Automated Storage and Retrieval Systems Solutions for staging, sequencing, and order fulfillment Creating Logistics Results
Integrated technology for your staging, sequencing, replenishment, and order fulfillment needs.
Dematic Heritage of Innovation Dematic provides Automated Storage and Retrieval Systems (AS/RS) designed to fit your individual application needs, and interfacing transportation technology that completes your system. Conveyors, automatic guided vehicles, software and control systems can be included as part of a comprehensive supply chain solution. Our 70 year history, including our legacy Demag products, gives us unique knowledge and experience from installing over 9500 Storage Retrieval Machines (SRMs) and 3500 AS/RS worldwide. Our systems have a reputation for unmatched reliability. Dematic has the widest selection of SRMs, load handling devices, interfacing transportation technology, and controls in the industry. This allows us to provide an integrated solution optimized to meet your needs. Reduced floor space, just-in-time inventory, lower operating costs, as well as gentle handling and accuracy are a few of the time-tested benefits of a Dematic AS/RS solution. To satisfy individual needs, we offer a comprehensive line of automated miniload and unit-load storage systems that: Adapt to your storage strategy (FIFO, LIFO) Improve control over inventory Reduce inventory Provide security and safety Improve customer service Reduce product damage Reduce labor cost Improve floor space utilization Eliminate excessive / repetitive handling Reduce delays Contents: Mini-Load Systems 4 Unit-Load Systems 8 AS/RS Interfacing Systems 12 Software & Controls 14 Lifecycle 16 Technical Specifications 18 About Dematic 19 Improve logistics Improve housekeeping Increase worker safety Lower operating costs 3
Mini-Load Systems High Density Storage for Small SKUs Dematic Mini-Load Automated Storage and Retrieval Systems are designed to handle trays, totes and cartons. A Mini-Load AS/RS delivers product to and from task workers or transportation systems quickly and easily. Standard models are mated to extraction/insertion components and tailored to your individual product size and type. Pick-up and delivery stations and interfacing transportation systems are also designed specifically for your operation. All Dematic Mini-Load AS/RS offer fast pick-up and delivery, dense storage and quiet operation. State-of-the-art computer architectures coordinate input and output activity. Mini-Load AS/RS control systems can interface with your Warehouse Management System creating complete supply chain accountability. A Mini-Load AS/RS that handles totes and interfaces with a conveyor system. This Mini-Load shuttle handles metal containers full of books for a university. 4
Dematic Mini-Load Product Line Dematic Mini-Load AS/RS solutions offer: High speed automated order fulfillment Ultra-dense storage Accurate replenishment Quiet operation High throughput Goods to the person order selection Lifting Beam 10 m/ 32 ft Lifting Beam Lifting Beam Lifting Beam Mini-Load AS/RS technology easily handles plastic totes of products. SR-M SR-M 50/1 50/1 SR-M SR-M 100/1 SR-M 100/1 100/1 SR-M 100/2 SR-M 100/2 SR-M 300/1 300/1 100/2 SR-M 300/1 SR-M 300/2 SR-M 300/2 10 m/ 32 ft 14 m/ 46 ft 14 m/ 46 ft SR-M 50/1 SR-M 300/1 SR-M 300/2 Lifting Beam SR-M 100/2 SR-M 200/2 18 m/ 60 ft SR-M SR-M 300/1 300/2 SR-M 300/2 20 m/ 65 ft 5
Retrieval Made Easy We have a wide range of proven load handling attachments to handle loads of almost every conceivable shape and size. One example is our pneumatic gripper which securely holds and extracts cartons that may not be in the best condition. The design features of the load handling attachments facilitate spacesaving storage. Single or multiple load handling attachments can handle several boxes or bins simultaneously, increasing system performance. We also offer various other extraction devices. Two gripper extractors on a single SRM handling two totes at a time. Pneumatic gripper for single deep storage. Pneumatic gripper for double deep storage. Dematic Lifting Beam. 6
Proven Experience Dematic s extensive AS/RS application experience in different industrial and distribution markets provides a knowledge basis for new customer applications. We specialize in staging systems for food and beverage, frozen food, general merchandise, hardware, newspapers, chemicals, and manufacturing, as well as niche applications for mini-load systems, such as library or small parts management systems. Dematic provides stand-alone or fully integrated systems that employ AS/RS for storage, staging, work-in-process/assembly, module replenishment, and order fulfillment. Our modular, flexible technology can be customized to meet any customer requirement. Goods to the person order fulfillment. 7
