Lecture Notes - Week 5 Material Handling - Storage

Industrial Automation
BMFA 3443
MATERIAL HANDLING STORAGE
Chapter Objectives
To understand and
explain the storage
system performance
and location strategies.
To understand the
analysis method of
storage system.
To differentiate between
conventional and
automated storage and
identify the reasons for
automated storage.
2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material
may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems,
and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
Categories of
Material Handling Equipment
1. Material transport equipment - to move materials
inside a factory, warehouse, or other facility
2. Storage - to store materials and provide access to
those materials when required
3. Unitizing equipment - refers to (1) containers to hold
materials and (2) equipment used to load and package
the containers
4. Identification and tracking systems - to identify and
keep track of the materials being moved and stored
Storage Systems
Sections:
1. Storage System Performance and Location Strategies
2. Conventional Storage Methods and Equipment
3. Automated Storage Systems
4. Engineering Analysis of Storage Systems
2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
Storage Systems
Function to store materials (e.g., parts, work-in-process,
finished goods) for a period of time and permit retrieval
when required
Used in factories, warehouses, distribution centers,
wholesale dealerships, and retail stores
Important supply chain component
Storage Systems
Current situation
manual methods for
storing and retrieving
items
Inefficient
Human resources
Factory floor space
Material control
Alternative solution
Automation
to improve efficiency
Storage System Performance

Performance measures for storage systems:
Storage capacity - two measures:
Total volumetric space
Total number of storage compartments (e.g., unit loads)
Storage density - volumetric space available for storage
relative to total volumetric space in facility
Accessibility - capability to access any item in storage
System throughput - hourly rate of storage/retrieval
transactions
Utilization and availability (reliability)
Storage Location Strategies

Randomized storage - incoming items are stored in any
available location
Usually means nearest available open location
Dedicated storage - incoming items are assigned to
specific locations in the storage facility
Typical bases for deciding locations:
Items stored in item number sequence
Items stored according to activity level
Items stored according to activity-to-space ratios
Each item type stored in a warehouse is known as StockKeeping-Unit (SKU)
Inventory Level as a Function of Time

Example: No. of SKU to be stored = 50 SKUs
Comparison of Storage Strategies

Randomized storage strategy
The number of locations required
for each SKU is equal to the
average inventory level of the
item, since incoming orders are
scheduled each day throughout
the 50-day cycle
This means that when the
inventory level of one SKU near
the beginning of its cycle is high,
the level for another SKU near
the end of its cycle is low.
Thus, the number of storage
locations required in the system
is
Dedicated storage strategy

The number of locations required
for each SKU must be equal its
maximum inventory level
Thus, the number of storage
locations required in the system
is
50 SKUs x 110 cartoons = 5500
locations
50 SKUs x 60 cartoons = 3000 locations

Comparison of Storage Strategies

Less total space is required in a storage system that uses
a randomized storage strategy
Dedicated storage requires space for maximum
inventory level of each item
Higher throughput rates are achieved in a system that
uses dedicated storage strategy based on activity level
The most active items can be located near the
input/output point
Compromise: Class-based dedicated storage
Items divided into classes according to activity level
Random storage strategy used within each class
Conventional Storage Methods

Bulk storage - storage in an open floor area
Problem: achieving proper balance between storage
density and accessibility
Rack systems - structure with racks for pallet loads
Permits vertical stacking of materials
Shelving and bins - horizontal platforms in structural frame
Steel shelving comes in standard sizes
Finding items can be a problem
Drawer storage - entire contents of each drawer can be
viewed
Bulk Storage
Bulk storage arrangements: (a) high-density bulk storage

provides low accessibility, (b) bulk storage with loads
forming rows and blocks for improved accessibility
Pallet Rack System

Pallet loads placed on
racks in multi-rack
structure
Drawer Storage
Automated Storage Systems

Mechanized and automated storage equipment to reduce the
human resources required to operate a storage facility
Significant investment
Level of automation varies
In mechanized systems, an operator participates in
each storage/retrieval transaction
In highly automated systems, loads are entered or
retrieved under computer control
Objectives and Reasons for

Automating Storage Operations
To increase storage capacity

To increase storage density
To recover factory floor space currently used for WIP
To improve security and reduce pilferage
To reduce labor cost and/or increase productivity
To improve safety
To improve inventory control
To improve stock rotation
To improve customer service
To increase throughput
Types of Automated Storage System

