retrieval system 1.INDEX 1. Introduction . 2. Storage System Performance and Location Strategies 3. Conventional Storage Methods and Equipment 4. Automated Storage Systems 5. Engineering Analysis of Storage Systems • Definition (1) - An AS/RS is a combination of equipment and controls which handles, stores, and retrieves materials with precision, accuracy, and speed under a defined degree of automation. (Materials Handling Institute)
• Definition (2) - AS/RS systems transport, storage, retrieve,
and report on every inventory item with up-to-the minute accuracy
• Definition (3) – The Basic AS/RS consists of a rack structure for
storing loads and a storage/retrieval mechanism whose motions are linear (x-y-z, motions). Automated Storage/Retrieval Systems • An AS/RS consists of one or more storage aisles that are each serviced by a storage/retrieval (S/R) machine. • The aisles have storage racks for holding the stored materials. • The S/R machines are used to deliver material to the storage racks and to retrieve materials from the racks Warehouses Storing, Moving, and selecting parts Manufacturing Just in time arrival of parts Clean Rooms Moving and storing of material that cannot be contaminated Libraries Book storage and retrieval Hospitals and pharmaceutical purpose Storage and retrieval of dangerous material Grocery Distributer Moving and storing of material that cannot be contaminated Function – to store materials (e.g., parts, work-in-process, finished goods) for a period of time and permit retrieval when required.
* Used in factories, warehouses, distribution centers, wholesale
dealerships, and retail stores * Important supply chain component * Automation available to improve efficiency Performance measures for storage systems: 1.Storage capacity - two measures: * Total volumetric space * Total number of storage compartments (e.g., unit loads) 2.Storage density - volumetric space available for storage relative to total volumetric space in facility 3.Accessibility - capability to access any item in storage 4.System throughput - hourly rate of storage/retrieval transactions 5.Utilization and availability (reliability) STORAGE SYSTEM STRATEGY
Two strategies: 1. Randomized, and
2. Dedicated Randomized storage – . In coming items are stored in any available location . Usually means nearest available open location Dedicated storage – In coming items are assigned to specific locations in the storage facility Typical bases for deciding locations: * Items stored in item number sequence * Items stored according to activity level * Items stored according to activity-to-space ratios 1. Less total space is required in a storage system that uses a randomized storage strategy * Dedicated storage requires space for maximum inventory level of each item 2. Higher throughput rates are achieved in a system that uses dedicated storage strategy based on activity level * The most active items can be located near the input/output point * Compromise: Class-based dedicated storage 1.Items divided into classes according to activity level 2.Random storage strategy used within each class. 1.Bulk storage - storage in an open floor area * Problem: achieving proper balance between storage density and accessibility 2.Rack systems - structure with racks for pallet loads * Permits vertical stacking of materials 3.Shelving and bins - horizontal platforms in structural frame * Steel shelving comes in standard sizes * Finding items can be a problem 4.Drawer storage - entire contents of each drawer can be viewed (a) Bulk storage arrangements: (b) high-density bulk storage provides low accessibility, (c) bulk storage with loads forming rows and blocks for improved accessibility (d) Low cost per sq meter (a) Pallet loads placed on racks in multi-rack structure (b) Low cost (c) Good storage density (d) Good accessibility * Contents easily visible * Good accessibility * Relatively high cost
Small items (tools, repair
parts, etc.) Mechanized and automated storage equipment to reduce the human resources required to operate a storage facility 1. Significant investment 2. Level of automation varies * In mechanized systems, an operator participates in each storage/retrieval transaction * In highly automated systems, loads are entered or retrieved under computer control * To increase storage capacity * To increase storage density * To recover factory floor space currently used for WIP * To improve security and reduce pilferage * To reduce labor cost and/or increase productivity * To improve safety * To improve inventory control * To improve stock rotation * To improve customer service * To increase throughput 1. Automated Storage/Retrieval System (AS/RS) * Rack system with mechanized or automated crane to store/retrieve loads 2. Carousel Storage System * Oval conveyor system with bins to contain individual items * Unit load AS/RS - Large automated system designed to use S/R machines to move unit loads on pallets into and out of storage racks.
* Deep-Lane AS/RS – High-density unit load storage
system, designed to store large amounts of stock with relatively little amounts of stock types. It generally stores ten or more loads in a single rack with the input on one side and output on the other
* Mini-load AS/RS - Smaller automated system designed to
move smaller loads into and out of storage bins or drawers.
* Man-on-board AS/RS - Uses personnel to pick items from
racks or bins, reducing transaction time.
* Automated item retrieval system - Items to be moved
are stored in single file lanes, rather than in bins or drawers.
* Vertical lift storage modules –same principle of using a
center aisle to access loads is used except that the aisle is vertical. Helps to save floor space Unit load on pallet AS/RS with one aisle 1. Unit load storage and retrieval * Warehousing and distribution operations * AS/RS types: unit load, deep lane (food industry) 2. Order picking * AS/RS types: mini load, man-on-board, item retrieval 3. Work-in-process storage * Helps to manage WIP in factory operations * Buffer storage between operations with different production rates * Supports JIT manufacturing strategy * Kitting of parts for assembly * Horizontal * Operation is similar to overhead conveyor system used in dry cleaning establishments * Items are stored in bins suspended from the conveyor * Lengths range between 3 m and 30 m * Horizontal is most common type * Vertical * Operates around a vertical conveyor loop * Less floor space required, but overhead room must be provided Manually operated horizontal carousel storage system 1. Storage and retrieval operations * Order picking * Kitting of parts for assembly 2. Transport and accumulation * Progressive assembly with assembly stations located around carousel 3. Work-in-process * WIP applications in electronics industry are common 4. Unique applications * Example: time testing of electrical products 1. Automated Storage/Retrieval Systems * Sizing the AS/RS * AS/RS throughput analysis. Automated Storage/Retrieval Systems
• Each AS/RS aisle has one or more input/output stations where
materials are delivered into the storage system or moved out of the system.
• The input/output stations are called pickup-and-deposit (P&D)
stations in AS/RS terminology.
• P&D stations can be manually operated or interfaced to some form
of automated system. Analysis of Automated Storage/Retrieval Systems • The total storage capacity of one storage aisle depends on how many storage compartments are arranged horizontally and vertically in the aisle. This can be expressed as follows:
CAPACITY PER AISEL=2 ny nz
• Where ny = number of load compartments along the
length of the aisle, and nz = number of load compartments that make up the height of the aisle. • The constant 2 accounts for the fact that loads are contained on both sides of the aisle Analysis of Automated Storage/Retrieval Systems
• If we assume a standard size compartment (to accept a
standard size unit load), then the compartment dimensions facing the aisle must be larger than the unit load dimensions. • Let x and y = the depth and width dimensions of a unit load, and z = the height of the unit load. • The width, length, and height of the rack structure of the AS/RS aisle are related to the unit load dimensions and number of compartments as follows: Where