APPLICATION OF AUTOMATED STORAGE AND RETRIEVAL SYSTEMS AT FATIH UNIVERSITY CIM LAB

by

lyas STN

June 2008

APPLICATION OF AUTOMATED STORAGE AND RETRIEVAL SYSTEMS AT FATIH UNIVERSITY CIM LAB

by

lyas STN

A thesis submitted to

The Industrial Engineering Department

of

Fatih University

June 2008 Istanbul, Turkey

III

APPLICATION OF AUTOMATED STORAGE AND RETRIEVAL SYSTEMS AT FATIH UNIVERSITY CIM LAB lyas STN

Bachelor Thesis- Industrial Engineering June 2008

Supervisor: Ass. Prof. Fahrettin ELDEMR

ABSTRACT

Warehousing and distribution centers constitute and important part of manufacturing and logistics. They make up an essential proportion of the time spent from manufacturing till customer. However, in general the activities performed are mainly non value added, so just increasing the cost. Thats why warehouses have a lot of opportunities to increase service level while decreasing the costs. Automation systems such as automated storage and retrieval systems are one of these. The objective of the automation project at Fatih University was to implement such a system in a small scale at the computer integrated manufacturing lab in order to benefit from hands on learning. After completed, the students will be able to apply their theoretical knowledge in this automation lab. Thus, the project when finished will not only benefit the academia but the industry as well. The industry will be able to exercise this system at the CIM lab, and also the experienced students will be ready for them. After the analysis of basic warehousing activities automated storage and retrieval systems have been analyzed thoroughly. Final part is devoted to the project at Fatih University. The system parts, the stages of the project, and how the system works are shown.

Keywords: Warehouse, Warehousing, Storage, Orderpicking, AS/RS, Automated Storage and Retrieval Systems

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OTOMATK DEPOLAMA VE GER AIRMA SSTEMLERNN FATH NVERSTES BLGSAYAR ENTEGREL RETM LABORATUARINDA UYGULANMASI

lyas STN

Lisans Tezi- Endstri Mhendislii Haziran 2008

Tez Yneticisi: Yrd. Do. Dr. Fahrettin ELDEMR

Depolar ve datm merkezleri retim ve lojistiin temel talar arasndadr. retimden tketiciye ulancaya kadar geen srenin nemli bir blmn tekil ederler. Fakat burada sorun bu zaman dilimi iinde gerekleen olaylarn ounluk itibariyle katma deer oluturamamasdr. Bundan dolay depolarda servis seviyesini artrmak ve maliyetleri azaltmak iin ok byk imknlar mevcuttur. Otomasyon sistemleri bir zm olabilir mesela. Otomatik depolama ve geri arma sistemleri (AS/RS) depolarda kullanlan otomasyon sistemlerinin banda gelmektedir. Bu projeyi yaparkenki amacmz da kk apta AS/RS sistemlerini Fatih niversitesi Bilgisayar Entegreli retim Laboratuarnda (CIM) uygulamaya koymakt. Proje bittiinde renciler derslerde rendikleri teorik bilgileri uygulama imknna kavuacaktr. Bu proje sonular itibariyle sadece akademik evrelere deil, endstriyel evrelere de byk imknlar salayacaktr. nk hem tecrbeli eleman ihtiyalar karlanacak, hem de kendileri de bu sistemleri inceleme imknna kavuacaklardr. Tezde depolar, depolama sistemleri ve AS/RS hakknda teorik bilgi verildikten sonra, okulumuzda hayata geirdiimiz projenin paralar, aamalar ve nasl alt anlatlmtr.

Anahtar kelimeler: Depolar, Datm merkezleri, Depolama, Otomatik Depolama ve Geri arma Sistemleri, AS/RS

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DEDICATION

I would like to dedicate this bachelor thesis to my parents, without whom I would not be able to succeed at all. Their care and love has brought me up until now, and will help me in the future too.

ACKNOWLEDGMENT

I would like to express my great thanks to my supervisor Fahrettin ELDEMIR, whose knowledge and guidance has helped me get through the hard process while preparing this thesis. I would also express my gratitude towards my parents whose love and support have been the greatest asset in my life as well in this thesis. I would to thank my classmates too, who have shared their last four years with me. I have to specially thank mer Faruk Doan who has helped me a lot in the technical drawings

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TABLE OF CONTENTS

APPLICATION OF AUTOMATED STORAGE AND RETRIEVAL SYSTEMS AT FATIH UNIVERSITY CIM LAB...................................................................................I APPLICATION OF AUTOMATED STORAGE AND RETRIEVAL SYSTEMS AT FATIH UNIVERSITY CIM LAB..................................................................................II APPLICATION OF AUTOMATED STORAGE AND RETRIEVAL SYSTEMS AT FATIH UNIVERSITY CIM LAB.................................................................................iii OTOMATK DEPOLAMA VE GER AIRMA SSTEMLERNN FATH NVERSTES BLGSAYAR ENTEGREL RETM LABORATUARINDA UYGULANMASI.................................................................................................................iv DEDICATION............................................................................................................v ACKNOWLEDGMENT............................................................................................vi TABLE OF CONTENTS..........................................................................................vii LIST OF TABLES.....................................................................................................ix LIST OF FIGURES.....................................................................................................x 2.1 WAREHOUSE CHARACTERIZATIONS....................................................xix 2.1.1 Warehouse Processes ................................................................................xx 2.1.2 Warehouse Resources...............................................................................xxi 2.1.3 Warehouse Organization.........................................................................xxii 3.1 STORAGE SPACE PLANNING.................................................................xxiv 3.2 STORAGE LAYOUT PLANNING..............................................................xxv 4.1 ORDERPICKING OBJECTIVES................................................................xxix 4.2 Layout design for orderpicking.....................................................................xxxi 4.2.1 Orderpicking Routes.............................................................................xxxii 5.1 THE MAIN COMPONENTS OF AN AS/RS ........................................xxxviii 5.2 TYPES OF AUTOMATED STORAGE AND RETRIEVAL SYSTEMS .....xl 5.3 ENGINEERING ANALYSIS OF AUTOMATED STORAGE SYSTEMS ........................................................................................................................................xliii

