Material handling and Equpment Assignment

Name ID
Zelalem Tesfaye 1248/08

Sub. Date march 17, 2020

Sub. To: - Dr. Belete sirahbizu
 Storage and Retrieval System

Introduction

AS/RS are means to high density hands free buffering of materials in distribution and
manufacturing environments.AS/RS is a complete system designed to transport, stage/store,
retrieve, and report on every item in any industrial inventory with up-to-the minute accuracy.
An automated storage/retrieval system (AS/RS) can be defined as 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. These automated storage and mechanized systems
eliminate human intervention in performing basic sets of operations that includes

 Removal of an item from a storage location automatically

 Transferring the items to a specific processing or interface point
 After receiving an item from a processing or interface point, it is automatically stored at a
predetermined location.

Types of AS/RS

1. According to Structure of Rack System

Rack: Unit loads or pallets are stored over horizontal beam.

Portable Racks: Portable rack frames holds unit load which are stacked one over another.

Cantilever Racks: Same as pallet rack only horizontal beams are cantilevered from vertical
centered frame used to store long bars, rods, pipes.

Drive through racks: Aisles are open at each end provides access to vertical rails or forklift trucks.

Flow through Racks: long conveyor tracks carry unit loads. Unit loads are loaded from one side
and moved from another side of racks.

2. According to types of racks

Stationary Racks: Location of racks and storage spaces are fixed.

 Single Deep: Only one-unit load is stored at each storage space which is commonly
preferred

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  Dual Deep: Two loads are stored one facing another at each space. Useful when less
variety of unit loads are provided.

Movable rack System:

 Mobile Racks: Racks can be moved over guided rail track.

 Carousel System: Rotary shelves or stacks are moved across overhead conveyers or long
oval rail system. Crane is used to transfer load to the system. Stacks may move vertical or
horizontal direction. Used to store small or medium sized items
3. According to usage of crane

Movement of Crane

 Aisle Captive: Each aisle has one S/R machine.

 Changing: Few cranes are provided than number of aisles able to change aisle.

Number of Shuttles:

 Single Shuttle: S/R machine handles only one-unit load at a time.

 Multi Shuttle: S/R machine handles two or more unit loads at a time. Several important
categories of AS/RS can be distinguished based on certain features and applications. The
following are the principle types
4. According to Method of Handling a load

Unit Load AS/RS: The unit load AS/RS is used to store and retrieve loads that are palletized or
stored in standard-sized containers. The system is computer controlled. The S/R machines are
automated and designed to handle the unit load containers. Usually, a mechanical clamp
mechanism on the S/R machine handles the load. However, there are other mechanisms such as a
vacuum or a magnet-based mechanism for handling sheet metal.

Mini Load AS/RS: This system is designed to handle small loads such as individual parts, tools,
and supplies that are contained in bins or drawers in the storage system. Such a system is applicable
where the availability of space is limited. It also finds its use where the volume is too low for a
full-scale unit load system and too high for a manual system.

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Deep-lane AS/RS: This is a high-density unit load storage system that is appropriate for storing
large quantities of stock. The items are stored in multi deep storage with up to 10 items in a single
rack, one load behind the next. Each rack is designed for flow-through, with input and output on
the opposite side. Machine is used on the entry side of the rack for input load and loads are retrieved
from other side by an S/R- type machine. The S/R machines are similar to unit load S/R machine
except that it has specialized functions such as controlling rack-entry vehicles.
Man-on-board AS/RS: This system allows storage of items in less than unit load quantities.
Human operator rides on the carriage of the S/R machine to pick up individual items from a bin or
drawer. The system permits individual items to be picked directly at their storage locations. This
provides an opportunity to increase system through put. The operator can select the items and place
them in a module. It is then carried by the S/R machine to the end of the aisle or to a conveyor to
reach its destination.

Automated Item Retrieval System: This system is designed for retrieval of individual items or
small product cartoons. The items are stored in lanes rather than bins or drawers. When an item is
retrieved from the front by use of a rear-mounted pusher bar, it is delivered to the pickup station
by pushing it from its lane and dropping onto a conveyor.

