Department Of Mechatronics

Engg

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 MTS-419 Manufacturing
Automation

Lecture # 7
Storage Systems

Nasir Rashid, PhD (Department of Mechatronics Engg)

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 MTS-419 Manufacturing Automation

• Part - I
• Storage System Performance and Location Strategies
• Conventional Storage Methods and Equipment
• Automated Storage Systems
• Analysis of size automated storage (Rack Sytem)
• Part - II
• Analysis of throughput of Storage Systems (Rack System)
• Analysis of throughput of Storage Systems (Carousel
System)
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 MTS-419 Manufacturing Automation
• Analysis of AS/RS
▪ AS/RS throughput [1]
• Assumption
▪ Randomized storage of load
▪ Storage compartments are of
equal size
▪ P/D station is located at the base
and end of aisle
▪ Constant horizontal and vertical
speeds of SR machine
▪ Simultaneous vertical and
horizontal travel

[1] Chase R. B. and N. J. Aquiland, Production and Operation Management, A life cycle
Approach 5th Edition 4
 MTS-419 Manufacturing Automation

[1] Chase R. B. and N. J. Aquiland, Production and Operation Management, A life cycle
Approach 5th Edition 5
 MTS-419 Manufacturing Automation

[1] Chase R. B. and N. J. Aquiland, Production and Operation Management, A life cycle
Approach 5th Edition 6
 MTS-419 Manufacturing Automation

[1] Chase R. B. and N. J. Aquiland, Production and Operation Management, A life cycle
Approach 5th Edition 7
 MTS-419 Manufacturing Automation

• Analysis of AS/RS
▪ AS/RS throughput
▪ Example
▪ Consider the 4 aisle AS/RS with an S/R machine used for each aisle. The
length of the storage = 280 ft and height = 46 ft. Suppose horizontal and
vertical speeds of S/R machine are 200 ft/min and 75 ft/min,
respectively. The S/R machine requires 20 secs to accomplish a P&D
operation. Find (a) the single command and dual command cycle times
per aisles and (b) throughput per aisles under the assumption that
storage system utilization = 90% and the number of single command
cycles and dual command cycles are equal

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MTS-419 Manufacturing Automation
▪ Example
Consider the 4 aisle AS/RS with an S/R machine used for
each aisle. The length of the storage = 280 ft and height =
46 ft. Suppose horizontal and vertical speeds of S/R
machine are 200 ft/min and 75 ft/min, respectively. The
S/R machine requires 20 secs to accomplish a P&D
operation. Find (a) the single command and dual
command cycle times per aisles and (b) throughput per
aisles under the assumption that storage system
utilization = 90% and the number of single command
cycles and dual command cycles are equal

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 MTS-419 Manufacturing Automation
• Analysis of AS/RS (Class based Dedicated Storage)
▪ AS/RS throughput
▪ Assignment for own Time

The aisles in the AS/RS of the previous example will be organized following a class-
based 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 80% of the
transactions. and the less-active stock accounts fort he remaining 20%. As before,
assume that system utilization = 90%, and the number of single command cycles is
equal to number of dual command cycles. Determine the throughput of the AS/RS,
basing the computation of cycle times

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 MTS-419 Manufacturing Automation
• Analysis of AS/RS (Class based Dedicated Storage)
Solution ▪
▪
AS/RS throughput
Assignment for own Time

The aisles in the AS/RS of the previous example will be organized following a class-based 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 80% of the transactions. and the less-active
stock accounts fort he remaining 20%. As before, assume that system utilization = 90%, and the number of
single command cycles is equal to number of dual command cycles. Determine the throughput of the AS/RS,
basing the computation of cycle times

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 MTS-419 Manufacturing Automation
• Analysis of AS/RS (Class based Dedicated Storage)
Solution ▪
▪
AS/RS throughput
Assignment for own Time

The aisles in the AS/RS of the previous example will be organized following a class-based 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 80% of the transactions. and the less-active
stock accounts fort he remaining 20%. As before, assume that system utilization = 90%, and the number of
single command cycles is equal to number of dual command cycles. Determine the throughput of the AS/RS,
basing the computation of cycle times

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 MTS-419 Manufacturing Automation
• Analysis of AS/RS (Class based Dedicated Storage)
▪ AS/RS throughput
▪ Assignment for own time
An AS/RS with one aisle is 300 ft long and 60 ft high. The S/R machine has a
maximum speed of 300 ft/min in the horizontal direction. It accelerates from zero to
300 ft/min in a distance of 15 ft. On approaching its target position (where the S/R
machine will transfer a load onto or off of its platform), it decelerates from 300
ft/min to a full stop in 15 ft. The maximum vertical speed is 60 ft/min, and the
acceleration and deceleration distances are each 3 ft. Assume simultaneous horizontal
and vertical movement, and that the rates of acceleration and deceleration are
constant in both directions. The pick and deposit time = 0.3 min. Compute cycle time
but adding considerations for acceleration and deceleration, determine the single
command and dual command cycle times.

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 MTS-419 Manufacturing Automation

• Carousal Storage System

▪ 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

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 MTS-419 Manufacturing Automation

• Carousal Storage System

▪ Horizontal

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 MTS-419 Manufacturing Automation
• Carousal Storage System
▪ Horizontal (Storage capacity)

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 MTS-419 Manufacturing Automation

• Carousal Storage System

▪ Storage Capacity
C = Circumfrance (m,ft)
sc = Carrier spacing (m/carrier, ft/carrier)
nc = No of carriers

C = 2( L − W ) +  W
Total No of Bins = nc nb
sc nc = C

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 MTS-419 Manufacturing Automation

• Carousal Storage System

▪ Horizontal (Throughput Analysis)

•Assumptions
➢Only single comd cycle
are performed
➢Carousal operates with vc
constant speed
➢The carousal can move
in either direction

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 MTS-419 Manufacturing Automation

• Carousal Storage System

▪ Horizontal (Throughput Analysis)
•Assumptions
➢The carousal can move in
either direction
C
Tc = + Tpd
4 vc
where Tc = S/R cycle time (mins) 60
vc = Carousal velocity (m/min, ft/min) Rt = Rc =
Tpd = Average time required to pick or deposit items Tc

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 MTS-419 Manufacturing Automation

• Carousal Storage System

▪ Example
▪ The oval rail of a carousal storage system has length = 12 m
and width = 1 m. There are 75 carriers equally spaced
around the oval. Suspended form each carrier are six bins.
Each bin has volumetric capacity = 0.026 m3. Carousel
speed= 20 m/min. Average P&D time for retrieval = 20 sec.
Determine: (a) volumetric capacity of the storage system
and (b) hourly retrieval rate of the storage system.

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MTS-419 Manufacturing Automation

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 MTS-419 Manufacturing Automation

• Practice Problems in own time (Answers)

▪ 11.1 (a)Capacity = 800 loads/aisle, (b) W=63ft, L=233.3ft, H=26.67ft
▪ 11.2 (W=3.45m/aisle, L=50.4m, H=10.85m)
▪ 11.5 (Tcs = 1.6 min/cycle, Tcd = 2.7 min/cycle, Rt =35.58 transactions/hr)
▪ 11.7 (Rt = 281.25 transactions/hr, U=71.1%)
▪ 11.8 (Rt = 245.5 transactions/hr)
▪ 11.12 (Rt = 244.25 transactions/hr)
▪ 11.13 (Tcs = 1.8 min/cycle, Tcd = 3.0 min/cycle)
▪ 11.14 (Tcs = 1.3167 min/cycle, Tcd = 2.175 min/cycle,
Rt =185.6 transactions/hr)

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