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5.3.1 Sizing the AS/RS Structure.....................................................................xliii 5.3.2 Travel Time Models................................................................................xliv 5.4 DESIGN OF AS/RS ......................................................................................xlix 5.4.1 The Interdependence Between AS/RS And Other Systems........................l 5.4.2 The Physical Design of an AS/RS .............................................................li 5.4.3 The Control of an AS/RS..........................................................................liii 6.1 AUTOMATED STORAGE AND RETRIEVAL SYSTEM IN THE LAB...lxi 6.1.1 Aluminum Bar..........................................................................................lxii 6.1.2 Pallet ........................................................................................................lxii 6.1.3 Rack Structure.........................................................................................lxiii 6.1.4 S/R Crane..................................................................................................lxv 6.2 KEY ELEMENTS IN THE OPERATION OF THE AUTOMATION SYSTEM........................................................................................................................lxvi 6.2.1 Warehouse Management System (WMS).............................................lxvii 6.2.2 SCADA Systems....................................................................................lxvii 6.2.3 PLC..........................................................................................................lxix 6.2.4 Relay........................................................................................................lxxi 6.2.5 Servo Motor............................................................................................lxxii 6.3 HOW DOES THE SYSTEM WORK?.......................................................lxxvii REFERENCES.......................................................................................................lxxx

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LIST OF TABLES

TABLE 2.1. Description of warehouse design and operation problems [10].......xviii TABLE 5.2. Overview of design decisions for AS/RS [3].......................................liii

ix

LIST OF FIGURES

FIGURE 2.1. Framework for warehouse design and operation problems [10]......xvii FIGURE 2.2. Typical warehouse processes and flows [8].....................................xxi FIGURE 2.3. Illustration of two common ways of class based storage [1]..........xxiii FIGURE 4.4. Classification of order picking systems [1].....................................xxix FIGURE 4.5. Typical distribution of an order pickers time [8].............................xxx FIGURE 4.6. Decisions to be given in the aisle design........................................xxxii FIGURE 4.7. Illustration of an order picking situation (left) and its graph representation (right)......................................................................................................xxxiii FIGURE 4.8. Different routing methods in a single block warehouse [1]...........xxxv FIGURE 5.9. AS/RS at Green Mountain Distribution Center Waterbury, Vermont, USA [22].......................................................................................................................xxxviii FIGURE 5.10. AS/RS crane [23].........................................................................xxxix FIGURE 5.11. AS/RS crane family [24]..............................................................xxxix FIGURE 5.12. Unit load automated storage retrieval system [16]............................xl FIGURE 5.13. Classification of various AS/RS system options [3]........................xli FIGURE 5.14. AS/RS unit load storage buffer for supply chain delivery [25]......xlii FIGURE 5.15. AS/RS mini load storage buffer for order picking and fulfillment [25]......................................................................................................................................xlii FIGURE 5.16. FEM Standards: Dual Command Travel Time Calculation............xlv FIGURE 5.17. MHI Standards: Single Command Travel Time Calculation.........xlvi FIGURE 5.18. MHI Standards: Dual Command Travel Time Calculation..........xlvii

FIGURE 5.19. AS/RS with bays, aisles, and rows [16].......................................xlviii FIGURE 5.20. Cost of making design changes [8]......................................................l FIGURE 5.21. Design of an AS/RS system [3]..........................................................li FIGURE 6.22. Turn and Milling Machines in the CIM lab.......................................lv FIGURE 6.23. Front view of the lab. The new structures will be installed to the behind of these machines.....................................................................................................lvi FIGURE 6.24. The robot arm that will pick the parts and take them to the machines. In the middle the buffer zone is shown...............................................................................lvi FIGURE 6.25. Top view of the projected CIM lab................................................lviii FIGURE 6.26. Pallets are moving on the conveyors................................................lix FIGURE 6.27. The conveyors take the pallets to the available S/R crane...............lix FIGURE 6.28. The S/R cranes are waiting for orders................................................lx FIGURE 6.29. A pallet is being loaded to the S/R crane...........................................lx FIGURE 6.30. S/R crane is taking the pallets to the storage area............................lxi FIGURE 6.31. Aluminum part.................................................................................lxii FIGURE 6.32. Pallet................................................................................................lxiii FIGURE 6.33. Rack structure and its sizes.............................................................lxiv FIGURE 6.34. Rack structure together with S/R crane in between........................lxiv FIGURE 6.35. S/R crane and its sizes......................................................................lxv FIGURE 6.36. S/R crane.........................................................................................lxvi FIGURE 6.37. Interaction between the PLCs and the SCADA system [26].......lxviii FIGURE 6.38. Control panel with PLC (grey elements in the center). The unit consists of separate elements, from left to right; power supply, controller, relay units for in- and output......................................................................................................................lxx FIGURE 6.39. PLC with many inputs and outputs [27].........................................lxxi FIGURE 6.40. The grey/green cylinder is the brush-type DC motor. The black section at the bottom contains the planetary reduction gear, and the black object atop the

xi

motor is the optical encoder for position feedback. This is the steering actuator of a large robot vehicle [26].............................................................................................................lxxiv FIGURE 6.41. A servo motor disassembled [28]..................................................lxxv FIGURE 6.42. Motion of the servo motor according to the duration of the current [28]...................................................................................................................................lxxvi FIGURE 6.43. General control diagram of the system.........................................lxxvi

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LIST OF SYMBOLS AND ABBREVIATIONS

