New Products Trends and Benefits in AS/RS Presented by: Sponsored by: Tom Coyne, System Logistics Corp. Ed Romaine, Integrated Systems Design Stephan Reithmann, MIAS 2014 MHI Copyright claimed as to audiovisual works of seminar sessions and sound recordings of seminar sessions. All rights reserved.
A Presentation by; We are a Product Group under the auspices of MHI, the Material Handling Industry Association Our members are the Industry s leading suppliers of automated storage/retrieval systems. We supply systems worldwide and in virtually every major manufacturing and distribution sector. Our goal today is to provide general education about ASRS and new trends in ASRS..
What is ASRS ASRS = Automated Storage and Retrieval System Definition: An automated storage and retrieval system (ASRS or AS/RS) consists of a variety of computer-controlled systems for automatically placing and retrieving loads from defined storage locations (Wikipedia definition) Huh????
What is ASRS Let s Try Again Storage racking system Automated equipment for storing and retrieving loads (boxes, totes, pallets, wire bins, etc.) System to bring loads to/from the ASRS Computer controls to make everything work together as a system.
A Traditional ASRS System
But ASRS is Evolving as Well
Many Types of ASRS C r a n e B a s e d Totes and Boxes Trays Pallets S h u t t l e B a s e d Totes and Boxes Pallets
What Are the Benefits?
More Detailed Benefits? Space savings. Storage is denser as aisles are smaller and there is less need for space between loads. Labor savings as fork truck moves are eliminated, order picking time is faster, access to goods is automated and no time is wasted looking and searching for items Improved inventory accuracy due to computer control and systematic organization Inventory reduction based on real time knowledge for planning Reduced product damage due to eliminated manual handling Improved order accuracy due to computer control and direction
ASRS Makes Operations Run Better Pallet Systems Finished goods storage Raw materials storage Ready reserve for case picking Shipping sequencing or buffering Frozen storage Box or Tote Systems Each order picking Production kitting Order consolidation Case buffering Case sequencing before palletizing Sequencing buffer in manufacturing
Latest and Greatest in ASRS Very fast pallet storage and retrieval Very fast case / tote storage and retrieval Mid-load ASRS Load handling device explosion
NEW: Pallet Shuttle ASRS Multiple depth storage (L.I.F.O.) Shuttles operate on each level within the rack structure (Fast Rotating Storage) Load/unload with forklifts or automated by conveyor or AGV Aisle shuttles on each level In rack vehicles for pallet pick-up and deposit
NEW: Pallet Shuttle ASRS MAIN USE: Very fast access of a low to medium amount of SKU s. Speed of this solution makes it very good for supporting case picking operations, and sequenced truck loading.
NEW: Pallet Shuttle ASRS
NEW: Tote / Carton ASRS Putting multiple load handling vehicles within a racking system allows for ultrahigh throughput, opening up many new applications for ASRS in distribution operations!
NEW: Tote / Carton ASRS Revolutionary new concept(s) that puts ASRS into many new applications and allows for new types of automated systems! Wave buffering Shipping staging and sequencing for route loading Sequenced delivery for pallet building Product delivery to support high speed each order picking Automatic case order picking Perform the function in less space, with more control, in less time, with a total lower cost for your distribution operation
NEW: Tote / Carton ASRS
NEW: Mid-Load ASRS New ASRS Genre Fits between the mini-load and unit load Provides some unique features and applications
NEW: Mid-Load ASRS MAIN USE: General purpose ASRS solution with unique advantages through flexible configurations: No need for a crane rail which leads to economic advantages. Standard and custom load handlers Redundant up time features
NEW: Mid-Load ASRS
NEW: Load Handling Devices Storing and retrieving successfully means the equipment must properly handle the load. Changes in packaging means unit loads, especially non-palletized loads, can be harder to handle.
NEW: Load Handling Devices How do you handle the variety? How do you handle the raw packaging with no pallet or special carrier? There are many new types of load handling devices.
NEW: Load Handling Devices Telescopic fork with lateral belt transfers. Allows stable handling of cardboard cartons Side gripping arms with fingers to allow Storage and retrieval from shelving, and the handling of multiple sized cases together in same system
NEW: Load Handling Devices Telescopic fork with fingers that comb through custom racking. Allows bottom handling of loads, extending the range of what can be put into a system. Multiple load handlers are now commonly being put onto mini-load cranes, increasing throughput and extending the application range into box buffering and sequencing.
NEW: Load Handling Devices Dual Pallet handling machines improve throughput dramatically, extending the range of ASRS into faster turning inventory situations. Rotating turret ASRS provides two large benefits. First, you can spike the pallet, allowing for more secure handling. Second, the machine can interface with conventional pallet racking.
Application Information Loads Load Weight Shuttle Based ASRS Case / Tote Up to 50 lbs Very High. Dependent on number of shuttles. Micro-Load ASRS Case / Tote Up to 50 lbs 2 6 loads per minute dependent on number of LHD s Throughput Application Markets Buffering, sequencing, picking Buffering, sequencing, picking Mini-Load ASRS Tray storage Up to 750 lbs ~1 load per minute Dense storage, picking Mid-Load ASRS Unit Load ASRS (With shuttle forks) Unit Load ASRS (With in-rack vehicles) Pallet shuttles (Typically with in-rack vehicles) Pallet, Case, Tray, Unique Load Pallets Pallets Pallets Up to 2,000 lbs 1-2 tons typically 1-2 tons typically 1-2 tons typically Up to 1 load per minute Up to 1 load per minute Less than 1 load per minute High. Dependent on number of shuttles. Storage, buffering, sequencing, picking Pallet storage, case picking support Low SKU, super dense storage Low SKU, super dense storage with high throughput E-commerce, retail, wholesale, grocery, food Retail, wholesale, grocery, food, medical Wholesale, manufacturing Manufacturing, CPG, Food Food, CPG, manufacturing Beverage, Food, CPG Beverage, Food, CPG
ASRS Application Criteria Two major criteria Selectivity required to your stored items Velocity or throughput required from the system
ASRS Classification System Using Selectivity as a Variable Selectivity Required High to Low Single Deep Storage Double Deep Storage Multiple Deep Storage L o a d Loads up to 5,000 lbs CRANE based ASRS One pair of forks for typical applications Two pairs of forks for higher throughput CRANE based ASRS One pair of forks for typical applications Two pairs of forks for higher throughput CRANE or SHUTTLE ASRS Cranes for low to moderate throughput Multiple shuttles for higher throughput UNIT- LOAD ASRS H a n d Up to 2,000 lbs. Pans 100 to 750 lbs. CRANES that handle Pans, cases, pallets or unique loads. CRANES that store and retrieve metal pans. MID- LOAD ASRS MINI- LOAD ASRS l i n g Totes or cartons under 125 lbs. Lightest CRANES using devices that can handle plastic totes and/or cardboard boxes. Rack SHUTTLE ASRS that can handle plastic totes and/or cardboard boxes t MICRO- LOAD
ASRS Classification System Using Throughput as a Variable This idea generally applies, whether thinking about pallet ASRS or tote/box ASRS.
Take Away ASRS has been a good intra-logistics solution for decades Recent technical advances have expanded the range where ASRS can apply. These same advances also improve the business case for ASRS You should investigate this week, and over time as you develop your business operations!
Member Companies
For More Information: Gary Forger, AS/RS Managing Executive, MHI Email: gforger@mhi.org Website: http://www.mhi.org/as-rs