The document discusses automatic storage and retrieval systems (AS/RS), which use automated equipment to store and retrieve materials precisely and efficiently. It describes the basic components and operations of AS/RS, different types including unit load and miniload systems, and methods for automatic identification of items using barcodes, RFID, and machine vision. The advantages of AS/RS are also highlighted such as increased storage capacity and reduced labor costs.

1. Automatic Storage and
Retrieval System
Mujeeb Pasha
Assistant Professor
Vemana Institute of Technology
Bangalore-560034

2. Definition- AS/RS by material handling Institute as
“ A combination of equipment and controls which handles,
stores, and retrieves materials with precision, accuracy and
speed under a defined degree of automation.”
2. AS/RS perform a basic set of operations without human
intervention:
1. Automatic removal of an item from a storage location
2. Transportation of this item to a specific processing or
interface point
3. Automatic storage of an item in a predetermined location,
having received an item from a processing or interface point.

3. AS/RS COMPONENTS AND TERMINOLOGY
USED
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.
7. Storage structure- A storage structure comprises

4. 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

5. • Several types of ASRS are distinguished based on certain
features and applications. Some of the important categories
include:
1. Unit Load ASRS
2. Miniload ASRS
3. Person-on-board ASRS
4. Deep-lane ASRS
5. Automated item retrieval
system

6. UNIT LOAD ASRS
It is used to store and retrieve loads that are
palletized or stored in standard-sized containers.
• The system is computer controlled.
• The S/R machines are automated and designed to
handle the unit load containers.
• Usually, a mechanical clamp mechanism on the
S/R machine handles the load.
• However, there are other mechanisms such as a
vacuum or a magnet-based mechanism for handling
sheet metal.
• The loads are generally over 200 Kgs per unit.

7. MINILOAD ASRS
This system is designed to handle small loads such
as individual parts, tools, and supplies that are
contained in bins or drawers in the storage system.
This system is applicable where the availability of
space is limited.
Also useful where the volume is too low for a full-
scale unit load system and too high for a manual
system
A mini load AS/RS is generally smaller than a unit
load AS/RS and is often enclosed for security of
items stored.

8. PERSON-ON-BOARD ASRS
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.
The operator can select the items and place them in a
module.
It is then carried by the S/R machine to the end of
the aisle or to a
conveyor to reach its destination.

9. DEEP-LANE ASRS
This is a high-density unit load storage system that
is appropriate for storing large quantities of stock
The items are stored in multi deep storage with up
to 10 items in a single rack, one load behind the next.
Each rack is designed for flow-through, with input
and output on the opposite side.
Machine is used on the entry side of the rack for
input load and loads are retrieved from other side by
an S/R- type machine.
The S/R machines are similar to unit load S/R
machine except that it has specialized functions such
as controlling rack-entry vehicles.

10. 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

11. Advantages of AS/RS
• Increased storage capacity
• Reduced factory floor space used for storing
• Reduced labour cost
• Reduced labour productivity in storage function
• Improves safety in the storage function
• Improves control over inventories

12. Automatic identification and data capture
Automatic identification and data capture (AIDC)
refers to the methods of automatically identifying
objects, collecting data about them, and entering
them directly into computer systems, without
human involvement. Automatic part identification
technology consists of three major components
Encoder data
Machine reader or scanner
Decoder

13. Methods for AIDC
Barcode technology
Radio Frequency identification
Magnetic strips
Optical character recognition
Machine vision

14. Barcode Technology
A barcode is the small image of line and spaces that
is affixed on the components.
The code uses a sequence of vertical bars and spaces
to represent numbers and other symbols
Machine Vision
Is the ability of a computer to see: it employs one or
more video cameras, analog-to-digital conversion
and digital signal processing units. The resulting
data is stored in a controller. Machine vision
recognizes the parts based on the inherent geometric
features of the object

15. Radio Frequency identification
A RFID , an identification tag containing
electronically coded data is attached to the item and
communicates these data by radio frequency to a
reader as the item passes
Magnetic strip
A magnetic strips is the black or brown strip
attached to the item. The strip is made up of tiny
magnetic particles in a resin whose pole orientation
are to encode the data in the film strip. This film is
attached to the part for further identification

16. Line Balancing
Line balancing is a procedure by which the work is
distributed evenly to all the workstation and among
all the workers.
Minimum Rational Work Elements
The minimum rational work elements are the smallest
practical indivisible tasks into which the job can be
divided

17. Objective of line balancing
To minimize the total amount of unassigned or idle
times at the workstations
To eliminate bottleneck to ensure smoother flow of
production
To determine optimal number of workstations and
operations in each stations
To maximize the manpower utilize by minimizing
the idle times of operations