AS/RS S/R CIM WMS SCADA PLC ERP LAN HMI RTU RFID

Automated Storage and Retrieval Systems Storage and Retrieval Computer Integrated Manufacturing Lab Warehouse Management System Supervisory Control and Data Acquisition Programmable Logic Controller Enterprise Resource Planning Local Area Network Human Machine Interface Remote Terminal Unit Radio Frequency Identity

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CHAPTER 1

INTRODUCTION

Warehouses and distribution centers are becoming more important over time. As the companies try to cut their costs, warehousing and order picking are of great concern [1]. The trend towards product variety and short response times has placed great importance and opportunities in efficient logistics operations. Since the logistic costs constitute a great portion of the total cost it is one of the managements priorities to decrease these costs. In manufacturing, smaller lot sizes, cycle time reductions become popular over time. Distribution logistics becomes more customer oriented. Late orders are accepted, though deliveries are trying to be made on time and as rapid as possible. Larger warehouses take place those of the smaller ones because of the advantages, namely economies of scale. Postponement strategy by Van Hoek which includes activities like kitting, labeling, product assembly, customized packaging or palletisation which are done in the warehouse is being adopted by many companies, so that the companies can earn from manufacturing time and reduce the costs [2]. In order to achieve the mentioned goals above, the industry tends to be more and more automated over time. Though the first costs of investment may be high for automated systems the rate of return is high in the long run. Besides they are more reliable, fast, and accurate than personnel oriented systems. One such automation system: the automated storage and retrieval systems have been used since the 1950s in the distribution and production systems [3]. AS/RS consists of an S/R crane, racks, and pallets. The pallets are stored in the racks by the S/R crane, and retrieved from their location when needed. The system is fully automatic, with very little human intervention where control and maintenance is done.

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This thesis is meant to provide a project of an AS/RS in a small scale, which was applied in Fatih University Computer Integrated Manufacturing Lab. This project was initiated by Fatih University in the spring of 2008 in which a group of professors and students were involved including me. The aim was to add an AS/RS to the already existing CIM lab. Of course some other features needed to be added too, to make the system a full automated system. These were the conveyor system, robot arm to pick the pallets and put them to the buffer area, and some other machines for control and maintenance. Automation control and motion systems such as SCADA, PLC, servo motors were also researched and applied to the system. The thesis is structured as follows: First of all we have to know what warehousing is. So the second chapter is all about warehouse organization, resources, and processes. Third and fourth chapters are devoted for the details of storing and orderpicking processes which will help us understand the concept of warehousing better. Now as we know more or less about warehouses and storage we can further our knowledge and technology by adopting automation systems. Fifth chapter is about the automated storage and retrieval systems. It talks about the components, types, and the design of an AS/RS. Engineering analysis is also done at the end of the chapter where AS/RS sizing, AS/RS travel time, and AS/RS throughput have been analyzed. Finally we are ready for our project. Chapter six is devoted to the project we have done. After giving brief information about the project I go into details of the AS/RS in the lab with the parts, and sizing of the structure. The AS/RS on its own wont benefit much. It needs to be integrated with the other parts of the automation system, running smoothly and in accordance with them. Automatic control and motion systems need to be in use for this purpose. Such systems include the SCADA system, programmable logic controller (PLC), relays, and servo motors. Key elements in the operation of an automation system provide this information about these systems. Lastly, I talk about how our system works in the computer integrated manufacturing lab.

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CHAPTER 2

WAREHOUSES

Warehouses are the centers where items are stored. This is the main function of a warehouse. All other transactions are related to this. Retrieval, packaging, shipping are done because we have a storage. In 2003 warehousing contributed to approximately 20% of the surveyed companies logistics costs, where the other activities are categorized as administration, inventory, transportation, transport packaging, and value added activities [4]. So, close care must be taken to improve warehousing in order to decrease the costs. A basic chart showing the warehouse design and operation problems are shown in the figure below. The numbers below the boxes show how many papers are written concerning that subject. The numbers with * shows papers concerning both receiving and shipping. On the table after the figure we see the details of this framework. I will not go into the detail of warehouse design, as it is out of the scope of this thesis. The other parts will be talked about as much as needed.

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FIGURE 2.1. Framework for warehouse design and operation problems [10]

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TABLE 2.1. Description of warehouse design and operation problems [10]

Warehouse design Overall structure Material flow Department identification Relative location of departments Size of the warehouse Size and dimension of departments Pallet block-stacking pattern (for pallet storage) Aisle orientation Number, length, and width of aisles Door locations Level of automation Storage equipment selection Material handling equipment selection (order picking, sorting) Storage strategy selection (e.g., random vs. dedicated) Order picking method selection Warehouse operations Receiving and shipping Truck-dock assignment Order-truck assignment Truck dispatch schedule Assignment of items to SKU-department different warehouse departments assignment Space allocation Storage Zoning Assignment of SKUs to zones Assignment of pickers to zones

Sizing and dimensioning

Department layout

Equipment selection

Operation strategy

Storage location assignment Storage location Specification of storage classes assignment (for class-based storage) Batching Order picking Routing and sequencing Sorting Batch size Order-batch assignment Routing and sequencing of order picking tours Dwell point selection (for AS/RS) Order-lane assignment

We have to distinguish between some words used for warehouses. Warehouse is the place where goods are stored and buffered. In addition to storage if distribution is another main function, then the word distribution centre is used. If the main objective is to receive and send out the goods where storage is not so vital, then the terms cross dock, transshipment, or platform centre are used [4].