Applications AS/RS Systems

Storage: - Providing high density storage parts and components used in a manufacturing process

Order picking: - Offering compact, fast and reliable access to items required for distribution,
bringing stored items to the operator for fast order fulfillment, supported by software integration.
Kitting: - Managing the process of receiving inventory, group (kitting) component parts for
assembly and storing kits until required.

Order Consolidation: - Providing a compact solution to temporarily hold incomplete orders

awaiting additional items before shipment.

Buffering: - Offering a highly dense storage solution for inventory or process buffering
Assembly: - Storing work-in-process or sub-assemblies for later use Tools, Dies & Molds:
Ergonomic and secure handling of heavy and often expensive tooling required in an automated
production process.

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Maintenance & Repair Parts: - Providing compact storage of maintenance parts onsite to reduce
downtime

Replenishment & Returns: - Managing inventory for replenishment and returns processes

Climate Controlled and Clean Room Environments: - Provides cold, clean and dry management
of storage

Advantage and disadvantages of AS/RS

Advantages
By automating the low-value and easily repeated task of inventory storage and retrieval, AS/RS
brings many powerful benefits to the operations that utilize it, including:
Reduction of variable costs
Automated storage and retrieval systems reduce the variable cost of operations by reducing
the need for manual labor for tasks such as picking, storing, assembly and inventory
replenishment. These costs are variable, with expenses such as overtime, bene¹ts and
payroll taxes adding to the total cost of manual labor.
Automating manual, repetitive storage and retrieval costs
As mentioned, AS/RS solutions reduce the need for manual labor by automating manual,
repetitive storage and retrieval tasks. Automating these tasks increase accuracy and
efficiency while also freeing up human workers to focus on higher-value activities.
Better safety
Human workers who handle manual, repetitive tasks for several hours can experience
fatigue and muscle strain, increasing the risk of errors and injury. Likewise, errors made
when operating heavy equipment in a manufacturing or warehouse environment can be
dangerous, resulting in injury or death.
Better space utilization
Shelving and proper grouping of items are vital in warehouses and distribution centers.
Raw materials, work-in-progress, and finished goods inventories need to be replenished
regularly to keep processes moving without interruption. Warehouses and distribution
centers alike depend on effective space utilization to maintain a healthy bottom line.
Ability to reclaim unused vertical space

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 Increased inventory storage density
Improved ergonomics and safety, resulting in fewer accidents
Often modular design for maximum flexibility
Increased order picking accuracy
Improved product security for premium inventory
Provides real-time inventory control and etc.
Disadvantages
 Despite their advantages, AS/RS solutions have a few important disadvantages companies
should consider before making an investment decision. AS/RS systems requires
knowledge, skills and experience, it requires significant investments of the company’s
capital, particularly for the maintenance and updating of different subsystems. The capital
expenses can tempt some business owners to cut the financial corners to buy the bargain
systems that are ill-equipped for extensive, long-term use can end up costing far more in
the long run.
1. Large initial investment
Installation and implementation of automated storage and retrieval systems are costly. The
initial capital investment can be significant and installation requires substantial infrastructure
changes. If a company is looking for a long-term solution, then the cost-benefit-analysis can
show a positive ROI over the long term, but for companies in need of a faster return on their
investment, AS/RS solutions may not be practical. For smaller companies, the large initial
capital investment is often cost-prohibitive.
2. Repair and maintenance
While the one-time upfront investment can be viewed as an advantage, despite being
substantial, there are some ongoing costs associated with AS/RS solutions. These systems
require ongoing maintenance and periodic repairs. What’s more, repairing AS/RS equipment
may require special expertise, meaning repairs may be costlier compared to the cost of
making repairs on traditional warehouse equipment, such as forklifts or conveyor systems.
So, while AS/RS solutions eliminate some costs associated with manual labor, the cost of
maintenance and repairs shouldn’t be ignored. Maintenance activities may require a partial
or complete shutdown of operations, so companies implementing AS/RS solutions should
consider the cost of downtime and production interruptions for equipment breakdowns.

