1. Large Scale Automated Storage Retrieval Systems
Bryan Anderson
10/26/2012

2. Very Broad Overview – Current State
Automated Storage and Retrieval System: A system that performs storage and retrieval operations with speed and accuracy under a defined degree of automation.
Very Broad
This is the definition. We’ve already heard it, and read it. Under this definition, we can include carousel systems, but it could also include Automatic Teller Machines and vending machines. In short, it’s pretty broad.
Ref:
Mikell P. Groover, Automation, Production Systems, and Computer-Integrated Manufacturing

3. Unit Load Large standard unit packages
Deep Lane Deep aisles of single SKU items
Mini Load Items stored in bins, which are retrieved
Man On Board Picker is carried to retrieval location
Item Retrieval Stored in lanes, pushed onto a conveyor
Vertical Lift Vertically stored unit loads
When we discuss AS/RS systems in the industry, they tend to be one of the following systems.
Unit Load, Deep Lane, Mini Load, Man On Board, Item Retrieval, and Vertical Lift.
Unit load your stereotypical AS/RS we’ve seen so far, where unit loads on pallets are stored and retrieved.
Deep Lane is for high volume, low SKU count storage. This reminds me of food storage racks. You pick the front unit, and the rest of the rack comes forward on a flow rack.
Mini Load retrieves compartmented containers to pick, rather than full unit loads.
Man on Board, is just as it sounds – takes the picker to the items. Why would you think this has some advantages? No return trips, move directly from location to location until batch is filled, etc.
Item Retrieval was described in the text as being similar to a vending machine. Small items are kicked off onto a conveyor and brought to the picker.
And vertical lift is like unit load systems, but are vertical.

4. Overview – Where Used
Where are AS/RS systems used? Pretty much any industry has them.
CSU, Northridge claims to be the first library to install such a system. What kind of system does this look like? (Mini-Load)
Daifuku, a Japanese firm that I’ll talk about in a moment, has pages of case studies of companies that have integrated AS/RS systems, including:
References:
CSU Northridge Library =
Diafuku Case Studies =

5. Overview – Who? Retailers Libraries Groceries and Bakeries
Manufacturers
Healthcare
Almost any mature firm willing to invest
They’re used in retail, like with Amazon, or Zappos.
Libraries, as we just saw.
Food distribution centers and bakeries, manufacturers.

6. Overview – Who, What for, and When?
Space is Limited
Conditions are unsuitable for humans (- 20º refrigerated storage)
Volume is High
Orders are Complex
Read the slide

7. Overview – Who, What for? Save Money Improve Accuracy
Improve Efficiency and Productivity
Utilize Space
Improve Safety
They do it to save money, improve accuracy, improve safety

8. Use in Industry – Limitations
Capital
Expertise and Training
Compatible Space and Facilities
Nature of Product
Speed and Flexibility
Software and Systems
Automation shouldn’t be considered an immediate need in all situations. Many factors can limit their integration, like:
How much available capitol your firm is willing to invest, and its expected ROI, training implications, and your facilities. It may not be worth adding an asrs to your existing facilities, so you’d have to plan and build one with automation intended from the start.
The type of product you’re dealing with Contacts logistics manager shared with our class that with their custom orders, and how small their product was, and the low stock they carry at any given time, no automation company could make a good sales pitch that they could actually improve their operations.
Speed and flexabilty are also important. Boeing’s 3PL has too many SKUs for the 787. They package kits together for each task, which has pickers selecting screws and washers. And demand varies so much, it’s not economical to invest in systems that aren’t utilized at near full rates. It’s easier to fill aisles with more part-time workers than robots.
And, software.

9. Therefore, costs vary greatly
Use in Industry – Application
Depends on your needs
Standards and applications are expanding as firms innovate to meet their unique needs
So, how are these systems used in the industry? Well, it depends on your needs. I know, that’s a cop out, but the standards and applications are expanding everyday.
Therefore, costs vary greatly

10. Use in Industry – Standards
Size Standards
Standardized Storage Modules - 10' x 20' maximum module which can be subdivided into standard industry sizes (Example: 5' x 5'; 5' x 10'; 5' x 15'; 10' x 10'; 10' x 15'; and 10' x 20')
Racks Store Modules - 2 to 15 levels high
There are some basic standards for safety, and module sizes. Typically, unit load systems operate off of the standard of 10 x 20, and the modules are subdivided to meet the firm’s unique needs.
There are also safety standards given here. You are free to look those up.
Size Standards, cited by vendor:
Safety Standards Link:
Safety Standards
MH24.1: Safety Standard for Horizontal Carousel Material Handling and Associated Equipment
B : Storage/Retrieval (S/R) Machines and Associated Equipment

11. Large Scale Example 1 – Daifuku Rack-Supported Building
Double-deep
Locations for 66,000 pallets
System processes over
60 pallets per hour
Occupies 165,000 square feet
of floor space.
I’ll give two examples of more specific Large Scale usage here.
One trend we’re seeing is more warehouses designed for automation from the start. An example of this is Rack-Supported Buildings. Another example from a Daifuku case study is they warehouse they built for Meyer Corporation, the cookware company.
A rack-supported warehouse is one that has no need of structural support besides the racks themselves. It makes much better use of space, and is cheaper than a conventional building with the same capacity.
As you can see here, they build the interior first. This site has 6, double-deep aisles, holding 2 pallets per slot. The system can process over 60 pallets an hour, and does it in one quarter the space of a conventional warehouse.
Source:
“The equivalent number of pallets in a flat traditional warehouse would have taken up 750,000 square feet.”
- Cathleen Mandigo, Meyer spokeswoman