1. Automated Storage/Retrieval System (AS/RS)
Rack system with mechanized or automated crane to
store/retrieve loads
2. Carousel Storage System
Oval conveyor system with bins to contain individual
items
AS/RS
Unit load AS/RS
with one aisle
AS/RS Types
Unit load AS/RS - large automated system for pallet loads
Deep-lane AS/RS - uses flow-through racks and fewer
access aisles
Miniload AS/RS - handles small loads contained in bins or
drawers to perform order picking
Man-on-board AS/RS - human operator rides on the
carriage to pick individual items from storage
Automated item retrieval system - picks individual items
Vertical lift storage modules (VLSM) - uses a vertical aisle
rather than a horizontal aisle as in other AS/RS types
AS/RS Applications
1. Unit load storage and retrieval
Warehousing and distribution operations
AS/RS types: unit load, deep lane (food industry)
2. Order picking
AS/RS types: miniload, man-on-board, item retrieval
3. Work-in-process storage
Helps to manage WIP in factory operations
Buffer storage between operations with different
production rates
Supports JIT manufacturing strategy
Carousel Storage Systems

Horizontal
Operation is similar to overhead conveyor system used
in dry cleaning establishments
Items are stored in bins suspended from the conveyor
Lengths range between 3 m and 30 m
Horizontal is most common type
Vertical
Operates around a vertical conveyor loop
Less floor space required, but overhead room must be
provided
Horizontal Carousel Storage System
Manually operated
horizontal carousel
storage system
Vertical Carousel Storage System

Example of Vertical
carousel storage
system
Carousel Applications
1. Storage and retrieval operations
Order picking
Kitting of parts for assembly
2. Transport and accumulation
Progressive assembly with assembly stations located
around carousel
3. Work-in-process
WIP applications in electronics industry are common
4. Unique applications
Example: time testing of electrical products
Engineering Analysis of
Automated Storage Systems
1. Automated Storage/Retrieval Systems
Sizing the AS/RS
AS/RS throughput analysis
2. Carousel storage systems
Storage capacity
Throughput analysis
Sizing an AS/RS System

The total storage capacity of one storage aisle
depends on how many storage compartments
are arranged horizontally and vertically in the
aisles
Capacity per aisle can be expressed as:
Capacity per aisle = 2nynz
ny = number of load compartments along the length
of the aisle
nz = number of load compartments that make up
the height of the aisle
2 is the constant, accounts for the fact that loads
are contained on both sides of the aisle
Top and Side Views of a Unit Load AS/RS

W
Pick up & Deposit (P & D) station
Overhead rails
Storage
compartments
P & D station
Bottom rail
ny= 9 nz= 6
Assuming a standard size compartment

Let x and y = the depth and width dimensions of a unit load, z =
the height of the unit load
The width, length, and height of the rack structure of the AS/RS
aisle are related to the unit load dimensions and number of
compartments as follows:
W = 3 (x + a)
L = ny (y +b)
H = nz (z + c)
Where W, L, and H are the width, length, and height of one aisle of the
AS/RS rack structure (mm, in);
x, y, and z are the dimensions of the unit load (mm, in);
and a, b, and c are allowances designed into each storage compartment
to provide clearance for the unit load and to account for the size of the
supporting beams in the rack structure (mm, in). Recommended values a=
150mm (6 in), b = 200mm (8 in), and c=250 mm (10 in)
Example: Sizing an AS/RS System

Each aisle of four-aisle AS/RS is to contain 60 storage
compartments in the length direction and 12
compartments vertically. All storage compartments will be
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 following allowances a= 6 in, b=8 in,
and c= 10 in determine:
How many unit loads can be stored in the AS/RS
The width, length and height of the AS/RS
Answer
(a)Storage Capacity
Capacity per aisle = 2(60)(12) = 1440 unit
Total for 4 aisles = 4(1440) = 5760 unit
(b)Structure dimension
W = 3(42 + 6) = 144 in = 12 ft
Overall W = 4(12) =48 ft
L = 60(48 + 8) = 3360 in = 280 ft
H = 12(36 + 10) = 552 in = 46 ft
AS/RS Throughput Analysis
Defined as the
hourly rate of
Storage /
Retrieval
transactions that
the automated
storage system
can perform.
Several methods are

available to compute
AS/RS cycle times to
estimate throughput
performance. The next
following method assumes:
Material
Handling
Institute (MHI)
methods
Randomized storage of loads in

the AS/RS
Storage compartments are of
equal size
The P & D station is located at
the base and end of the aisle
Constant horizontal and vertical
speeds of the Storage/Retrieval
machines
Simultaneous horizontal and
vertical travel
Travel Trajectory of The

