MANUAL WAREHOUSE

Manual warehouses / storage systems are storage locations and racking systems
which are not accessed by automated systems, but operated by humans. Such
warehouses can be narrow aisle warehouses, manual pallet racks or shelf storage
systems. Such installations can be found with Big, Spinner, Marburger Tapeten,
Riegler and other customers. In most cases, access to the storage locations is
ensured through the "man-to-goods" principle. Especially in narrow aisle
warehouses, however, you can also find order picking stations where goods are
collected or made available (goods-to-man).
The general warehouse topology and the coordinate system do not differ from
automatic warehouses. With the latter, merely the automation in terms of the
operating device is fixed. Transport control is identical as well. However, when the
man-to-goods principle is applied, no route optimization take place like in the case
of an AS/RS, but routes can be saved that describe zig-zag, loops, U-courses and
any other sequence. Manual warehouses can also be supported by conveyors
ensuring material supply and disposal. Accordingly, handover positions and
zones/stations are configured and which storage areas and aisles they operate. In
most cases, processing takes place without vouchers (RF, voice) or with storage
and picking documents which then are reported back.
Several load handling attachments
The control system and the MFC (material flow computer) are able to use several
load handling attachments (and multiple load handling attachments) in an optimal
manner. Corresponding installations with pallet AS/RS are in use at Rotho and
Marburger Tapeten.
Route optimization through several load handling attachments In case of several
load handling attachments accumulating runs are possible that allow a high
throughput even with slower devices. In X-direction, the AS/RS feature two load
handling attachments. Order planning is done according to the route optimization by
building packages (transport sequences) to place an order with the
AS/RS. During this process, both load handling attachments are considered. If no
second order exists at the time the order is allocated (only one load handling
attachment occupied), the transport orders are again read after taking up the first
loading unit to account for changes. It is also taken into account that possibly not all
storage locations or handover positions to the conveyor system can be reached by
both load handling attachments (due to the racking design). Their sphere of action
is defined by configuring the load handling attachments. In case one load handling
attachment fails (defective), the configuration also allows changing the settings such
that orders are assigned to the AS/RS correspondingly with only one load handling
attachment. Operating such devices is possible in automatic small parts warehouses
and high-bay warehouses.

AUTOMATED STORAGE
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. Automated storage and retrieval systems (AS/RS) are
typically used in applications where:

• There is a very high volume of loads being moved into and out of storage
• Storage density is important because of space constraints
• No value is added in this process (no processing, only storage and transport)
• Accuracy is critical because of potential expensive damages to the load

An AS/RS can be used with standard loads as well as nonstandard loads, meaning
that each standard load can fit in a uniformly-sized volume; for example the film
canisters in the image of the Defense Visual Information Center are each stored as
part of the contents of the uniformly sized metal boxes, which are shown in the
image. Standard loads simplify the handling of a request of an item. In addition,
audits of the accuracy of the inventory of contents can be restricted to the contents
of an individual metal box, rather than undergoing a top-to-bottom search of the
entire facility, for a single item.
AS/RS systems are designed for automated storage and retrieval of parts and items
in manufacturing, distribution, retail, wholesale and institutions. They first originated
in the 1960s, initially focusing on heavy pallet loads but with the evolution of the
technology the handled loads have become smaller. The systems operate under
computerized control, maintaining an inventory of stored items. Retrieval of items is
accomplished by specifying the item type and quantity to be retrieved. The computer
determines where in the storage area the item can be retrieved from and schedules
the retrieval. It directs the proper automated storage and retrieval machine (SRM) to
the location where the item is stored and directs the machine to deposit the item at
a location where it is to be picked up. A system of conveyors and or automated
guided vehicles is sometimes part of the AS/RS system. These take loads into and
out of the storage area and move them to the manufacturing floor or loading docks.
To store items, the pallet or tray is placed at an input station for the system, the
information for inventory is entered into a computer terminal and the AS/RS system
moves the load to the storage area, determines a suitable location for the item, and
stores the load. As items are stored into or retrieved from the racks, the computer
updates its inventory accordingly.

The benefits of an AS/RS system include reduced labor for transporting items into
and out of inventory, reduced inventory levels, more accurate tracking of inventory,
and space savings. Items are often stored more densely than in systems where
items are stored and retrieved manually.

Advantages
An effective automated storage and retrieval system provides several benefits
for supply chain management:

• An efficient AS/RS system helps companies cut expenses by minimizing the

amount of unnecessary parts and products in storage, and improving
organization of the contents of a warehouse. Due to automated processes, it
also allows for more storage space due to high-density storage, narrower
aisles, etc.
• Automation reduces labor costs while lowering workforce requirements and
increasing safety.
• Modeling and managing the logical representation of the physical storage
facilities (e.g. racking, etc.). For example, if certain products are often sold
together or are more popular than others, those products can be grouped
together or placed near the delivery area to speed up the process of picking,
packing and shipping to customers.
• Enabling a seamless link to order processing and logistics management in
order to pick, pack, and ship product out of the facility.
• Tracking where products are stocked, which suppliers they come from, and
the length of time they are stored. By analyzing such data, companies can
control inventory levels and maximize the use of warehouse space.
Furthermore, firms are more prepared for the demands and supplies of the
market, especially during special circumstances such as a peak season on a
particular month. Through the reports generated by an AS/RS system, firms
are also able to gather important data that may be put in a model for it to be
Types

• Vertical Lift storage Modules (VLSM) - These are also called vertical lift
automated storage/retrieval systems.All of the next AS/RS types are
designed around a horizontal aisle. The same principle of using a center aisle
to access loads is used expect that the aisle is vertical. Vertical lift storage
modules, some with heights of 10 meter or more, are capable of holding large
inventories while saving valuable floor space in the factory.
• Unit load stackers - The unit load stackers is typically a large automated
system designed to handle unit loads stored on pallets or in other standard
containers. The system is computer controlled, and the S/R machines are
automated and designed to handle the unit load containers.
• ASRS Gantry Robots - These are a type of Automated Storage/Retrieval
Systems used in warehousing and logistics sectors. Some common uses for
these are in the Tire Industry for stacking tire inventory. Most of these systems
 • span 50–60 ft in width and average 200–300 feet in length. These systems
use End Effectors a.k.a. End of Arm Tooling to pick and place the tire stacks
from conveyors.

Man-aboard systems
A man-aboard system can provide significant floor space savings over manual or
forklift operations but is not truly an AS/RS, as the operation is still manual. Storage
system heights are not limited by the reach height of the order picker, as the picker
rides along on the platform as it is moved vertically or horizontally to the various
storage locations. Shelves or storage cabinets can be stacked as high as floor
loading, weight capacity, throughput requirements, and/or ceiling heights will permit.

BIBLIOGRAPHIC SOURCES

Frazelle, E. (2001), World-class Warehousing and Material Handling,

McGraw-Hill, New York, NY.
Dan Hingling (2013) "Automated Storage and Retrieval System". The
University of Chicago Library. Retrieved 9 January 2013.
Klinkhammer Intralogostics (2014). Manual warehouse Consulted in:
https://www.klinkhammer.com/en/glossary/manual-warehouse/