12. Large Scale Example 1 – Daifuku Rack-Supported Building
Daifuku Unit Load System:
Standard load weight capacity: 500-3,000 kg (1,100-6,600 lbs.)
Standard S/R machine height: 3-26 m ( ft.)
Standard horizontal speed: m/min. ( ft./min.)
Standard vertical speed: m/min. ( ft./min.)
Standard shuttle speed: m/min. ( ft./min.)
Standard load footprint: mm x mm ( in. x in)
When building a rack-supported warehouse, they obviously make them compatible to their unit load and mini-load systems. Daifuku Unit load specifications are shown here.
They systems are also constrained by the number of robots, number of aisles, length of aisles, etc.

13. Large Scale Example 2 - Hatteland Group Auto Store
HQ in Norway
Invented in 1990s
In 2011, won a prestigious award at LogiMAT for "Best Product" in the "procurement, transport, storage“
As at 2012, a total of 16 systems are up and running in Europe
Another system emerging is a stacked module, cube system, utilizing AVGs that run along tracks on top to grab mini load bins. This system, called Auto Store, was developed by a firm called Hatteland Group, to meet internal needs. Based in Norway, they have much higher premiums on land, and higher burden rates for employees. This system is gaining popularity in Europe, with over a dozen systems in place since the system gained attention a few years ago.
Ref:

14. Video Link Large Scale Example 2 - Hatteland Group Auto Store
Includes:
the grid structure
the bins
the work stations
robots
chargers
all necessary control software and hardware
installation
project services
Excludes:
conveyors
software customizations and/or interfaces to other systems
permits
taxes
duties
We’ll watch the video here.
0:45 - Notice the similarity with the traffic control issues we discussed on Wednesday. These certainly play a role here.
1:00 – 1:25Here, we see that the picking process is sped up by the machine grabbing the bin as the picker prepares to receive it. You see how as she’s packing the last order, she had already scanned the next order, so it’s on its way.
Now it’s here. She grabs the items, and scans the next SKU.
If you watch the entire video, you’ll see that the AGVs need to “dig” the bins out if other are stacked on them. How might that be a drawback?
Ref:
Video Link

15. Video Link Large Scale Example 2 - Hatteland Group Auto Store
Cost of an AutoStore System?
A system that includes:
50,000 bins in a 1,200 m² (13,000 sq. ft.) footprint;
1 standard receiving station;
2 multi-order pick stations with pick-to-light;
2 - 8 robots
Costs $3 - 5 Million
These systems are pretty pricey. As you see here, it’s $3 – 5 million for a relatively simple system of a half dozen robots and 2 picking stations.
You would need to have a fairly large scale need to spread these costs.
Ref:
Video Link

16. Use in Industry – Primary Vendors
When I searched for vendors, it was hard for me to figure who was the leading vendors. Thomasnet.com yielded over 550 companies. So, there is apparently some competition. Some of the bigger names are,
DaiFuku
DEMATIC, who acquired HK Systems Products in 2010
Kasto
Modula
Bastian Solutions

17. Application - Integration
We’re assuming the as/rs system includes the Storage Retrieval Machine. To integrate this system into the rest of your system, you may need conveyors, AGV’s, RFID’s and sensors, and integration with a warehouse managing and tracking system.

18. Application – Class Application
Reverse of Example 11.2
The aforementioned Meyer Corporation warehouse has six double deep (two pallets wide) aisles, and are 675’ long and 100’ tall. Assuming pallet dimensions of 40 x 48 x 48, and allowances of 5 x 12 x 12, what would we expect the storage capacity in pallets to be for this warehouse?
For our application:

19. What we know Pallet Size (x,y,z) 40 x 48 x 48 Pallets per slot 2
Allowance (a,b,c)
5 x 12 x 12
N Aisles 6
Height
100 ft
1200
Inches
Length
675 ft
8100
*Width = 3(x + a)
Length = Ny (y + b)
Height = Nz (z + c)
Total Capacity = (Number of Aisles)*(Nx)*(Ny)*(Nz)
For our application:

20. Solve for variables Pallet Size (x,y,z) 40 x 48 x 48
Pallets per slot 2
Allowance (a,b,c)
5 x 12 x 12
N Aisles 6
Height
100 ft
1200
Inches
Length
675 ft
8100
Nx = 4
8100 = Ny ( ) => Ny = (60)/8100 = 135
1200 = Nx ( ) => Nz = (60)/1200 = 20
Total Capacity = (Number of Aisles)*(Nx)*(Ny)*(Nz)
For our application:

21. Done Pallet Size (x,y,z) 40 x 48 x 48 Pallets per slot 2
Allowance (a,b,c)
5 x 12 x 12
N Aisles 6
Height
100 ft
1200
Inches
Length
675 ft
8100
Nx = 4
8100 = Ny ( ) => Ny = (60)/8100 = 135
1200 = Nx ( ) => Nz = (60)/1200 = 20
Total Capacity = (6)*(4)*(135)*(20) = Pallets
For our application:

22. References
Mikell P. Groover, Automation, Production Systems, and Computer-Integrated Manufacturing
Summarize and include technical paper? ______

23. Questions
Daifuku Product List =
Wireless communication =
Industry Listing =
Thomasnet =