Automated Storage/Retrieval System

Automated Storage/Retrieval System (AS/RS)

To increase storage capacity

To increase storage density To recover factory floor space presently used for storing work-in-process (WIP) To improve security and reduce pilferage

Automated Storage/Retrieval System (AS/RS)

()

To reduce labor cost and/or increase labor productivity in storage operation To improve safety in the storage function To improve control over inventories To improve stock rotation To improve customer service To increase throughput

Automated Storage/Retrieval System (AS/RS)

Storage structure => Rack system to support pallets or shelf system to support tote bins Motions => Linear motions Storage/retrieval operation => travels to compartments in rack structure Replication of storage capacity => Multiple aisles

Unit load AS/RS

Storage structure Storage module
S/R machine

pickup-and-deposit station

Components and operating features of an AS/RS

1.
2. 3. 4.

Storage structure Storage/Retrieval machine Storage module One or more pickup-and-deposit station

Application

AS/RS associated with warehouse and distribution operation Application AS/RS

1. 2. 3.

Unit load storage and handling Order picking work-in-process (WIP) storage system

AS/RS for WIP

Buffer storage in production Support of just-in-time (JIT) delivery Kitting of parts for assembly Compatible with automatic identification systems Computer controls and Tracking of materials Support of factory-wide automation

Engineering analysis of AS/RS

Sizing the AS/RS rack structure

Engineering analysis of AS/RS

Sizing the AS/RS rack structure

Capacity per aisle = 2 ny nz

ny = number of load compartments along

the length of the aisle

nz = number of load compartments that make up the height of the aisle

Engineering analysis of AS/RS

Sizing the AS/RS rack structure

number of compartments W = 3(x + a) L = ny (y + b) H = nz (z + c) x y z = dimension of the unit load

a b c = Allowances design =>

a = 150 mm b= 200 mm c = 250 mm

EXAMPLE
Four aisles AS/RS is to contain 60 storage compartments in length and 12 compartments vertically and x = 42 y = 48 the height of a unit load z = 36 a) The storage capacity capacity per aisle = 2(60) (12) = 1440 unit loads

EXAMPLE
b) The width length and height of the AS/RS W = 3(42+6) = 144 in = 12 ft/aisle Overall width = 4 (12) = 48 ft L = 60(48+8) = 3360 in = 280 ft H = 12(36+10) = 552 in = 46 ft

Exercise
6- aisle AS/RS , 50 storage compartments in the length, 8 compartments in vertical unit load x=36 y = 48 z = 30 a = 6 b=8 c=10 a) unit load b) x x

AS/RS Throughput
Methods of AS/RS cycle time to estimate throughput performance : assumes 1. Randomized storage of loads 2. Storage compartments are of equal size 3. The P&D station is located at the base and end of the aisle 4. Constant horizontal and vertical speed of S/R machine 5. Simultaneous horizontal and vertical travel

AS/RS Throughput

The single command cycle time

AS/RS Throughput
The single command cycle time Tcs = 2 Max{ 0.5L , 0.5H} + 2 Tpd Vy Vz = Max { L , H } + 2 Tpd Vy Vz Tcs = Cycle time of a single command cycle L = length of the AS/RS H = Height Vy = velocity along the length Vz = velocity in the vertical direction Tpd = Pick/Deposit time

AS/RS Throughput
The Dual command cycle time

Tcd = Cycle time of a dual command cycle Tcd = 2 Max{ 0.75L , 0.75H} + 4 Tpd Vy Vz = Max { 1.5L , 1.5H } + 4 Tpd Vy Vz

AS/RS Throughput
The relative numbers Rcs Tcs + Rcd Tcd = 60 U Rcs = number of single command cycles performed per hour Rcd = number of dual command cycles performed per hour U = system utilization during the hour

AS/RS Throughput

The total S/R cycle rate (cycles/hr) Rc = Rcs + Rcd

The total number of transactions performed per hour Rt = Rcs + 2 Rcd

Example 2
L = 280 ft H=46 ft
The S/R machine is Horizontal speed = 200 ft/min Vertical speed = 75 ft/min P&D operation is 20 sec to accomplish
a) Tcs , Tcd Tcs = Max{280/200 , 46/75} + 2 (20/60)

= 2.066 min/cycle Tcd = Max {1.5x 280/200 ,1.5x 46/75} + 4(20/60) = 3.432 min/cycle

Example 2
b) Throughput per aisle U = 90 % Single command = Dual command Rcs Tcs + Rcd Tcd = 60 U Rcs x2.066 + Rcd x3.432 = 60 (0.90) Rcs = Rcd 5.498 Rcs = 54 Rcs = Rcd = 9.822 cycle /hr Rt = Rcs + 2 Rcd Rt = 9.822 + 2(9.822) = 29.36 transaction/hr = 29 transaction/hr/aisle

4 aisle

Rt

= 4x 29
= 116 transaction/hr