans : B

26. DESIGN OF AN AS/RS Retrieval Systems

27. Load size determination is the most important element in the design of an AS/RS and is based on work flow information . The movement frequency of parts, tools, fixtures, pallets , and other supplies define the overall work flow. Work flow is determined by variety and volume of part types and the type of production system . The width, length and height of rack structure of the AS/RS aisle are related to the unit load dimensions. The dimensions of the unit loads with proper clearances provide the individual storage space dimensions. Storing unique items of unusual and complex shape are excluded from the AS/RS design. Weight of the unit load is also considered in the structural design. Load Sizes Determination

28. Calculating Individual Storage Space Dimensions Constant ‘2’ is multiplied because loads are contained on both sides of the aisle. No. of unit loads stored in an aisle = u x Capacity per aisle

29. PROBLEM:

30. SYSTEM THROUGHPUT System throughput is defined as hourly rate of S/R transactions ( number of loads stored and number of loads retrieved ) that an automated storage system can perform . Following are the factors that influence system throughput :

31. Number of S/R Machines

32. Estimating the Size Parameters of the Storage and Retrieval System ( i ) Number of Rows and the Number of Bays in Each Row of a System: The number of rows in case of one S/R machine per aisle is :

33. (ii) Estimation of Bay Width, System Width, Rack Length, System Length, Bay Depth and Aisle Uni t

34. The single command cycle system of a XYZ Inc. has S/R machine capacity as 2 cycles/min. Expected system throughput for the corporation is 360 operations per hour . Number of storage space per system height is 15 and total number of storage spaces using a randomized policy is 9000. Assuming storage and retrieval operation take same time, determine : ( i ) Number of S/R machines; (ii) Number of rows; and (iii) Number of bays in each rows. PROBLEM:

35. Single-command Cycle It performs either storage or a retrieval operation. In case of storage cycle, machine picks up a load, travels to the storage location, deposits the load , and returns empty to the P/D station. Similarly , in a retrieval cycle, the S/R machine begins at the P/D station and travels empty to the retrieval location. Thereafter, it picks up the load, travels to the P/D station, and deposits the load.

36. Dual-command Cycle The machine picks up the load and travel to the storage location to put down the load. Thereafter, the machine travels to the retrieval location to recover the load. Finally, it travels back to the P/D station to deposit the load.

37. PROCESS ACTIVITY Differentiate between Single and Dual command Cycle ? Single command Cycle Dual-command Cycle In case of storage cycle, machine picks up a load, travels to the storage location, deposits the load, and returns empty to the P/D station. Similarly, in a retrieval cycle, the S/R machine begins at the P/D station and travels empty to the retrieval location. Thereafter, it picks up the load, travels to the P/D station, and deposits the load. The machine picks up the load and travel to the storage location to put down the load. Thereafter, the machine travels to the retrieval location to recover the load. Finally, it travels back to the P/D station to deposit the load.

38. Thank you!!