Storage Systems

Sections:
1. Storage System Performance and Location Strategies
2. Conventional Storage Methods and Equipment
3. Automated Storage Systems
4. Engineering Analysis of Automated Storage Systems

Storage Systems
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

Storage System Performance

Performance measures for storage systems:
Storage capacity - two measures:
Total volumetric space
Total number of storage compartments (e.g., unit loads)
Storage density - volumetric space available for storage
relative to total volumetric space in facility
Accessibility - capability to access any item in storage
System throughput - hourly rate of storage/retrieval
transactions
Utilization and availability (reliability)

Storage Location Strategies

Two strategies: 1. Randomized, and 2. Dedicated
Randomized storage
. Incoming items are stored in any available location
. Usually means nearest available open location
Dedicated storage
Incoming 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

Conventional Storage Methods

Bulk storage - storage in an open floor area
Problem: achieving proper balance between storage
density and accessibility
Rack systems - structure with racks for pallet loads
Permits vertical stacking of materials
Shelving and bins - horizontal platforms in structural
frame
Steel shelving comes in standard sizes
Finding items can be a problem
Drawer storage - entire contents of each drawer can be
viewed

Bulk Storage

Bulk storage arrangements:

(a) high-density bulk storage provides low accessibility,
(b) bulk storage with loads forming rows and blocks for improved accessibility
(c) Low cost per sq meter

Pallet Rack System

Pallet loads placed on
racks in multi-rack
structure
(a) Low cost
(b) Good stroge density
(c) Good accessibility

Drawer Storage

Contents

easily visible
Good accessibility
Relatively high cost
Small items (tools,
repair parts, etc.)

Automated Storage Systems

Mechanized and automated storage equipment to reduce
the human resources required to operate a storage facility
Significant investment
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

Objectives and Reasons for

Automating Storage Operations

To increase storage capacity

To increase storage density
To recover factory floor space currently used for WIP
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

Types of Automated Storage System

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

AS/RS
Unit load on
pallet AS/RS
with one aisle

AS/RS Types
Unit load AS/RS - large automated system for pallet loads
Deep-lane AS/RS - uses flow-through racks and fewer
access aisles
Miniload AS/RS - handles small loads contained in bins or
drawers to perform order picking
Man-on-board AS/RS - human operator rides on the
carriage to pick individual items from storage
Automated item retrieval system - picks individual items
Vertical lift storage modules (VLSM) - uses a vertical
aisle rather than a horizontal aisle as in other AS/RS types

Unit Load AS/RS

The AS/RS Unit Load technology
designed to handle unitized loads into
and out of very high density storage.
While sometimes used to replenish
picking locations with palletized
commodities.
The most common application of this
equipment is for the buffering of supply
chain deliveries, storing and controlling
the inventory until it has been released
from QC, or is requested out for use in
downstream processes.
This would include the buffering of
palletized finished goods waiting for
distribution to the end user.

Mini load AS/RS

The unique compact design of the Mini
Load AS/RS allows you to store more
material in less space.
This AS/RS is designed with strong,
lightweight alloys making the mini load
less expensive to install, operate, and
maintain.
The most common usage of this class
of AS/RS is for small parts storage
and management for picking and order
fulfilment.
Often paired with a hybrid combination of
Carousels, flow lanes and static racks or
shelves, the Miniload provides the best
solution for those small parts like nuts,
bolts, hand tools that represent the midrange of activity.

Man-On-Board AS/RS
Used for in-aisle picking;
operator picks from shelves,
bins, or drawers within the
storage structure.
Manual or automatic control
S/R machine is similar to an
order picker or turret truck and
can sometimes operate as an
industrial truck when outside an
aisle, except the S/R is guided
along a rail when operating in an
aisle.

Deep-Lane AS/RS
Similar to unit load AS/RS,
except loads can be stored to
greater depths in the storage
rack.
A rack-entry vehicle is used to
carry loads into the racks from
the S/R machine, and is
controlled by the S/R machine.
Another S/R machine functions
as a retrieval vehicle to extract
the parts from the other end of
the storage lane.

Automated item retrieval system

These systems are also designed
for retrieval of individual items
or small unit loads such as cases
of product in a distribution
warehouse.
However, in this system, the
items are stored in single-file
lanes rather then in bins or
drawers.
When an item (or case) is to be
retrieved, it is released from its
lane onto a conveyor for
delivery to the pickup station.

Components of an AS/RS

1.Storage structure / Bins

2.S/R Machine
3.Storage module (Pallet Loads)
4.Pick and deposit station
5.Control system

AS/RS Applications
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: miniload, 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

Carousel Storage Systems

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

Horizontal Carousel Storage System

Manually operated
horizontal carousel
storage system

Vertical Carousel Storage System

Features of a Vertical Carousel System
1.Carriers / bins attached to the rotating mechanism
2.Multifunction Carrier for variable applications
3.Drive System housed internally
4."Soft Start" Control uses three phase motors
5.Work Counter made of high-grade stainless steel
6.Rack for item retrieval and storage by operator
7.Light Barriers
8.Microprocessor Control Unit
9.Wiring Cabinet located for easy access
10.Multifunction Positioning System
11.Lockable Sliding Doors provide protection of stored
items
12.Protective Cover
13.Maintenance Accessat the front.

Carousel Applications
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

Engineering Analysis of
Automated Storage Systems
1. Automated Storage/Retrieval Systems
Sizing the AS/RS
AS/RS throughput analysis
2. Carousel storage systems
Storage capacity
Throughput analysis