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 Companies that don’t have an on-staff maintenance technician experience longer downtimes
while waiting for outside technicians to respond.
3. Not ideal for varied tasks
AS/RS equipment moves in pre-established routes and is best suited for regular, predictable
and repetitive tasks. They’re not ideal for applications in which varying products are handled
at different times, such as a warehouse that handles different products by season, due to the
downtime required to reprogram and re-train the AS/RS solution to move new products
following each transition.
4. Lengthy onboarding
While they’re automated, performing storage and retrieval tasks with minimal human
intervention, AS/RS solutions must be programmed to follow the necessary routes and
retrieve and store the correct items in the right locations. Employees require training to
operate the system effectively.

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 Automated Guided Vehicles (AGV)

Introduction

The AGV can tow objects behind them in trailers to which they can autonomously attach. The
trailers can be used to move raw materials or finished product. The AGV can also store objects on
a bed. The objects can be placed on a set of motorized rollers (conveyor) and then pushed off by
reversing them. AGVs are employed in nearly every industry, including pulp, paper, metals,
newspaper, and general manufacturing. Transporting materials such as food, linen or medicine in
hospitals is also done. An AGV can also be called a laser guided vehicle (LGV). Lower cost
versions of AGVs are often called Automated Guided Carts (AGCs) and are usually guided by
magnetic tape. AGCs are available in a variety of models and can be used to move products on an
assembly line, transport goods throughout a plant or warehouse, and deliver loads. The first AGV
was brought to market in the 1950s, by Barrett Electronics of Northbrook, Illinois, and at the time
it was simply a tow truck that followed a wire in the floor instead of a rail. Out of this technology
came a new type of AGV, which follows invisible UV markers on the floor instead of being towed
by a chain. The first such system was deployed at the Willis Tower (formerly Sears Tower) in
Chicago, Illinois to deliver mail throughout its offices.

Generally, the advances in robotics can offer significant contributions to the enhancement of the
capabilities of automated guided vehicles (AGV). While robotics implements algorithms on
mobile platforms that operate in strictly controlled and undisturbed environments, AGVs are built
to operate in manufacturing environments that are noisy and constrained. An AGV shares its
operating environment with factory workers and other expensive machinery. Nevertheless, the
AGVs can reap direct benefits in the form of more powerful and capable sensors and sophisticated
algorithms developed from research in robotics.

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 Advantages and Disadvantage of AGV

Advantages of AGVs

1. Reduced Labor Costs

AGVs reduce labor costs in your operation in many ways: By replacing a human worker with an
AGV, a company pays a single expense for the equipment the initial investment versus ongoing
costs that would come with a new hire such as health care coverage, payroll taxes, salary increase,
vacation time, etc.

2. Increased Safety

AGVs are programmed with safety in mind, and as such are crammed full of cameras, lasers, and
other sensors that allow them to safely operate around personnel and structures. By contrast,
equipment run by human operators, such as forklifts, do not have as many built-in safety
mechanisms and ultimately rely on human input, which can be compromised in any number of
ways. Additionally, AGVs can operate in conditions that humans either aren’t able to operate in
or in conditions that humans don’t operate optimally in, such as in extreme heat or cold or around
hazardous materials. All of this increased safety leads to reduced cost and reduced operational
downtime, which can ultimately increase the profitability of many operations.

3. Increased Accuracy and Productivity

Humans make mistakes. By replacing the human element with AGVs, you remove some of the
potential for inaccurate workflows, ultimately reducing waste and increasing output, allowing your
operations to become more productive and accurate. In addition to the obvious improvements in
accuracy and productivity, by integrating AGVs with a warehouse control system or a warehouse
management system, you can streamline processes such as inventory and materials ordering.

4. Modularity

As your operations expand, it is easy to add additional AGVs as necessary. This allows you to
avoid an incredibly high initial investment because instead of purchasing you are able to start with
one or two and transition slowly, eventually expanding your fleet to a fully-automated or mostly-
automated operation.

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 Disadvantages of AGVs

1. Potentially High Initial

Initial investment for Purchasing an AGV, in the short term, is likely going to be more expensive
than hiring personnel or using other equipment such as forklifts. It is usually in the long term that
savings are fully realized. This initial investment can be burdensome on operations that may not
have ready access to capital.

