The automated warehouse system at American Airlines' Dallas/Fort Worth maintenance facility uses miniload and unit load automated storage and retrieval systems to store and deliver aircraft parts. It is controlled by redundant computers and maintained full-time by technicians from the system's manufacturer, Dematic. The highly available system operates 24/7 to supply parts to four hangars and has achieved over 99% uptime due to the on-site maintenance contract.

1. Case Study
American Airlines
Dallas/Fort Worth, Texas
The automated warehouse system at the Overview The miniload ASRS has 5,928
Dallas – Fort Worth Line Maintenance Shipping notices are pan locations. Each pan has
downloaded from the Host multiple compartments with
Facility consists of three aisles of miniload
to the WCD and Hanger welded-in-place dividers and a
ASRS, three aisles of Unit Load ASRS, Cell Directors. The orders 300 lbs. storage capacity. There
Tote Conveyor, Trash Conveyor, and an are converted to movement is a miniload ASRS transfer
Automated Overhead Monorail System with commands on the WCD and device which allows the storage
sent to the equipment. and retrieval machine to be
11 Carriers. The system is controlled by
routed from one aisle to another
redundant computers with software developed Workstation operators retrieve as a backup in the event of a
by Dematic, referred to as the Warehouse parts from the miniload ASRS major component failure.
Cell Director (WCD). Additionally, there are 2 and place them on conveyor
which routes them to their The Unit Load ASRS contains
Hanger Cell Directors connected via modem in
destination. Unit Load pallet 1,560 free standing locations
hangers 3 and 4. parts are retrieved from the each with a capacity of 1200 lbs.
ASRS and routed to pickup Then conveyor transports the
points via conveyor. heavy and large parts inventory
on metal clad pallets. Lift trucks
The system provides aircraft move the pallets, directed by
parts to 4 hangers. The commands via radio frequency
overhead monorail system terminals.
transports parts to the hangers
3 and 4. Parts arrive in totes via Full Time On-Site Maintenance
a lowerator and are returned to American Airlines has
the warehouse via an elevator contracted with Dematic
to the monorail. to provide full-time on-site
equipment maintenance for the

2. DFW facility. This option gives Software package. This ensures
American Airlines a direct link to that the required expertise and
all of the resources Dematic has required parts will be ready
to offer. when minor repairs are required,
and that the system will be
Having a full maintenance repaired as quickly as possible.
crew comprised of trained
Dematic technicians means This mission-critical facility
that someone will be there to operates 365 days per year, 24
handle planned and unplanned hours per day and is covered by
maintenance any time the a skilled staff of factory-trained
system is operating. This option technicians supported by
leaves nothing to chance. Every Dematic’s engineering team.
precaution is taken to ensure
the highest possible system The Dematic full-time on-site
reliability. maintenance contract at
American Airlines includes an
The technicians perform uptime performance guarantee,
© Dematic Corp. | Order-No. CS-1046 | Printed in USA 03/11
preventative maintenance and uptime has averaged 99.6%
and manage the required over the 8 years of Dematic
spare parts inventory using staffing the maintenance of this
an Dematic’s Computerized system.
Maintenance Management
Dematic
507 Plymouth Ave. NE
Grand Rapids, MI 49505
Tel 1 (877) 725-7500
Fax 1 (616) 913-7701
USinfo@dematic.com
www.dematic.us