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AS/RS

AS/RS. Automated Storage/Retrieval Systems Jed Nieveen October 29, 2010. Definition.

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AS/RS

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  1. AS/RS Automated Storage/Retrieval Systems Jed Nieveen October 29, 2010

  2. Definition Automated Storage/Retrieval System (AS/RS) – is a storage system under which a defined degree of automation is to be implemented to ensure precision accuracy and speed in performing storage and retrieval operations http://www.youtube.com/watch?v=ScuFo1x751M&feature=related

  3. Overview • How is it used? • Costs • Supporting Technologies • Limitations • Vendors • Failure Rates • Standards • Technical Paper

  4. Current State • Unit Load – Pallets or standard containers • Deep lane – High density storage, for similar types of stock • Miniload – Handles individual parts stored in bins • Carousel – Revolving Bins • Man on board – A human operator rides on the carriage • Automated Item – Handles individual parts stored in lanes • Vertical lift – Stores high instead of wide (10 m)

  5. Specific Specifications • Always changing and updating • Depends on application • Example – KastoUnitTower Double Loading per storage location: 5t (11,000lbs.) Economic storage size: 1-100 locations Economic storage length: 3-12 m (10’-40’) Economic system height: 4-20m (13’-66’)

  6. Who/What/Where/When Used? • Everywhere • Highly organized operations • High volume storage • Factories • Warehouses • Distribution • Utah State University The Barn at USU

  7. Who/What/Where/When Used? • Bakeries • Food applications • Medical Records Storage • Libraries • Manufacturing • Retail • Biological Storage Pan Storage System

  8. Who/What/Where/When Used? • Vending Machine • Slide Projector • ATM • Cars Inside ATM – Selling up to Six Different Gift Cards

  9. Who/What/Where/When Used? • Used to save money • Used to create safer work environments • Used to increase efficiency and productivity • Used to keep things well organized • Used for long term storage as well as short term storage • Minimize errors

  10. Costs • Starting at $14.99 • Up to Millions of Dollars • It really depends on the application

  11. Supporting Technologies • Conveyors • AGVS • Control Systems • RFID Chips • Tracking Technologies • Sensors • Grippers

  12. Limitations • Cost to Implement • Maintenance - Mechanics • Replacement Parts • Updating Software • Training of Personnel – Highly Educated • Time to implement • Change in Organization

  13. Failure Rates • Mean Time Between Failure (MTBF) • KardexRemstar Vertical Carousels is 12,642 hours and 7.15 hours for repair. • KardexRemstar Shuttle™ Vertical Lift Modules (VLM) is 5,856 hours and 5.4 hours for repair.

  14. Speed • http://www.bastiansolutions.com/automation/automated-storage-and-retrieval-system/duosys_asrs.asp • http://www.bastiansolutions.com/automation/automated-storage-and-retrieval-system/high_speed_buffers_asrs.asp • Speeds up to 300 ft/min

  15. Standards • Standards • Two American National Standards Institute (ANSI) approved safety standards currently exist for Automatic Storage / Retrieval Systems (AS/RS) related technologies: • MH24.1: Safety Standard for Horizontal Carousel Material Handling and Associated EquipmentThis newest standard, approved January 15, 2005, for horizontal carousels, was developed by the Carousel and Vertical Lift Module (C/VLM) Working Group of the AS/RS Product Section following the ANSI Public Canvass method.   • B30.13 - 2003: Storage/Retrieval (S/R) Machines and Associated Equipment This AS/RS safety standard published in 2003 deals solely with the Crane and Aisle (C/A) technology for automatic storage and retrieval. This standard, also following the ANSI Public Canvass method, was developed by the American Society of Mechanical Engineers (ASME).

  16. Vendors • Search returned 554 results • Utah Companies • GcaSystems, Inc. - Salt Lake City, UT • CambeltInternational Corporation - Salt Lake City, UT • American Interior Systems, Inc. - Sandy, UT • Daifuku America Corp. - Salt Lake City, UT • AFT, Inc. - Salt Lake City, UT • Eskay Corp. - Salt Lake City, UT

  17. Primary Vendors • Daifuku • Kasto • KardexRemstar • Bastian Material Handling • HK Systems Products

  18. Technical Paper • 1 picker – 2 carousels • Alternates between the 2 carousels • Pick Time – Time it takes carousel to turn and picker to get part. • Throughput - maximum long-run average rate at which the system can process request . • Picker Utilization - The long-run proportion of time that the picker is busy when the system is processing items at the maximum rate.

  19. Example Problem • Example 11.2 Sizing an AS/RS System • Each aisle of a four-aisle AS/RS contains 60 storage compartments in the length direction and 12 compartments vertically. All storage compartments are the same size to accommodate standard size pallets of dimensions: x = 42 in and y = 48 in. The height of a unit load z = 36 in. Using the allowances a = 6 in, b = 8 in, and c = 10 in, determine (a) how many unit loads can be stored in the AS/RS and (b) the width, length, and height of the AS/RS.

  20. Tools • Eq 11.1 – Capacity per aisle = 2*ny*nz • Eq 11.2 a – W = 3(x+a) • Eq 11.2 b – L = ny(y+b) • Eq 11.2 c – H = nz(z+c) • ny = number of load compartments along the length of the aisle • nz = number of load compartments that make up the height of the aisle

  21. Solution • Part A Capacity per aisle = 2*(60)*(12) AS/RS Capacity = 4(1440) = 5760 unit loads • Part B W = 3(42+6) = 144 in = 12 ft/aisle Overall width of the AS/RS = 4*(12) = 48 ft L = 60*(48+8) = 3,360 in = 280 H = 12(36+10) = 552 in = 46 ft

  22. Summary • Great Potential • We will see more and more of them • Costs will come down • Extra videos http://www.youtube.com/watch?v=pf1dTNSJBu8&feature=related http://www.youtube.com/watch?v=5JbkkukZmFU

  23. References • http://www.thomasnet.com/products/automated-storage-retrieval-systems-as-rs-2243038-10.html • http://library.usu.edu/main/library_information/barn.php • http://www.dunbarsystems.com/bakery-equipment/pan-storage-retrieval-systems/default.html • http://www.mhia.org/industrygroups/as-rs/standards • http://www.labautopedia.com/mw/index.php/Automated_Storage_and_Retrieval_Systems_%28AS/RS%29 • http://www.kardexremstar.com/content/news/pressreleases/PRNumberP00-223.aspx • http://www.jstor.org.erl.lib.byu.edu/stable/3215938?seq=4&Search=yes&term=SYSTEMS&term=STORAGE%2FRETRIEVAL&term=AUTOMATED&list=hide&searchUri=%2Faction%2FdoBasicResults%3Fhp%3D25%26la%3D%26wc%3Don%26acc%3Don%26gw%3Djtx%26jcpsi%3D1%26artsi%3D1%26Query%3DAUTOMATED%2BSTORAGE%252FRETRIEVAL%2BSYSTEMS%26sbq%3DAUTOMATED%2BSTORAGE%252FRETRIEVAL%2BSYSTEMS%26si%3D1%26jtxsi%3D1&item=3&ttl=161&returnArticleService=showFullText&resultsServiceName=null • http://www.kastoracine.com/item_details.cfm?id=65 • http://www.unarcorack.com/AS-RS/ASRS-mini.html • http://www.diversatech-metalfab.com/warehouseing.htm • http://cuesskybox.typepad.com/nexus_connection/2007/11/sell-prepaid-ca.html • Automation , Production Systems, and Computer – Integrated Manufacturing – Third Edition – Mikell P. Groover

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