2. Maintenance Cost

As with any equipment, AGVs will need to undergo routine maintenance and occasional repair.
And though AGVs will not be operated directly by staff, there is bound to be some operational
downtime as the staff is trained and AGVs are implemented.

3. Not Suitable for Non repetitive Task

AGVs make the most sense in operations that deal with repetitive tasks since that is what they
are programmed to do. If the tasks in your operations tend not to be repetitive, then they can
probably be done more quickly and efficiently by staff operating other equipment (such as a
forklift

4. Decreased Flexibility of Operations

one of the benefits of having human personnel is that sometimes operations require flexibility,
such as the ability to jump between tasks. For example, maybe you need Steve to stop doing
what he’s doing and cover for Joe, who has a family emergency and needs to leave, and who was
doing something completely different.

Types of AGV
I. Towing Vehicles

were the first type introduced and are still a very popular type today. Towing vehicles can pull a
multitude of trailer types and have capacities ranging from 2,000 pounds to 160,000 pounds.

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 II. AGVS Unit Load Vehicles

They are equipped with decks, which permit unit load transportation and often automatic load
transfer. The decks can either be lift and lower type, powered or non-powered roller, chain or
belt decks or custom decks with multiple compartments.

III. AGVS Pallet Trucks

They are designed to transport palletized loads to and from floor level; eliminating the need for
fixed load stands.

IV. AGVS Fork Truck

Has the ability to service loads both at floor level and on stands. In some cases these vehicles can
also stack loads in rack. They can sometimes lift up to 30' to store or retrieve on high-bay
racking.

V. AGVS Hybrid Vehicles

are adapted from a standard board truck so that they can run fully automated or be driven
by a fork truck driver. These can be used for trailer loading as well as moving materials around
warehouses. Most often, they are equipped with forks, but can be customized to
accommodate most load types.

VI. Light Load AGVS

are vehicles which have capacities to transport small parts, baskets, or other light loads though a
light manufacturing environment. They are designed to operate in areas with limited space.

VII. AGVS Assembly Line

These are an adaptation of the light load AGVS for applications involving serial assembly
processes. Automated Guided Vehicles can be used in a wide variety of applications to transport
many different types of material including pallets, rolls, racks, carts, and containers. AGVs excel
in applications with the following characteristics.

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 Applications of AGV
1. Handling raw materials

This includes transporting materials from receiving to the warehouse, and delivering materials
directly to production lines.

2. Pallet handling

Pallet handling is an extremely popular application for AGVs as repetitive movement of pallets is
very common in manufacturing and distribution facilities. AGVs can move pallets to stretch
wrapping to the warehouse/storage or to the outbound shipping docks.

3. Work in process movement

Work-in-Process movement is one of the first applications where automated guided vehicles were
used, and includes the repetitive movement of materials throughout the manufacturing process.
AGVs can be used to move material from the warehouse to production/processing lines or from
one process to another.

4. Finished product handling

Moving finished goods from manufacturing to storage or shipping is the final movement of
materials before they are delivered to customers. These movements often require the gentlest
material handling because the products are complete and subject to damage from rough handling.
Because AGVs operate with precisely controlled navigation and acceleration and deceleration this
minimizes the potential for damage making them an excellent choice for this type of application.

5. Trailer loading

Automatic loading of trailers is a relatively new application for automated guided vehicles and
becoming increasingly popular. AGVs are used to transport and load pallets of finished goods
directly into standard, over-the-road trailers without any special dock equipment. AGVs can pick
up pallets from conveyors, racking, or staging lanes and deliver them into the trailer in the specified
loading pattern. Some Automatic Trailer Loading AGVs utilize Natural Targeting to view the

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walls of the trailer for navigation. These types of AGVs can be either completely driverless or
hybrid vehicles.

6. Roll handling

AGVs are used to transport rolls in many types of plant including paper mills, converters, printers,
newspapers, steel producers, and plastics manufacturers. AGVs can store and stack rolls on the
floor, in racking, and can even automatically load printing presses with rolls of paper.

7. Container handling

AGVs are used to move sea containers in some maritime container terminal. The main benefits are
reduced labor costs and a more reliable performance.

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