Unit-Load Systems Solutions for Large Loads Dematic Unit-Load systems are designed to handle a variety of standard and custom loads, including pallets, rolls, and containers. Unit-Load pallet handling machines utilize lifting carriages equipped with telescopic forks, satellites, or other load extracting devices. Single deep, double deep or deep lane storage configuration loads can be accommodated. Alternative, pre-engineered extraction/insertion devices are available to suit your product type and size. Large products are handled gently and consistently. Storage Retrieval Machines can be mated to transfer cars that allow them to work multiple aisles within the rack. Many types of interfacing transportation systems are available. The latest controls technology for automatic or manual Unit-Load machines makes them efficient and accurate. Machine controls can interface with your Warehouse Management System to improve product flow and tracking. Reliability and ease of maintenance are engineered into each machine. Transfer cars with integrated input/output conveyor move storage and retrieval machines from aisle to aisle. SR-U 1000/1 10 m/ 32 ft SR-U 1000/2 24 m/ 78 ft SR-U 1200/1 30 m/ 98 ft SR-U 1500/1 46 m/ 150 ft 8
This AS/RS moves multiple pallet loads of barrels. 9
Unit-Load technology can be utilized in a variety of applications including the food and beverage industry, chemicals/pharmaceuticals, or specific solutions for deep-freeze storage or integrated order-picking. From pallet handling systems, to textile reels, to order picking and picking stock replenishment, Dematic has the breadth of experience to supply you with an AS/RS that fits your supply chain needs. High performance, cost effectiveness, space efficiency and reliability, are just some of the significant attributes of a Dematic AS/RS. A SRM services multiple storage aisles. Unit-Load AS/RS offer: Real time inventory control Automatic or manual operation Quiet and gentle handling Ultra-dense storage Load handling devices include: Single deep load shuttles Double deep load shuttles Deep lane satellite load shuttles Multiple load handling devices Load handling device design criteria includes: Product/container type, weight, and size Single or multiple deep storage Single or multiple product pick-up and delivery based on performance needs A satellite pallet shuttle accommodates deep lane storage. This single deep pallet shuttle handles heavy loads. Order fulfillment AS/RS can be utilized to replenish picking modules. 10
Load handling devices must manipulate product gently, efficiently, and precisely and must be compact in order to minimize aisle and storage cell size. Precise placement in and out of storage cells allows maximum storage space utilization. Dematic load handling devices require minimum operating space, creating optimum storage density. Load handling devices are performance matched to throughput rates, assuring product will arrive on time, every time. Dematic s vast experience in fitting products to the application gives us the ability to provide you with the best solution. Dairy products pallet loads being transferred to a delivery station. Hardware staging and order picking. 11
AS/RS Interfacing Systems Moving Materials Interfacing transportation systems route product to and from Automated Storage and Retrieval Systems. Transportation systems can include conveyor, automatic guided vehicles and automated electrified monorail. The system choice must match the throughput capabilities of the AS/RS, and it must coordinate the AS/RS input and output process. From frozen food storage, to pallet handling systems, to work-in-process operations, Dematic can provide a complete, integrated AS/RS interfacing transportation system. Product size and type, as well as routing, and throughput needs are some of the factors that determine the type of interfacing equipment to be used. Routing demands and throughput rates are also key considerations. Complex automated systems are computer driven and can interface with Warehouse Management Systems. AS/RS interfaces with order processing station. This system interfaces with automatic guided vehicles to keep aisleways open. 12
Interfacing systems include: Conveyor systems Automatic Guided Vehicle Systems (AGVS) Robotics Palletizing/de-palletizing Automated electrified monorail Stretch wrappers Scales and sizing stations Dematic BK-25 conveyor provides transportation between AS/RS and order fulfillment workstations. 13