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Some of the warehouse functions could be named as follows: Provide temporary storage of goods Put together customer orders Serve as a customer service facility Protect goods Segregate hazardous or contaminated materials Perform value-added services Inventory Buffer location for direct delivery To minimize the time and space difference between producers and customers Make use of purchase discounts and/ or forward buys Make possible the JIT policy of the company

2.1

WAREHOUSE CHARACTERIZATIONS Processes, resources, and organization make up the characterizations of a

warehouse. A process can be defined as the steps which are applied to products. Resources are personnel, equipment and all other means operating in a warehouse. Organization is planning and control procedures in order to run the system [5]. Some definitions should be made to get rid of ambiguity. There is a general confusion between the words product and item. These words are used in each others place many times which is incorrect. To give an example water bottles under a unique brand are called products. Stock keeping unit or an item is one individual water bottle.

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2.1.1 Warehouse Processes Some distinct phases encountered in a warehouse can be classified as follows [5]: Without arrival of a product no other processes can be talked about. So the first process is the receiving process. After receiving the products wait for the second process. Meanwhile they can be checked or transformed which could be repacking into smaller lots, or combining them with other products. The storage process occurs when the items are placed in the storage areas. If needed the storage area can be divided into the reserve area and the forward area. The reserve area is for bulk storage, while the forward area is for items in continuous or high demand use. Replenishment is the word used for transferring from reserve area to forward area. When an item is ordered by the customer, retrieval from the storage is called orderpicking. Orderpicking can be performed manually or automated. To arrange the items wanted by the customer is called sorting. Consolidation is the grouping together of the items wanted by the same customer. As we have the customer order in our hands, one last operation is to ship them to the customer. The shipping area is where the orders are checked, packed, and loaded into trains, ships, airplanes, trucks or any other means of transport. After that the transportation is done. The figure below depicts basic warehouse processes and flows.

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FIGURE 2.2. Typical warehouse processes and flows [8].

2.1.2 Warehouse Resources Storage unit provides the means of storage of items. They can be pallets where the items are stored on top of, carton boxes and plastic boxes where the items are stored inside. Storage unit is often abbreviated as SKU (Storage keeping unit). Storage system is the storage units in a hole. This involves shelves, racks, automated systems like automated cranes, lifts, and conveyors. Pick equipment do the job of retrieving from the storage area. Pick equipment could be a reach truck, or in automated systems an AS/RS crane. They are also used for storing the items. Support equipment for the pick equipment is called orderpick auxiliaries. Bar code scanners are one kind of auxiliaries. Personnel are of course the human labor constituting the major resource. However in systems where automation is largely used their number and importance decreases.

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2.1.3 Warehouse Organization Organizational decisions concerned with warehousing are of great importance, because the success of a warehouse primarily depends on the management and the policies applied. Process flow is the most important decision at the design stage. Handling the items in batches, use both replenishment and reserve areas or only forward areas, using a single dock or separate docks for receiving and shipping, are some of the decisions concerning process flow. Assignment policy concerns with assigning the trucks to the doors at receiving and shipping. The allocation of items to storage areas are made according to storage policies determined earlier. Five often used storage assignment policies are as follows [6], [7]. 1. Dedicated storage assignment 2. Random storage assignment 3. Closest open location storage assignment 4. Full turnover based storage assignment 5. Class based storage assignment (ABC zoning) 6. Hybrid storage In dedicated storage each product type is assigned to a particular place, where only that product type can be stored. Random storage policy is flexible for storage, where the products can be stored to any empty place available. The items are stored to the first empty location in the closest open location storage policy, which can be used in combination with other storage types. Demand frequency of items leads the policy of full turnover based storage. Here the most frequently used items are stored close to I/O points, whereas the less frequently demanded items are stored further back. Class based storage divides the warehouse into zones where the fastest moving items are classified as A items, the next fastest items as B and so on. In hybrid storage we can combine these storage

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policies. For example, after the classification A, B, and C, these items can be placed according to the full turnover based storage policy. That is the A items close to I/O points, B items back and C further back.

FIGURE 2.3. Illustration of two common ways of class based storage [1]

Orderpicking process has various policies. Zoning policy divides the total area into smaller areas and assigns each area one or more different order pickers. If orders are picked one by one this is called single order picking or discrete picking. In batch picking however, orders are picked in batches. Batch picking also needs to be sorted. This can be done later (pick and sort) or simultaneously while picking (sort while pick).

Dwell point policy assigns the idle orderpick equipment where and how to wait.

The allocation of orders and trucks is determined by the dock assignment policy.

Operator and equipment assignment policies concern with the distribution of tasks to personnel and equipment.

After this information about warehouses, lets go into detail of storage and orderpicking operations.

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CHAPTER 3

STORAGE OPERATIONS

There are two functions of storage and warehousing [8]. 1. Maximize resource utilization while satisfying customer requirements. 2. Maximize customer satisfaction while staying in the limits of resource constraints, which are space, equipment, and personnel.

3.1

STORAGE SPACE PLANNING There are different kinds of material storage policies. 1. Fixed (assigned) storage: each SKU has a specific location, and only that SKU can go there. 2. Random (floating) storage: SKUs dont have special locations, so any SKU can go to any available location. 3. Closest open location storage assignment: Items go to the open location found first. 4. Full turnover based storage assignment: Items are stored according to the demand frequency. 5. Class based storage assignment (ABC zoning): The storage area is divided into zones of usage rate. 6. Hybrid storage: makes use of both fixed and random storage policies.

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As you can guess fixed storage needs more space than random storage, because in fixed storage even if the item is out of hand, the space will be still allocated to that item. Hence it will remain empty. However, for random storage the first item to come goes to first available section. Thus, needs less space. For fixed storage or random storage there are some policies to optimize. SKUs should be assigned according to their ratio of their activity [8]. Fast movers should be stored up front and slow movers in the back, so the throughput will be maximized. When basing activity we should take into consideration: The fraction of storages/ retrievals per unit time. (not the quantity moved) Taking into account part families. Items that are ordered together should go together. After deciding on these one or more of the storage assignment policies can be applied which are mentioned in the previous section.

