ASRS - Modex

New Products
Trends and
Benefits in
AS/RS
Presented by:
Sponsored by:
Tom Coyne, System Logistics Corp.
Ed Romaine, Integrated Systems Design
Stephan Reithmann, MIAS
© 2014 MHI®
Copyright claimed as to audiovisual works of seminar sessions and
sound recordings of seminar sessions. All rights reserved.
A Presentation by;
• We are a “Product Group” under the auspices of MHI,
the Material Handling Industry Association
• Our members are the Industry’s leading suppliers of
automated storage/retrieval systems. We supply
systems worldwide and in virtually every major
manufacturing and distribution sector.
• Our goal today is to provide general education about
ASRS and new trends in ASRS……..
What is ASRS
• ASRS = Automated Storage and Retrieval
System
• Definition: 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 (Wikipedia
definition)
• Huh????
What is ASRS – Let’s Try Again
• Storage racking system
• Automated equipment for storing and
retrieving loads (boxes, totes, pallets, wire
bins, etc.)
• System to bring loads to/from the ASRS
• Computer controls to make everything
work together as a “system”.
A Traditional ASRS System
But ASRS is Evolving as Well…
Many Types of ASRS
C
r
a
n
e
B
a
s
e
d
Totes and Boxes
S
h
u
t
t
l
e
Trays
Pallets
B
a
s
e
d
Totes and Boxes
Pallets
What Are the Benefits ?
More Detailed Benefits?
• Space savings. Storage is denser as aisles are smaller and
there is less need for space between loads.
• Labor savings as fork truck moves are eliminated, order
picking time is faster, access to goods is automated and no
time is wasted looking and searching for items
• Improved inventory accuracy due to computer control and
systematic organization
• Inventory reduction based on real time knowledge for
planning
• Reduced product damage due to eliminated manual
handling
• Improved order accuracy due to computer control and
direction
ASRS Makes Operations Run Better
• Pallet Systems
– Finished goods
storage
– Raw materials storage
– Ready reserve for
case picking
– Shipping sequencing
or buffering
– Frozen storage
• Box or Tote Systems
–
–
–
–
–
Each order picking
Production kitting
Order consolidation
Case buffering
Case sequencing
before palletizing
– Sequencing buffer in
manufacturing
Latest and Greatest in ASRS
• Very fast pallet storage and retrieval
• Very fast case / tote storage and
retrieval
• Mid-load ASRS
• Load handling device explosion
NEW: Pallet Shuttle ASRS
Multiple depth storage
(L.I.F.O.)
Shuttles operate on each level
within the rack structure
(Fast Rotating Storage)
Load/unload with forklifts or
automated by conveyor or AGV
Aisle shuttles on each
level
In rack vehicles for pallet
pick-up and deposit
NEW: Pallet Shuttle ASRS
MAIN USE: Very fast
access of a low to
medium amount of SKU’s.
Speed of this solution
makes it very good for
supporting case picking
operations, and
sequenced truck loading.
NEW: Pallet Shuttle ASRS
NEW: Tote / Carton ASRS
Putting multiple load handling
vehicles within a racking system allows for ultrahigh throughput, opening up many new
applications for ASRS in distribution operations !
NEW: Tote / Carton ASRS
Revolutionary new concept(s) that puts ASRS into many new
applications and allows for new types of automated systems!
• Wave buffering
• Shipping staging and sequencing for route loading
• Sequenced delivery for pallet building
• Product delivery to support high speed each order picking
• Automatic case order picking
Perform the function in less space, with more control, in less time, with a
total lower cost for your distribution operation
NEW: Tote / Carton ASRS
NEW: Mid-Load ASRS
• New ASRS Genre
• Fits between the
mini-load and unit
load
• Provides some
unique features
and applications
NEW: Mid-Load ASRS
MAIN USE: General
purpose ASRS solution with
unique advantages through
flexible configurations:
• No need for a crane rail
which leads to economic
advantages.
• Standard and custom
load handlers
• Redundant up time
features
NEW: Mid-Load ASRS
NEW: Load Handling Devices
• Storing and retrieving successfully means
the equipment must properly handle the
load.
• Changes in packaging means unit loads,
especially non-palletized loads, can be
harder to handle.