Storage/Retrieval Machines
Single
Command
Cycle
Dual
Command
Cycle

Single Command Cycle
The load to be entered
or retrieved is
assumed to be located
at the center of the
rack structure
Thus, the S/R machine
must travel half the
length and half the
height of the AS/RS,
and must return the
same distance
Cycle Time
The single command cycle time:
Where:
Tcs = cycle time of a single command cycle (min/cycle)

Tpd = pickup-and-deposit time (min)
L = length of the AS/RS (m, ft)
Vy = velocity of S/R machine along the length, L (m/min, ft/min)
H= height of the rack structure (m, ft)
Vz = velocity of the S/R machine along vertical direction (m/min,
ft/min)

Dual Command Cycle
The S/R machine is
assumed to travel to
the center of the rack
structure to deposit a
load,
Then, the S/R machine
must travel the
length and height of
the AS/RS to retrieve
the load
Thus, the total distance
is the length and
height, and back
Cycle time
The dual command cycle time:
Tcd = cycle time of a dual command cycle (min/cycle)

Tpd = pickup-and-deposit time (min)
L = length of the AS/RS (m, ft)
Vy = velocity of S/R machine along the length, L (m/min, ft/min)
H= height of the rack structure (m, ft)
Vz = velocity of the S/R machine along vertical direction (m/min,
ft/min)
System throughput analysis

Depends on the relative numbers of single and
dual command cycle performed by the system
Let,
Rcs = number of single command cycles performed per
hour
Rcd = number of dual command cycles performed per
hour
At a specified or assumed utilization level, U, the amount
of time spent in performing single command and double
The total
command cycles each hour is as follow:
number of
minutes of
operation per
hour
System throughput analysis

To solve the previous equation, the relative proportions of
Rcs and Rcd must be determined, or assumptions about
these proportions must be made.
Then, the total hourly cycle rate is calculated as follow:
Where, Rc is the total S/R cycle rate (cycles/hr).
Since there are two transaction accomplished in each dual
command cycle, the total number of storage and retrieval
transactions per hour will be greater than this value unless
Rcd = 0,
Let Rt = the total number of transactions performed per
hour, then:
Example: AS/RS Throughput Analysis

Consider the AS/RS in previous example which an
S/R machine is used for each aisle. The length of
the storage aisle = 280 ft and its height = 46 ft.
suppose horizontal and vertical speeds of the S/R
machine are 200 ft/min and 75 ft/min,
respectively. The S/R machine requires 20 sec to
accomplish a P & D operation. Determine:
(a) the single command and dual command cycle times
per aisle, and
(b) throughput per aisle under the assumptions that the
storage system utilization = 90% and the number of
single command and dual command cycles are equal
Answer
(a) Cycle times
Tcs =2.066 min/cycle
Tcd = 3.432 min/cycle
(b) Throughput
Rcd = Rcs = 9.822 cycles/hr
Rt = 29.46 transactions/hr
For 4 aisles, Rt = 4(29.46) = 117.84 transaction/hr
Example: AS/RS Throughput Using a ClassBased Dedicated Storage Strategy

The aisles in the AS/RS of the previous example will be
organized following a dedicated storage strategy. There will be
two classes, according to activity level. The more active stock is
stored in the half of the rack system that is located closest to
the input/output station, and the less active stock is stored in the
other half of the rack system farther away from the input/output
station. Within each half of the rack system, random storage is
used. The more active stock accounts for 75% of the
transactions, and the less active stock accounts for the
remaining 25%. Assuming the utilization is 90% and the number
of single command cycles equal to the number of dual
command cycles.
Determine the throughput of the AS/RS, basing the computation
of the cycle times on the same kinds of assumptions use in MHI
method.
Answer
Cycle times
Class A
TscA = 1.366 min
TdcA = 2.382 min
Class B
TscB = 2.766 min
TdcB = 3.782 min
Throughput
RcsB = RcdB = 3.035 cycles/hr
RcdA = RcsA = 9.105 cycles/hr
Rt = 36.42 transactions/hr
For 4 aisles, Rt = 4(36.42) = 145.68 transaction/hr
Carousel Storage System