3.2

STORAGE LAYOUT PLANNING Meeting the above spoken objectives and policies needs to have a good storage

layout. Storage layout has similar objectives as the warehouse objectives, which is natural. They serve the same objective. Here are some of the objectives: Use space efficiently Increase the material handling efficiency Flexible enough for changing conditions like demand, handling equipment, storage requirements Efficient housekeeping

Meeting the storage and warehouse layout objectives need to have some underlying policies which can be classified as [8]: Popularity

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Similarity Size Characteristics Space utilization

Popularity: materials are stored according to the Paretos law, which states that 85% of the wealth is held by only 15% of the population. This rule can be applied anywhere. In a warehouse 15% of materials are the most used ones with 85% turnover. Thus, these materials should be stored as close as possible to the shipment area. Materials should be stored in a way that the travel time is inversely related to the popularity of the item. Similarity: items which are received, shipped, or used together should be stored in the same location. For example who buys a swimming goggle most likely would like to buy a snorkel too. So these items should be stored together in a sports shop. Size: heavy, bulky, hard to handle goods should be stored close to their point of use. These items are hard to handle and are costly than other items. Thus, for example if theyre ordered commonly, they should be stored close to the shipping area. Characteristics: some items need some special treatment. For example, perishable materials need a controlled environment. This could be cold storage spaces for fruits. The storage of hazardous materials, should meet the standards of safety codes. For example storing flammable and explosive items need great care because of high danger. Space utilization: space limitations like truss, posts, columns, ceiling height etc. should be taken into account for space utilization. Accessibility, enough space for receiving and shipment, enough aisles and aisle space should be provided.

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CHAPTER 4

ORDERPICKING OPERATIONS

Order picking is the process by which products are retrieved from specified storage locations on the basis of customer orders. Orderpicking makes up generally the highest cost involved in warehouse activities. It is either very labor intensive or capital intensive [9]. It is estimated to be as much as 55% of total warehouse costs [1]. Thus, it is important for a company to take care of orderpicking in terms of cost. Another importance of orderpicking is that it affects other processes. So the design of orderpicking needs to be robust and as optimal as possible. Some of the processes within the scope of orderpicking could be as follows [1]: Clustering customer orders Scheduling customer orders Assignment of stock on locations to order lines Releasing orders to the floor Picking the items from storage locations Disposal of picked items

There are two kinds of order picking systems: Human oriented or automated. Generally, the human power is used for orderpicking. If the order picker walks or drives towards the items to be picked up, this is called picker- to- order systems, which is the case for human used systems. In low- level order picking, the order picker simply gathers the items while passing by the aisles. In high- level order picking however, order picker travels aboard a lift, and a crane is used to pick up the items from the high storage racks.

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Worldwide low level, picker- to- parts order picking systems where humans are employed form the very large majority. 80% of all order picking systems in Western Europe is low level, picker- to- parts systems [1]. Parts- to- picker systems involve automated systems called automated storage and retrieval systems (AS/RS). Here, the S/R crane moves to the item to be picked, picks it, and brings it to the destiny. If a load is retrieved only, or if a load is stored only one at a time, this is called single command cycle. In dual command cycle, a load is stored by the picker and then another load is retrieved in a single cycle. If the S/R machine has more than one shuttle, it can load and unload multiple loads at a cycle. This sort of S/R working system is called multiple command cycle. Another way of order picking is put systems or order distribution systems. There are two phases in this system. First, making use of parts-to-picker or picker-to-parts system, items are retrieved. Then these prepicked items are put in customer cartons or pallets by the order picker, and distributed to the customer. This system is very useful when large number of customer order lines have to be fulfilled in a short time. For example, in the flower auctions in Amsterdam, the flowers are sold at early morning, immediately loaded in the trucks and distributed all over Europe. It has to reach the market by that day. The figure below shows the different kinds of order picking methods in a chart.

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FIGURE 4.4. Classification of order picking systems [1].

4.1

ORDERPICKING OBJECTIVES Some objectives trying to be reached in warehouse design and optimization are to

[1]: Maximize the use of space Maximize the use of equipment Maximize the use of labor Minimize throughput time of an order Minimize total costs Maximize service level

In todays increasing competitive world, in order to remain and develop in the business, firms have to increase their service level. The accuracy, integrity, and the punctuality of deliveries compose the service level. If an order can be retrieved in the shortest time possible, with the highest accuracy, then it will be available for delivery sooner, which means consumer satisfaction. Thus, the main and common objective of

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order picking systems is to maximize the service level subject to resource constraints which include labor, machine, and capital [10]. Case studies have shown that the highest contributor to order picking time is travel time which can be seen from the figure below. Travel is labeled as waste according to lean manufacturing and JIT philosophy. Minimizing travel time consequently leads to quicker order picking and eventually on time delivery. If automated systems like AS/RSs are used, travel time will be decreased on a further level. In the next chapter we will be analyzing the automated storage and retrieval systems.

FIGURE 4.5. Typical distribution of an order pickers time [8]

In order to be able to have a robust and optimized orderpicking process, decisions should be given at the design level [5]. If the design does not fit your orderpicking strategy then it will not be worth much. Besides the design of the layout and other processes also affect the performance of orderpicking. Some of these tactical and operational design criteria could be listed as follows: Layout design and dimensioning (tactical level) Storage assignment policies (tactical and operational level) Batching policies (tactical and operational level) Zoning policies (tactical and operational level) Order picker routing (operational level) Order accumulation and sorting (operational level) xxx

For example, certain orderpicking routings would work well with certain storage policies. This will also affect the batching and sorting policy. Shortly to say the system is interdependent to each other.

4.2

LAYOUT DESIGN FOR ORDERPICKING As I told above layout determines the performance of orderpicking together with

other policies. In general we can name two kinds of layout design. 1. General facility layout design: activity relationships between departments are taken and the locations of these departments are decided. The objective is to minimize the handling costs. 2. Internal layout design or aisle configuration: number, length, width of aisles in each block, and the number of blocks are tried be determined. The objective function is to minimize the travel, consequently leading to minimization of cost and time spent for orderpicking. The illustration below shows the aisle configuration problem.

