Theory of Time 2024 (Universal Theory for Everything)
Automated storage and retrieval systems
1. Automated Storage and Retrieval System
(AS/RS)
COURSE NAME- Automated manufacturing systems
COURSE CODE- MEM820
INSTITUTE- Dayalbagh Educational Institute, Agra
DEPARTMENT- Mechanical Engineering
PRESENTED BY-
Raja Gautam
Final year
Roll No:- 154159
PRESENTED TO-
Prof. Gurumukh Das
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2. TABLE OF CONTENT
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• Definition of AS/RS
• Where to use AS/RS
• Components of AS/RS
• Types of AS/RS
• Design of AS/RS
• Applications
• Benefits
• Limitations
3. DEFINITION
• An automated storage/retrieval system is a storage system that
performs storage and retrieval operations with speed ad accuracy
under a defined degree of automation.
• It consists of a variety of computer-controlled systems for
automatically placing and retrieving loads from defined storage
locations.
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4. WHERE TO USE AS/RS
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AS/RS perform a basic set of operations without human intervention:
• Transportation of this item to a specific processing or interface point
• Automatic removal of an item from a storage location
• Automatic storage of an item in a predetermined location, having
received an item from a processing or interface point.
6. COMPONENTS OF AS/RS
1. Storage space- 3-D space in the storage racks that is normally
required to store a single load unit of material.
2. Bay- Vertical stack of storage locations from floor to the ceiling.
3. Row- A series of bays placed side by side.
4. Aisle- The space between two rows for the AS/RS machine
operations
5. Aisle unit- Aisle space and racks adjacent to an aisle constitute an
aisle unit.
6. Storage racks- A structure entity comprising storage locations,
bays, and rows.
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7. COMPONENTS OF AS/RS
7. Storage structure- A storage structure comprises storage racks
and is used to store inventory items.
8. Storage/retrieval machine- An S/R machine moves items in and
out of inventory.
9. Storage modules- Storage modules are used to hold the inventory
items. The modules may be pallets, bins, wire baskets, pans, or
other containers.
10.Pickup and deposit stations- To allow inventory into the system, it
is necessary to have pickup and deposit (P/D) stations. These are
generally placed at the end of the aisles
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8. REASONS OF USING AS/RS
There several reasons of using AS/RS according to industrial point of
view:
• An AS/RS is highly space efficient.
• Increased storage capacity to meet long range plans.
• Improved inventory management and control.
• Reduced shortage of inventory items due to real-time information
and control.
• Reduced labor cost due to automation.
• Flexibility in design to accommodate a wide variety of loads.
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9. TYPES OF AS/RS
1. Unit Load AS/RS
2. Mini load AS/RS
3. Man-on-board AS/RS
4. Automated item retrieval system
5. Vertical lift storage modules (VLSM)
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10. TYPES OF AS/RS
1. UNIT LOAD AS/RS
Machines that store large loads (usually 1,000+ pounds), typically on
pallets. These systems include one or more long and narrow aisles of
storage rack structure, reaching 100 feet or more tall. Most systems are
less than 40 feet tall. Software directs the automatic placement and
retrieval of loads by a telescoping device that deposits loads into, or
retrieves them out of, specific storage positions.
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11. TYPES OF AS/RS
2. MINI LOAD AS/RS
Operating the same way as a unit-load AS/RS, a mini-load AS/RS
handle lighter loads, usually weighing less than 1,000 pounds. Instead
of storing pallets, the machines typically store trays, totes or cartons.
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12. TYPES OF AS/RS
3. MAN-ON-BOARD AS/RS
This system allows storage of items in less than unit load quantities.
Human operator rides on the carriage of the S/R machine to pick up
individual items from a bin or drawer. The system permits individual
items to be picked directly at their storage locations. This provides an
opportunity to increase system throughput.
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13. TYPES OF AS/RS
4. AUTOMATED ITEM RETRIEVAL SYSTEM
• This system is designed for retrieval of individual items or small
product cartoons.
• The items are stored in lanes rather than bins or drawers. When an
item is retrieved from the front by use of a rear mounted pusher bar,
it is delivered to the pickup station by pushing it from its lane and
dropping onto a conveyor.
• The supply of items in each lane is periodically replenished and thus
permitting first-in/first-out inventory rotation.
• After moving itself to the correct lane, the picking head activates
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14. TYPES OF AS/RS
5. VERTICAL LIFT STORAGE MODULES (VLSM)
VLSMs consist of a column of trays in the front and back of the module
with an automatic inserter/extractor in the center that stores and
retrieves the required trays. Trays can be stored in fixed positions to
improve throughput, dynamically to optimize storage capacity, or as a
combination of both. Integrated controls, software and pick-to-
light systems help increase accuracy and storage densities.
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15. DESIGN OF AS/RS
Here we will discuss following important issues related to the layout
and design of AS/RS:
1. Determining load sizes
2. Determining the individual storage space dimensions
3. Determining the storage space numbers
4. Determining the system throughput and number of S/R machines
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16. DESIGN OF AS/RS
5. Determining the size parameters of storage and retrieval system
• Determining the number of rows and number of bays in each row
• Determining bay width , rack length, system length, bay depth, aisle
unit, and system width
6. Determining single and dual command cycle times
7. Determining utilization of S/R machines
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17. DESIGN OF AS/RS
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SYSTEM THROGHPUT:- 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.
1. NUMBER OF S/R MACHINES
22. APPLICATIONS OF AS/RS
• Unit load storage and handling system – Warehousing
for finished goods/Products
• Order Picking – Used to store and retrieve materials in less than
full unit load quantities such as man-on-board or mini-load
applications
• Work-in-process – Support just-in-time production activities,
buffer storage, and as integral part of assembly systems
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BENEFITS OF AS/RS
• Saves up to 85%+ of otherwise wasted floor space
• Reduces labor requirements by up to two-thirds
• Extends order cut off times
• Provides individual and department accountability
• Enhances product security
• Increases ergonomics by delivering items to the operator at a
convenient height, eliminating time lost to walking, searching, lifting,
bending and twisting activities
• Increases accuracy levels to 99.99%+
• Increases throughput capabilities
• Creates new revenue generating activities by reclaiming otherwise
wasted space and labor
24. LIMITATIONS OF AS/RS
• The initial cost of the AS/RS is high.
• AS/RS requires automated guided vehicles or conveyors.
• AS/RS is feasible only for large manufacturing establishments.
• Not Suitable for Highly-Variable Operations
• Can Require Technical Skill and Retraining
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