Due to its
construction, carousel
systems do not
possess nearly the
volumetric capacity of
an AS/RS.
Usually, a typical
carousel system is
likely to have higher
throughput rates than
AS/RS
Storage Capacity
Individual bins or
baskets are suspended
from carriers that revolve
around the carousel oval
rail.
The circumference of the
rail is given by:
The following figure shows a typical

carousel storage system
Where,
C = circumference of oval
conveyor track (m, ft), and
L and W are the length and
width of the track oval (m,
ft)
Storage Capacity
The capacity of the carousel system depends on the number
and size of the bins (or basket) in the system.
Assuming standard size bins each of a certain volumetric
capacity, then the number of bins can be used as a measure of
capacity. From figure where nb is the number of bins hanging
vertically from each carrier and nc is the number of carriers
around the periphery of the rail. Then the total number of bins is
n c x nb .
The carriers are separated by a certain distance to maximize
storage density yet avoid the suspended bins interfering each
other while travel around the ends of the carousel. The carrier
spacing sc (m/carrier, ft/carrier) can be calculated using the
following relationship: sc x nc = C.
System Throughput Analysis

The storage/retrieval
cycle time can be
derived based on the
following assumptions:
Only single command cycles
are performed
The carousel operates at
constant speed vc.
Random storage is assumed
The carousel can move in
either direction
Under the last

assumption of
bidirectional travel, it
can be shown that the
mean travel distance
between the
load/unload station and
a bin randomly located
in the carousel is C/4.
thus the S/R cycle time
is given as:
System Throughput Analysis

Where
Tc = S/R cycle time (min)
C = carousel circumference (m, ft)
Vc = carousel velocity (m/min, ft/min)
Tpd = the average time required to pick or deposit items
each cycle by the operator at the load/unload station
(min)
The number of transaction accomplished per

hour is the same as the number of cycles and is
given by the following
Example: Carousel Operation

The oval rail of a carousel storage system has length =
12m and width = 1 m. There are 75 carriers equally
spaced around the oval. Suspended from each carrier are
six bins. Each bin has volumetric capacity = 0.026m 3.
Carousel speed = 20m/min. Average P&D time for retrieval
= 20 sec. Determine
(a) volumetric capacity of the storage system
(b) hourly retrieval rate of the storage system
Answer
(a) Total number of bins
nc x nb = 75 x 6 = 450 bins
Volumetric capacity = 450(0.026) = 11.7 m 3
(b) Hourly retrieval
Circumference, C = 2(12 - 1) + 1 = 25.14 m
Cycle time per retrieval Tc = 25.14/[(4)(20)] + 20/60 =
0.647 min
Throughput, Rt = 60/0.647 = 92.7 retrieval
transactions/hr
Summary
Storage system performance is measured through
capacity, density, accessibility, system throughput
and availability.
Two storage location strategies which are
randomized storage and dedicated storage.
AS/RS and Carousel Storage System are two
automated storage system.

Lecture Notes - Week 5 Material Handling - Storage

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Industrial Automation

MATERIAL HANDLING STORAGE

Storage System Performance

Storage Location Strategies

Inventory Level as a Function of Time

Comparison of Storage Strategies

Dedicated storage strategy

50 SKUs x 60 cartoons = 3000 locations

Comparison of Storage Strategies

Conventional Storage Methods

Bulk storage arrangements: (a) high-density bulk storage

Pallet Rack System

Automated Storage Systems

Objectives and Reasons for

To increase storage capacity

Types of Automated Storage System

Carousel Storage Systems

Horizontal Carousel Storage System

Vertical Carousel Storage System

Sizing an AS/RS System

Top and Side Views of a Unit Load AS/RS

Assuming a standard size compartment

Example: Sizing an AS/RS System

AS/RS Throughput Analysis

Several methods are

Randomized storage of loads in

Travel Trajectory of The

Travel Trajectory of The

Tcs = cycle time of a single command cycle (min/cycle)

Travel Trajectory of The

Tcd = cycle time of a dual command cycle (min/cycle)

System throughput analysis

System throughput analysis

Example: AS/RS Throughput Analysis

Example: AS/RS Throughput Using a ClassBased Dedicated Storage Strategy

Carousel Storage System

The following figure shows a typical

System Throughput Analysis

Under the last

System Throughput Analysis

The number of transaction accomplished per

Example: Carousel Operation

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