Software & Controls Dematic IT StagingDirector is a modular software program designed to enhance the functional operation of Automated Storage Retrieval Systems (AS/RS) and the associated, integrated conveyor delivery and take-away system. By acting as middleware between the Host Computer/WMS system and the machine level controls, StagingDirector provides a window of functions that allow users to maximize the efficiency of their AS/RS investment. StagingDirector offers comprehensive inventory control and reporting. Real-time decision making control and AS/RS component status are provided utilizing the Windows operating system. The software is pre-engineered and modular for flexibility, and is optimized for access through the Dematic IT Portal, so users have a single point of access to all Dematic IT Warehouse Control Software (WCS). With StagingDirector, the functional features of simple or complex systems are easily configurable. The system can be configured with automatic carrier routing, static or dynamic storage location assignments, round robin aisle selection, specific customer business rules, product attributes and automatic or manual order activation. Dematic supplies complete, easy to understand documentation for StagingDirector online, as well as direct system upgrades and support via the Internet. Host Computer/ WMS Dematic IT Staging Director Server and Controls Remote Stations StagingDirector workstation operator interface. SRM Controller PLC for: Conveyor, Size/Weigh Station, and Scanners StagingDirector architecture. 14
Dematic Storage Control System (SCS) is the PC based system that controls Storage Retrieval Machine (SRM) function and movement. SCS provides a real time, graphical interface of AS/RS functions, device level I/O and performance in a user friendly Windows environment. The Storage Control System (SCS) offers viewing and editing of AS/RS machine parameters. SCS also records an operational log that tracks system events, and message exchange, to higher level controls. Dematic offers long term SCS support with remote diagnosis and system updates. Direct online system and support is also available. Graphical interface screens for the SCS. 15
Life Cycle Investments that Last At Dematic, craftsmanship is not a lost art. Quality is our trademark. From research and development, to state-of-the-art manufacturing, to comprehensive on-site system testing, we understand that quality products mean long term productivity for our customers. Modular components allow AS/RS to be custom fitted to your needs, and provide consistent quality from machine to machine. Dematic utilizes state-of-the-art commercially available drives and positions technologies in the manufacturing of our SRMs. To keep on-site commissioning times to a minimum, each storage and retrieval machine is subject to complete testing prior to being shipped. All machine functions are tested using customer software. And, Dematic AS/RS solutions meet international quality standards. Customer training programs bring your staff up to speed with your AS/RS. The programs offer in-depth education on your specific equipment and controls. Dematic s after sale service keeps your AS/RS running at peak efficiency. 24/7 emergency service is available and our spare parts, product upgrades, and modernization programs provide maximum up-time and throughput. Extractor device testing. 16
AS/RS final assembly. Complete functional testing of SRM and load handling device is performed on each machine. State-of-the-art paint technologies are utilized to prevent corrosion. 17
Technical Specifications Unit-Load AS/RS Solutions * DEMATIC DEMATIC DEMATIC DEMATIC SR-U1000/1 SR-U1200/1 SR-U1500/1 SR-U1000/2 SRM Design Single-Mast Single-Mast Single-Mast Double-Mast SRM Max Height 10 m (33 ft) 30 m (100 ft) 46 m (150 ft) 24 m (78 ft) Load Capacity 1000 kg (2200 lbs) 1200 kg (2640 lbs) Std. 1500 kg (3300 lbs) Std. 1000 kg (2200 lbs) Std. 1500 kg (3300 lbs) Opt. 2000 kg (4400 lbs) Opt. 1200 kg (2640 lbs) Opt. Speed Horizontal 230 m/min (755 ft/min) 240 m/min (790 ft/min) 240 m/min (790 ft/min) 160 m/min (525 ft/min) Vertical 23 m/min (75 ft/min) 85 m/min (280 ft/min) 290 m/min (295 ft/min) 60 m/min (195 ft/min) Acceleration Horizontal 0.52 m/s 2 (1.7 ft/s 2 ) 0.78 m/s 2 (2.6 ft/s 2 ) 0.52 m/s 2 (1.7 ft/s 2 ) 0.52 m/s 2 (1.7 ft/s 2 ) Vertical 0.7 m/s 2 (2.3 ft/s 2 ) 1.3 m/s 2 (4.3 ft/s 2 ) 1.3 m/s 2 (4.3 ft/s 2 ) 0.65 m/s 2 (2.1 ft/s 2 ) Load Handling Suitable for Pallets, Containers, Rolls, Fixtures, etc. Devices Depending on the application, the following devices are available: Telescopic shuttle (single or double deep) Satellite (for deep lane storage) Multiple load handling devices available for some applications Aisle Width (min.) 1200 mm (48 in) 1200 mm (48 in) 1550 mm (61 in) 1500 mm (61 in) Control System PC Windows or PLC Aisle Transfer Yes, with transfer unit No Mini-Load AS/RS Solutions * DEMATIC DEMATIC DEMATIC DEMATIC DEMATIC SR-M50/1 SR-M100/1 SR-M200/2 SR-M300/1 SR-M300/2 SRM Design Single-Mast Single-Mast Double-Mast Single-Mast Double-Mast SRM Max Height 10 m (33 ft) 14 m (46 ft) 18 m (60 ft) 14 m (46 ft) 20 m (66 ft) Load Capacity 50 kg (110 lbs) 50 kg (110 lbs) x 2 50 kg (110 lbs) x 4 340 kg (750 lbs) 340 kg (750 lbs) Speed Horizontal 240 m/min (790 ft/min) 360 m/min (1180 ft/min) 360 m/min (1180 ft/min) 230 m/min (755 ft/min) 240 m/min (790 ft/min) Vertical 120 m/min (395 ft/min) 180 m/min (590 ft/min) 180 m/min (590 ft/min) 80 m/min (260 ft/min) 180 m/min (590 ft/min) Acceleration Horizontal 5.7 m/s 2 (18.7 ft/s 2 ) 5.2 m/s 2 (17.1 ft/s 2 ) 3.5 m/s 2 (11.5 ft/s 2 ) 1.3 m/s 2 (4.3 ft/s 2 ) 1.95 m/s 2 (6.4 ft/s 2 ) Vertical 3.0 m/s 2 (9.8 ft/s 2 ) 2.7 m/s 2 (8.9 ft/s 2 ) 2.7 m/s 2 (8.9 ft/s 2 ) 1.3 m/s 2 (4.3 ft/s 2 ) 2.6 m/s 2 (8.5 ft/s 2 ) Load Handling Suitable for Totes, Cartons, Trays Devices Quantity Single Multiple Depth Single Single/ Double/ Double Wide Type Depending on the application, the following devices are available: Pin Extractor (Tray) Telescopic Table Side Grippers Pneumatic Gripper Belt Conveyor/ Belt Table/ Extractor/ Combinations Aisle Width (min.) 750 mm (29.5 in) 850 mm (33.5 in) 850 mm (33.5 in) 1,000 mm ( 39.5 in) 850 mm (33.5 in) Control System PC Windows or PLC * Actual Values may differ depending upon specific design requirements. 18
About Dematic Technologies Package conveyors and systems New C-L Series package conveyor Low, medium, and high rate linear sorters Crossbelt and tilt tray unit sorters Order consolidation chutes & order processing stations Singulators & other special handling equipment Trailer loading conveyors Automatic Guided Vehicle (AGV) systems AS/RS (unit-load & mini-load) Pallet handling conveyors & systems Voice & light directed picking systems Warehouse Control Systems (WCS) Visualization/maintenance software Warehouse performance software RFID quick tag system Engineering Services Supply chain analysis Distribution network analysis Operations planning Facility layout & design Product slotting Labor optimization Simulation modeling Product conveyability testing Design validation Customer Services 24/7 365 phone support Emergency service Scheduled preventive maintenance Remote monitoring Parts support Modernization & upgrades Custom service contracts Resident maintenance program Rapidship conveyor products A Rich Tradition With 70 years of worldwide industry experience in creating logistics results, and over 10,000 systems installed around the globe, Dematic is the leading supplier of automated material handling systems for manufacturing, production, warehousing, and distribution. Dematic provides complete resources for supply chain and material flow analysis, systems concepting and engineering, project management, controlled quality manufacturing, installation, and comprehensive life cycle support. We design solutions for our customers based on a clear understanding of their business goals and material handling requirements. Throughout all our years in business, from Rapistan to Dematic, our focus has been customer satisfaction. Markets Served Dematic provides solutions for companies spanning the supply chain, including hard goods production and assembly, food and beverage, and wholesale/retail distribution of grocery, hardware, apparel, retail drug, office supplies, and general merchandise. We specialize in automated warehousing with high throughput order fulfillment systems, but have extensive experience in manufacturing across all sectors. We service small, local companies and national retailers with global solutions for global companies, and global expertise for local companies. Our application experience allows us to design systems to optimize material flow inside the four walls and across the supply chain. Adding Value Dematic s solutions allow companies to reduce production and distribution costs, maximize overall logistics efficiencies, and increase the operating speed of their supply chain. As a partner in each customer s success, we add value by deploying innovative system solutions based on global best practice experience, innovative products that are designed, tested, and manufactured in a controlled quality environment, customer support throughout every phase of project development/implementation, and finally, the most responsible and responsive customer service group in the industry. Operations The Dematic Campus in Grand Rapids, Michigan is home to the North American Corporate Headquarters, manufacturing plants, and Technology Center. Regional engineering and field offices are strategically located near major cities across North America. With over 1,500 employees, Dematic is affiliated with Dematic GmbH & Co. KG of Offenbach Germany. 19
www.dematic.com United States Dematic Corp. 507 Plymouth Avenue NE Grand Rapids, Michigan 49505 USA Phone: +1-877-725-7500 Fax: +1-616-913-7701 usinfo@dematic.com www.dematic.com Canada Dematic Limited 6711 Mississauga Road, Suite 200 Mississauga, Ontario L5N 2W3 Phone: +1-905-363-6970 Fax: +1-905-363-6969 info@dematic.com www.dematic.com Europe Dematic GmbH & Co. KG Carl-Legien-Strasse 15 63073 Offenbach Germany Phone: +49-69-8903-0 Fax: +49-69-8903-1299 info@dematic.com www.dematic.com Asia Pacific Dematic PTY Ltd. 24 Narabang Way Belrose NSW 2085 Australia Phone: +61-29486-5555 Fax: +61-29486-5511 info@dematic.com www.logisticsasiapacific.com Dematic Corp. Order-No. A018 Printed in USA 02/07