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FIGURE 4.6. Decisions to be given in the aisle design

4.2.1 Orderpicking Routes The routing policies determine the order picker how to travel for picking the products ordered. As stated earlier, the 55% of time spent during orderpicking is due to travelling. So if we can cut the travel distance we will also cut the time spent. Thus, the objective is to minimize the distance traveled. It can be said that the routing problem is a special case of travelling salesman problem [11]. In the travelling salesman problem, the salesman has to visit a certain number of cities. Starting from the home city he has to visit all these cities. He knows the cities and the distances. So the aim is to visit all, while minimizing the distance traveled. In a warehouse the case is the same. The order picker has to pick up all the orders and bring them to the depot. He knows where the items are stored and the distances. By setting a route for the order picker, the routing problem tries to minimize the distance traveled. To illustrate this, a figure is given below.

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FIGURE 4.7. Illustration of an order picking situation (left) and its graph representation (right)

In the figure seen above, the black areas are the locations of the ordered items. If this illustration is graphed we get the figure on the right. The black nodes are the locations of the ordered items. There are some differences though between the routing problem and the salesman problem. These nodes can be visited more than once, and the white nodes do not need to be visited. Whereas in the salesman problem, the cities should all be visited but only once. 4.2.1.1 Routing Heuristics

The routing problem in a warehouse is generally solved by heuristics due to the disadvantages of optimal routing policy [1]. The reasons for this could be as follows: Optimal algorithm is not available for every layout. Optimal routes may not be logical sometimes. Standard optimal algorithm cannot take aisle congestion into account.

Hall (1993), Petersen (1997) and Roodbergen (2001) have presented several routing heuristics which are stated below. The black boxes show the location of the ordered items [12], [13], [14]. S shape method: all aisles containing at least one pick are crossed entirely. Aisles without any picks are not entered. Return method: the picker goes until the furthest storage location and returns from this location in the aisle. Aisles only with orders are entered.

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Midpoint method: the storage area is divided into two areas. The front area picks are picked separately from the back area picks. The order picker passes to the back area either from the first aisle or the last.

Largest gap method: the order picker enters the aisle as far as the largest gap. The gap represents the separation between any two adjacent picks, between the first pick and the front aisle, or between the last pick and the back aisle. If the largest gap is between two adjacent picks, the order picker does a return route from both ends of the aisle. Otherwise, a return route from either the front or back aisle is used. From this we get that the largest gap is the portion of the aisle that the order picker does not traverse.

Combined or Composite method: aisles with picks are crossed entirely, or they are entered and left at the same end of the aisle. To decide what to do dynamic programming is used.

Optimal method: This is done by the computer using several algorithms. As the name suggests it results in the lowest distance available, however may not be applicable always.

These methods are illustrated in the figure below. To understand the methods better this figure should be analyzed carefully. When these methods are compared, it is found that the best heuristic applicable to that situation is on average 5% higher than the optimal solution [13]. These methods were originally developed for single block warehouses. However, with the necessary modifications done they can also be applied to multiple block warehouses [14], [1].

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FIGURE 4.8. Different routing methods in a single block warehouse [1]

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CHAPTER 5

AUTOMATED STORAGE AND RETRIEVAL SYSTEMS

Automated storage and retrieval systems consist of racks and cranes which run through aisles in order to put raw materials, semi finished goods, or finished products to the racks or to retrieve those items from the racks. The definition made by Automated Storage and Retrieval Systems Production Section of the Material Handling Industry of America is that, an AS/RS is a storage system that uses fixed path storage and retrieval machines running on one or more rails between fixed arrays of storage racks (2005). In a 10 year period of 1994 to 2004, AS/RSs used in the distribution sector of USA have increased significantly [22]. Automated Storage and Retrieval Systems (AS/RS) are typically used in applications where there is a very high volume of loads being moved into and out of storage where storage density is important because of space constraints, and where no value adding content is present in this process. They are used widely in both Manufacturing and Distribution operations to hold and buffer the flow of material moving through the process to the ultimate end user. Most systems operate in a fully automated mode with little or no human involvement in the handling of material except at the controlled input and output stations to the system. This results in extremely high inventory accuracy. AS/RSs as every system have both its pros and cons. The pros can be stated as follows: By bringing material to the operator it eliminates wait, walk, and search time. o Decreases cycle time and lead time.

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o Decreases labor costs. Reduces work-in-progress inventory. Better inventory accuracy and better responsiveness o Reduction or elimination of safety stock in the overall inventory model. This has the net effect of inventory reduction. o Reduces the need for floor space Dramatically increases operator productivity. For example The Part to Picker model of order fulfillment is 3 to 5 times more productive than having the picker travel to the part to complete the fulfillment (AS/RSBastian Solutions). Provides real-time inventory control with instant reports. With near 100% accuracy and real time information about the inventory on hand, achievable commitments can be made to your customer. Improves product quality and productivity. Real time information, faster response to a need, physical protection, and traceability of material access all contribute to a better process where time can be spent on improving the quality of the process instead of on expediting material to a point of use. Increased energy efficiency. Increased safety.

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FIGURE 5.9. AS/RS at Green Mountain Distribution Center Waterbury, Vermont, USA [22]

The most apparent disadvantage is of course its high investment costs (For a single aisle AS/RS approx. $634,000) [15].

5.1

THE MAIN COMPONENTS OF AN AS/RS Racks, cranes, aisles, I/O points, and pick positions make up the main components

of an AS/RS system. Racks: metal structures where loads, pallets can be stored. The consolidation of shelves make up the rack structure. Cranes: the machines which move autonomously, used for storing and retrieving. Sometimes referred to as the S/R crane, and sometimes as S/R machine. An S/R crane can be seen in the figure below.

