GROUP 8

Automated storage and retrieval system (AS/RS)

 An automated storage /retrieval system is a storage

system that performs storage and retrieval operations

with speed and accuracy under a degree of automation.
 It consists of a variety of computer-controlled systems

for automatically placing and retrieving loads from

defined storage locations.
 Where to use AS/RS

AS/RS perform a basic set of operations without

human intervention:
Transportation of this item to a specific processing
or interface point
Automatic removal of an item from a storage
location
Automatic storage of an item in a predetermined
location, having received an item from a processing
or interface point
 An example where AS/RS is used in Zimbabwe

Rank Zimbabwe Warehouse

It is the largest stationary warehouse in Zimbabwe with
5000sqm under one roof .The warehouse operates as
cash and carry and all distribution is carried out from
here.
• 50000 sqm purpose -built warehouse
• Customised secure receiving and dispatching bays
• Fully computerised stock control system
• 6 point -of sale terminals
• 25 professional staff
RANK ZIMBABWE WAREHOUSE

Figure 1: Rank Zimbabwe warehouse

 REASONS ROR USING AS/RS

An AS/RS is highly space efficient

Increased storage capacity to meet long range plans
Improved inventory management and control
Reduced shortage of inventory items due to real
-time information and control
Reduced labour cost due to automation
Flexibility in design to accommodate a wide variety
of loads
 USES OF AS/RS

Unit load storage and handling systems

warehousing for finished goods or products.
Order picking
used to store and retrieve materials in less than full
unit load quantities such as man- on -board or mini-
load applications.
Work -in process
Support just in-time production activities, buffer
storage, and as integral part of assembly systems.
Kitting
Provides an area for grouping parts for assembly
Consolidation
An area to hold parts until pieces of an order can be
merged ready for shipment
Production
Storage for tooling and materials for manufacturing
Security – software access control
 TYPES OF AS/RS

Unit Load AS/RS

Mini load AS/RS
Man -on board AS/RS
Automated item retrieval system
Vertical lift storage modules (VLSM)
Micro-load
Horizontal carousels
Cube-based storage
Collaborative Robots
Machines that store large loads (usually 450
kilograms), typically on pallets.
 These systems include one or more long and narrow
aisles of storage rack structure reaching 30 metres or
more tall.
Most systems are less than 12 metres tall.
 Software directs the automatic placement and
retrieval of loads by a telescoping device that
deposits loads into, or retrieves them out of specific
storage positions.
UNIT LOAD AS/RS

Figure 2: Unit load AS/RS

 BENEFITS

Allows for stable and fast transport of goods to and

from of high-density storage
Capable of handling multiple load types, including
roll cages and larger items
Low energy requirements for operation
 MINI LOAD AS/RS

It operates the same way as a unit load AS/RS, a

mini load AS/RS handles lighter loads ,usually
weighing less than 450 kilograms .
Instead of storing pallets, the machines typically
store trays ,totes and cartons
Figure 3: Mini- Load AS/RS
 BENEFITS

Minimal learning curve for operation and more

space-efficient
Enhanced goods security
Designed for optimal ergonomic operator use
Usually operates at multiple speeds
 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
throughput.
Figure 4: Man on board AS/RS
 AUTOMATED ITEM RETRIEVAL SYSTEM

This system is designed fir 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 dropping into a conveyor.
The supply of items in each lane is periodically
replenished and thus permitting first -in /first -out
inventory rotation
After moving itself to the correct lane, the picking head
activates.
Figure 5: Automated item retrieval system
 VERTICAL LIFT STORAGE MODULES

VLSMs consist of a column of trays in the front and

back of the module with an automatic
inserter/extractor in the centre that stores and
retrieves the required trays.
Trays can be stored in fixed positions to improve
throughput, dynamically to optimise storage
capacity, or as a combination of both, integrated
controls and software help increase accuracy and
storage densities.
 VLSM

Figure 6: Vertical lift storage modules (VLSM)

 OTHER VLSM FEATURES

Can combine multiple units into pods for multi-

tasking with other units
Takes up minimal floor space
Allows for dynamic storage capabilities
 MICRO LOAD

These units range in size from six to 72 feet, allowing

for placement in existing buildings or worked into the
design for new construction.
Using a storage rack structure with this AS/RS system
eliminates the need for using building columns.
Other features include
Can be outfitted with various load handlers
Only views items needing selecting at the moment
Great for working with goods-to-person order
fulfillment systems
MICRO LOAD

Figure 7: Micro-load
 HORIZONTAL CAROUSELS

Horizontal carousels it’s Ideal for storing small parts

and pieces.
It is comprised of a series of bins that rotate
horizontally around a track.
Operators input instructions telling the system which
positions to rotate into for item retrieval.
OTHER FEATURES
Lower costs compared to some other robotic systems
Eliminates wasted space
Efficiently stores materials between processing steps
HORIZONTAL CAROUSELS

Figure 8:Horizontal carousels

 CUBE BASED STORAGE

Ultra-high density goods-to-person piece picking

system which utilizes robots to store and retrieve
inventory bins from a cubical storage grid.

Figure 9: Cube-based storage

 COLLABORATIVE ROBOTS (cobots)

These are robots intended to work hand in hand with

humans
Mainly for repetitive tasks eg inspection, picking
This enables the human to focus on other tasks eg
problem solving tasks
COLLABORATIVE ROBOTS

Figure 10: Collaborative Robots

 BENEFITS

Can be used on all types of warehouse floors

Can be used in all picking, sorting, counting and
replenishment tasks
Instantaneous new associate onboarding
Two to three fold increase in in aisle rates
 BENEFITS OF AS/RS

Provides individual and department accountability

Enhances product security
Improved Floor Space Utilization.
Reduced Labour Requirements and Costs.
Increased Picking Accuracy (Reduced Picking
Errors)
Improved Picking Throughput (Speed)
Tighter Inventory Control.
Improved Ergonomics
 LIMITATIONS OF AS/RS

The initial cost of the AS/RS is high

AS/RS requires automated guided vehicles or
conveyors
AS/RS is feasible only for large manufacturing
establishments
Can require technical skill and retraining
Repair and maintenance