Storage and Warehouse System - Process Improvement - Flow Process Chart Based Industrial Engineering - Module Lessons
Industrial Engineering - Role of Engineering, Mechanization and Automation
Jidoka - Automation and Mechanization - Process Engineering and Industrial Engineering in Toyota Production System
Automation of Operations in Flow Process Chart
In engineering processes, storage is an important operation. There is cost associated with storage. As a part of process improvement, requirement for storage needs to be minimized and also unit cost of storage has to be reduced using methods similar to those used for reducing costs of material processing, inspecting and transporting. Automation is an approach to reduce total cost of storage.
Automated storage systems are available that reduce the cost in certain storage applications. The level of automation varies. In less-automated systems, a human operator is required in each storage/retrieval transaction. In highly automated systems, loads are entered or retrieved under computer control, with human participation limited data input to the computer.
Automated storage systems are available in two general forms: (1) automated storage/retrieval systems and (2) carousel storage systems.
An automated storage and retrieval system (AS/RS) is a storage system that performs storage and retrieval operations under a defined degree of automation. At the most sophisticated level. the operations are totally automated, computer controlled, and they respond to the instructions of factory and warehouse management systems. At lower levels of automation, human workers are involved in every storage and retrieval transaction with some automation in storage and retrieval actions.
An AS/RS consists of one or more storage aisles that are each serviced by a storage/retrieval (S/R) machine. (The S/R machines are sometimes referred to as cranes.)The aisles are located between storage racks for holding the stored materials. The S/R machines deliver materials to the storage racks and retrieve materials from the racks. Each AS/RS aisle has one or more input/output stations where materials are delivered into the storage system or moved out of the system. The input/output stations are called pickup-and-deposit (P&D) stations in AS/RS terminology. P&D stations can be manually operated or interfaced to automated handling system such as a conveyor or an AGV.
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https://www.youtube.com/watch?v=YYdgLAlogpY
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AS/RS Types and Applications.
• Unit load AS/RS. The unit load AS/RS is typically a large automated system designed to handle unit loads stored on pallets or in other standard containers.
Deep-lane AS/RS. The deep-lane AS/RS is a high-density unit load storage system that is appropriate when large quantities of stock are stored, but the number of SKUs is relatively small. Each rack is designed for "flow-through," with input on one side and output on the other side. Loads are picked from one side of the rack by an SIR-type machine designed for retrieval, and another machine is used on the entry side of the rack for load input.
• Miniload AS/RS. This storage system is used to handle small loads (individual parts or supplies) that are contained in bins or drawers in the storage system. The SIR machine is designed to retrieve the bin and deliver it to a P&D station at the end of the aisle so that individual items can be withdrawn from the bins. The P&D station is usually operated by a human worker. The bin or drawer must then be returned to its location in the system. A miniload AS/R system is generally smaller than a unit load AS/RS and is often enclosed for security of the items stored.
• Man-an-board AS/RS A man-an-board (also called man-aboard) storage/retrieval system represents an alternative approach to the problem of retrieving individual items from storage. In this system, a human operator rides on the carriage of the SIR machine. The man picks individual items. This offers an opportunity to increase system throughput
• Automated item retrieval system. These storage systems retrieve individual items or small product cartons stored in lanes. To retrieve an item. it is pushed from its lane and it drops onto a conveyor for delivery to the pickup station. The supply of items in each lane is periodically replenished, usually from the rear of the system so that there is first-in/first-out delivery.
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https://www.youtube.com/watch?v=dIn0GWlYDdc
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• Vertical lift storage modules (VLSM or/ VL-AS/RS). Vertical lift storage modules have vertical aisles, some with heights of 10 m (30 ft) or more, save floor space in the factories.
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https://www.youtube.com/watch?v=lWAgKvk5xC8
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Work-in-process (WIP) storage in AS/RS.
Work-in-process (WIP) storage is also being kept in AS/RS.
It is not unusual for a plant engaged in batch production to have hundreds of orders in progress simultaneously, all of which represent work-in-process. Automated storage systems help to store WIP neatly and efficiently. They deliver the jobs according to the priority decided by production schedulers and bring discipline in the shop.
More detailed description of AS/RS system for WIP Storage
Work-in-Progress Handling
Solving Challenges: Space Shortages, Production Inefficiencies, Labor Shortages, and Workplace Safety. Installing an AS/RS as an Inter-Process Buffer Solves Issues of Space, Labor, Safety, and Efficiency
By introducing a buffer system that combines an automated storage and retrieval system (AS/RS) with transport equipment such as shuttle carts or AGVs, it is possible to solve the above four problems and increase operational efficiency and safety.
• Support of just-in-time delivery. Some plants have installed automated storage systems as storage buffers for incoming materials.
• Kitting of parts for assembly. The storage system is used to store components for assembly of products or subassemblies. When an order is received, the required components are retrieved, collected into kits (tote pans), and delivered to the production floor for assembly.
• Compatible with automatic identification systems. Automated storage systems can be readily interfaced with automatic identification devices such as bar code readers. This allows loads to be stored and retrieved without human operators to identify the loads.