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FIGURE 5.10. AS/RS crane [23]

o There are different crane types and sizes for different purposes. If the AS/RS is too high, then low level cranes wont be enough. Also the load size and weight is another important concept. So proper cranes should be used which are strong and big enough within the limits of cost constraint. Different types of cranes are shown in the figure below.

FIGURE 5.11. AS/RS crane family [24]

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Aisles: the space between racks, used by the AS/RS to move. Input/ Output (I/O) point: The places where incoming goods are picked up for storage, and ordered goods are dropped off. There could be a single I/O point or more. Also called pick and deposit station.

Pick positions: the place where the personnel perform their duties regarding the loads to be stored or retrieved.

The figure below shows a one aisle part of the AS/RS. The S/R crane is positioned in the middle of the racks on the aisle. The items are stored in and retrieved from the shelves in the racks.

FIGURE 5.12. Unit load automated storage retrieval system [16]

5.2

TYPES OF AUTOMATED STORAGE AND RETRIEVAL SYSTEMS There are many options for AS/RSs. The concepts that constitute the AS/RS are

crane, handling, and rack systems. The figure below depicts these concepts in neat manner.

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FIGURE 5.13. Classification of various AS/RS system options [3]

Talking about the crane type the most common one is a single unit-load aislecaptive which consists of one crane in each aisle, transporting only one unit load at a time (single unit), moving only in its designated aisle (aisle captive) [3]. Because of the high investment costs, it is not always reasonable to invest in cranes for each aisle. If the orders are not so high, the cranes are able to change their aisles (aisle changing) and/ or they can handle two or more loads at a time (dual shuttle). This is called dual unit-load aislechanging crane system. With this system the AS/RS crane is able to retrieve and store a load in the same cycle, without the need to go back to the I/O point. Concerning the handling type we have person on board, end of aisle, and unit load systems. The unit loads are typically pallets, cartons, bins etc. Automated guided vehicles, conveyors, forklift trucks, or just human power is used to bring the unit loads to the I/O point. However, what do we do if only a proportion of the pallet is ordered? Person on board cranes can be used to pick up what and how much needed exactly. Another option could be that AS/RS brings the ordered pallets, and the picking is done at a workstation. After the amount of order has been picked out from the pallet, the AS/RS will bring back the remainder. This system is called end of aisle system. Unit loads bins can be used as unit loads sometimes, which in this case it is called a mini load AS/RS. The figures below simulate the unit load and mini load concept respectively.

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FIGURE 5.14. AS/RS unit load storage buffer for supply chain delivery [25]

FIGURE 5.15. AS/RS mini load storage buffer for order picking and fulfillment [25]

Rack structure is another concept in automated storage and retrieval systems. Stationary and movable racks are the kinds of racks used in storage. Single deep racks are the most commonly used storage locations. The AS/RS retrieves or stores unit loads from the shelves. In double deep stationary racks one load is stored in front the other. According to Tompkins et al. (2003) double deep storage system may be useful when the

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variety is low while the turnover rate is high [8]. Rotating carousels are interesting. The racks rotate here from left to right (horizontal), or from up to down (vertical). When the right rack arrives, the AS/RS crane picks the load out of the rack, or puts in a load. Mobile racks move on rails. Again, when the right racks comes, the AS/RS crane picks out, or puts in the unit load.

5.3

ENGINEERING ANALYSIS OF AUTOMATED STORAGE SYSTEMS

5.3.1 Sizing the AS/RS Structure The total storage capacity of one storage aisle depends on how many storage compartments are arranged horizontally and vertically in the aisle. Hence, Capacity per aisle= 2nynz Where; ny= number of load compartments along the length of the aisle and nz=number of load compartments that make up the height of the aisle. The constant 2 stands for the loads on the both sides of the aisle. Lets assume standard size loads, and let x= the depth, y= width, and z= the height of the unit load. According to these unit load dimensions the rack structure of the AS/RS is as follows: W= 3(x +a) L= ny(y+b) H= nz(z+c) (5.3.1.2) (5.3.1.3) (5.3.1.4) (5.3.1.1)

Where W, L, and H are the width, length, and height of one aisle of the AS/RS rack structure; x, y, and z are the dimensions of the unit load; and a, b, and c are the allowances to provide clearance for the unit loads.

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5.3.2 Travel Time Models The estimation of the transaction time is important in AS/RS systems. There are a number of travel time models. The hourly rate of S/R transactions (storing or retrieving loads) that an AS/RS can perform is called the system throughput. If only one of these transactions is done, then it is called single cycle command. A dual command cycle involves both storing and retrieving in one cycle, hence the total time is less than single command cycle. I have to remind that a cycle consists of one storage operation, and one retrieval operation. There are several methods for calculating the cycle time. Some will be considered here: 5.3.2.1 FEM Standard

Sometimes it is enough to use some rules of thumbs in industry. FEM is one of these standards used by Ashayeri and Gelders [17]. FEM states that the storage position is on average at 1/5 of the aisle length and at 2/3 of the aisle height while the retrieval position is at 2/3 of the aisle length and 1/5 of the aisle height. This can be seen from figure the figure below. The travel time is the largest time spent in vertical and horizontal distance. Tcd= Max {0.20L/vy, 0.66H/vz} + Max {0.46L/vy, 0.46H/vz} + Max {0.66L/vy, 0.20H/vz} + 4Tpd= Max {1.32L/vy, 1.32H/vz} + 4Tpd (5.3.2.1.1)

Where Tcd= cycle time of a dual command cycle (min/cycle), L= length of the AS/RS rack structure (m, ft), vy= velocity of the S/R machine along the length of the AS/RS (m/min, ft/min), H= height of the rack structure (m,ft), vz= velocity of the S/R machine in the vertical direction of the AS/RS (m/min, ft/min), and T pd= pick up and deposit time (min). 4 P&D times are needed per cycle, two for storing and two for retrieving.