NEW: Load Handling Devices
How do you handle the
variety?
How do you handle the
raw packaging with no
pallet or special carrier?
There are many new types of load handling devices…….
NEW: Load Handling Devices
Telescopic fork with lateral belt transfers.
Allows stable handling of cardboard cartons
Side gripping arms with “fingers” to allow
Storage and retrieval from shelving, and the
handling of multiple sized cases together in
same system
NEW: Load Handling Devices
Telescopic fork with “fingers” that comb
through custom racking. Allows bottom
handling of loads, extending the range
of what can be put into a system.
Multiple load handlers are now commonly
being put onto mini-load cranes, increasing
throughput and extending the application
range into box buffering and sequencing.
NEW: Load Handling Devices
Dual Pallet handling machines improve
throughput dramatically, extending the
range of ASRS into faster turning
inventory situations.
Rotating turret ASRS provides two large benefits.
First, you can “spike” the pallet, allowing for more
secure handling. Second, the machine can
interface with conventional pallet racking.
Application Information
Loads
Load
Weight
Throughput
Application
Markets
Shuttle Based ASRS
Case / Tote
Up to 50 lbs
Very High.
Dependent on
number of
shuttles.
Buffering,
sequencing, picking
E-commerce,
retail, wholesale,
grocery, food
Micro-Load ASRS
Case / Tote
Up to 50 lbs
2 – 6 loads per
minute dependent
on number of
LHD’s
Buffering,
sequencing, picking
Retail,
wholesale,
grocery, food,
medical
Mini-Load ASRS
Tray storage
Up to 750 lbs
~1 load per minute
Dense storage,
picking
Wholesale,
manufacturing
Mid-Load ASRS
Pallet, Case, Tray,
Unique Load
Up to 2,000
lbs
Up to 1 load per
minute
Storage, buffering,
sequencing, picking
Manufacturing,
CPG, Food
Unit Load ASRS
Pallets
1-2 tons
typically
Up to 1 load per
minute
Pallet storage, case
picking support
Food, CPG,
manufacturing
Pallets
1-2 tons
typically
Less than 1 load
per minute
Low SKU, super
dense storage
Beverage, Food,
CPG
Pallets
1-2 tons
typically
High. Dependent
on number of
shuttles.
Low SKU, super
dense storage with
high throughput
Beverage, Food,
CPG
(With shuttle forks)
Unit Load ASRS
(With in-rack vehicles)
Pallet shuttles
(Typically with in-rack
vehicles)
ASRS Application Criteria
• Two major criteria
– Selectivity required to your stored items
– Velocity or throughput required from the
system
ASRS Classification System Using
Selectivity as a Variable
Selectivity Required – High to Low
Single Deep Storage
L
o
a
d
H
a
n
d
Loads
up to
5,000
lbs
n
g
Multiple Deep Storage
CRANE based ASRS
• One pair of forks for
typical applications
• Two pairs of forks for
higher throughput
CRANE or SHUTTLE
ASRS
• Cranes for low to
moderate throughput
• Multiple shuttles for
higher throughput
UNITLOAD
ASRS
Up to
2,000
lbs.
CRANES that handle
Pans, cases, pallets or
unique loads.
MIDLOAD
ASRS
Pans
100 to
750
lbs.
CRANES that store and
retrieve metal pans.
MINILOAD
ASRS
l
i
CRANE based ASRS
• One pair of forks for
typical applications
• Two pairs of forks for
higher throughput
Double Deep Storage
Totes or
cartons
under
125 lbs.
Lightest CRANES using devices that can handle
plastic totes and/or cardboard boxes.
t
Rack SHUTTLE ASRS that can handle plastic totes
and/or cardboard boxes
MICROLOAD
ASRS Classification System Using
Throughput as a Variable
This idea generally applies, whether thinking about pallet ASRS or tote/box ASRS.
Take Away
• ASRS has been a good intra-logistics solution
for decades
• Recent technical advances have expanded the
range where ASRS can apply.
• These same advances also improve the
business case for ASRS
• You should investigate this week, and over time
as you develop your business operations!
Member Companies
For More Information:
Gary Forger, AS/RS Managing Executive, MHI
Email: gforger@mhi.org
Website: http://www.MHI.org/AS-RS