• Computer control and tracking of materials. Combined with automatic identification, an automated WIP storage system permits the location and status of work-in-process to be known.
• Support of factory-wide automation. Automated storage system becomes an important subsystem in a fully automated factory.
Components and Operating Features of an AS/RS.
(1) storage structure,
(2) S/R machine,
(3) storage modules and
(4) one or more pickup-and-deposit stations.
(5) control system
The S/R machine consists of a rigid mast on which is mounted a rail system for vertical motion of the carriage. The base of the mast has wheels to permit horizontal travel along a rail system that runs the length of the aisle.
The carriage includes a shuttle mechanism to move loads into and from their storage compartments and to receive the load from the P&D station.
To accomplish the desired motions of the S/R machine, three drive systems are required: horizontal movement of the mast. vertical movement of the carriage, and shuttle transfer between the carriage and a storage compartment. Modem S/R machines are available with horizontal speeds up to 200 m/min (600 ft/min) along the aisle and vertical or lift speeds up to around 50 m/min(150 ft/min).The speeds determine the time required for completing a task.
The storage modules include pallets. steel wire baskets and containers, plastic tote pans, and special drawers.
The pick -and-deposit station is where loads are transferred into and out of the AS/RS.
They are generally located at the end of the aisles for access by the external handling system that brings loads to the AS/RS and takes loads away.
Computer controls and programmable logic controllers are used to determine the required location and guide the SIR machine to its destination. The automatic controls can be superseded or supplemented by manual controls when required under emergency conditions or more frequently for man-an-board operation of the machine.
Carousel Storage Systems
A carousel storage system consists of a series of bins or baskets suspended from an overhead chain conveyor that revolves around a long oval rail system. The chain conveyor positions required bins at the load/unload station. Carousels are automated by using transfer mechanisms at the load/unload station to move loads into and from the carousel.
Carousel Technology. Carousels can be classified as horizontal or vertical. The more common is horizontal configuration. It comes in sizes, ranging between 3 m (10ft) and 30 m (100 ft) in length.
The structure of a horizontal carousel storage system consists of welded steel framework that supports the oval rail system. The carousel can be either an overhead system (called a top-driven unit) or a floor-mounted system (called a bottom-driven unit). In the top-driven unit. there is an overhead trolley system. The bins are suspended from the trolleys. In the bottom driven unit, the trolley system rides on a rail in the base. This provides more load-carrying capacity for the carousel storage system. Bin widths range from about 50 to 75 cm (20 to 30 in), and depths are up to about 55 cm (22 in). Heights of horizontal carousels are typically 1.8-2.4 m (6-8 ft). Bins are made of steel wire to increase operator visibility.
Vertical carousels are constructed to operate around a vertical conveyor loop. They occupy much less floor space than the horizontal configuration.
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https://www.youtube.com/watch?v=KNR_Dot7XG4
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Manual foot pedal control allows the operator at the pick station to rotate the carousel in either direction to the desired bin position. Hand control involves use of a hand-operated switch that is mounted on an arm projecting from the carousel frame within easy reach of the operator. Again, bidirectional control is the usual mode of operation. Keyboard control permits a greater variety of control features. The operator can enter the desired bin position, and the carousel delivers the bin to the pick station.
Computer control increases automation of the carousel and provides for management of the inventory records.
Carousel Applications. Carousel storage systems are an attractive alternative to a miniload AS/RS in manufacturing operations where its relatively low cost, versatility, and high reliability are recognized. Storage and retrieval operations can be efficiently accomplished using carousels when individual items must be selected from groups of items in storage. This kind of procedure is common in order-picking of tools in a tool-room, raw materials in a stockroom, service parts or other items in a wholesale firm, and work-in-process in a factory. Carousel storage systems often compete with automated storage and retrieval systems for applications where work-in-process is to be temporarily stored.
Automated Storage and Warehousing - AS/RS - Case Studies
RoboVault introduces a state-of-the-art automated self storage facility
Westfalia Technologies, Inc. was commissioned to develop a state-of-the-art automated self storage facility in Ft. Lauderdale Fla., RoboVault. This new venture was also a new era in the self storage industry which introduced Automated Storage and Retrieval Systems (AS/RS), typically seen in the warehouse and manufacturing plant.
News - More Information and Articles Automated Storage and Warehousing - Storage Operation Improvement
Automated Material Handling in Warehouse of Pitman Creek, Kentucky.
Benefit: a 250% improvement in picking efficiency.
January 20, 2022
The pickers were allotted to zones. For any order, the picker picks items in his zone and puts them in a totebox. Inventory in the zone was slotted such the most frequently picked items were stored nearest the conveyor. An order selector could pick 72% of most orders in the four rows nearest the conveyor and complete 97% in the eight rows nearest the conveyor.
Further, a recirculating conveyor is used as buffer storage until all of the totes needed for an order are ready and can be sent to a packing station. The packing section will receive all totes at the same time and will do the packing.
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