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FIGURE 5.16. FEM Standards: Dual Command Travel Time Calculation

5.3.2.2

MHI Standard

The material handling institute has also presented a method for travel time estimation. The following assumptions should be met in this method: Randomized storage of loads in the AS/RS. Storage compartments are equal in size. Pick and deposit station is located at the base and end of the aisle. Vertical and horizontal speeds are constant for the S/R machine or crane. The vertical and horizontal travel is done simultaneously.

In single command cycle, the load to be stored or retrieved is assumed to be at the center of the rack structure. Hence, the crane will travel half the length and half the width of the AS/RS as can be seen from the figure below.

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FIGURE 5.17. MHI Standards: Single Command Travel Time Calculation

Tcs= 2 Max {0.5L/vy, 0.5H/vz} + 2Tpd= Max {L/vy, H/vz} + 2Tpd

(5.3.2.2.1)

Where Tcs= cycle time of a single command cycle (min/cycle), L= length of the AS/RS rack structure (m, ft), vy= velocity of the S/R machine along the length of the AS/RS (m/min, ft/min), H= height of the rack structure (m,ft), vz= velocity of the S/R machine in the vertical direction of the AS/RS (m/min, ft/min), and T pd= pick up and deposit time (min). 2 P&D times are needed per cycle, one for storing and one for retrieving. For a dual command cycle, the S/R machine is assumed to travel to the center of the rack structure to deposit a load, then it travels to the length and height of the AS/RS to retrieve a load. Hence, total distance traveled by the S/R machine is the length and the height of the rack structure as can be seen in the figure below. So the cycle time is given by: Tcd=2Max{0.75L/vy, 0.75H/vz}+ 4Tpd=Max {1.5L/vy, 1.5H/vz} + 4Tpd (5.3.2.2.2) Where Tcd= dual command cycle time (min/cycle), and the other terms are defined above.

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FIGURE 5.18. MHI Standards: Dual Command Travel Time Calculation

5.3.2.3

Square-in-time Model

If the time to travel to the highest rack and to the deepest rack in the aisle is the same, this is called square in time rack design. This was studied by Hausman et al. (1976) [6]. They have developed discrete and continuous models and compared them. This study was further developed by Graves et al. (1977) by models of S/R machine travel time that operate under single or dual command interleaving policies and randomized, dedicated or class-based storage policies assuming square in time racks [7]. However Bozer and White (1984) state that the optimum solutions for AS/RS time is not square in time. They develop a model where the S/R machine travels horizontally and vertically at the same. They also develop discrete and continuous statistical travel time models for randomized storage polices with different I/O and dwell point locations with assumption of uniformly distributed storage locations [18]. 5.3.2.4 Statistical Continuous Travel Time Model

A model which is appropriate for randomized storage policies. The depot location is situated at the lower left corner. The configuration can be seen on the figure below.

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FIGURE 5.19. AS/RS with bays, aisles, and rows [16]

Vx= S/R velocity on the horizontal distance Vy= S/R velocity on the vertical distance xpal= Horizontal length of the pallet ypal= Vertical length of the pallet S= Volume (total capacity) lR= Deposit rate lS= Storage rate B= Number of bays R= Number of rows A= Number of corridors L= Length of the rack H= Height of the rack T= Farthest travel time b= Shape Factor

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m= Output E(SC)= Expected single-command round-trip travel time E(DC)= Expected dual-command round-trip travel time E(TB)= Expected travel time from one point to another point in the racks.

S, A, xpal, ypal, Vx ,Vy are given beforehand. S=2BRA (5.3.2.4.1)

S and A are given. B and R are chosen an appropriate number according to BR=S/2A and B>R. L=B xpal H=R ypal T= max (L/Vx, H/Vy) B= (1/T) min (L/Vx, H/Vy) E(SC)= ((1/3)(b^2) +1)T E(DC)=(4/3+(1/2)(b^2)-(1/30)(b^3))T a=min (lR+lS)/ max (lR+lS) E(TB)=(1-a)E(SC) + aE(DC) m=1/E(TB) (5.3.2.4.2) (5.3.2.4.3) (5.3.2.4.4) (5.3.2.4.5) (5.3.2.4.6) (5.3.2.4.7) (5.3.2.4.8) (5.3.2.4.9) (5.3.2.4.10)

E(TB) shows us the throughput time. By reversing the expected time (1/E(TB)), the pallet capacity of one AS/RS is found. If this value is multiplied by the number of aisles (aisle captive AS/RS), the total capacity of the AS/RS can be found.

5.4

DESIGN OF AS/RS The design of the AS/RS system is very important. The system itself has high

investment costs, so the management wouldnt like to just spend it out if they cannot realize a good rate of return. Besides in every system the cost increases as it goes through the phases of planning to implementation as depicted in the figure below. Thus, we should care from the beginning. The system should be designed in a way that it will be able to handle current and future demand without any bottlenecks or overcapacity.

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FIGURE 5.20. Cost of making design changes [8]

5.4.1 The Interdependence Between AS/RS And Other Systems The AS/RS is not a system working on its own, independent from other systems. It is constantly in relation with the other systems present in the environment. For example the personnel or the conveyor system should work properly and in accordance with the AS/RS system in order not halt the production in a manufacturing environment; delays, or stockpiles in a warehouse. Because if the AS/RS works properly and makes its own tasks, but the conveyor system is not, then the AS/RS will wait until the loads arrive at the I/O point. These delays will cause future orders to be fulfilled later. Delays in one system may cause delays in other systems, in other words a chain reaction takes place [3]. The figure below shows the design of an AS/RS system with dependencies between other systems. The physical design and control and design of other material handling systems cannot be separated from each other. Now Ill discuss these issues.

FIGURE 5.21. Design of an AS/RS system [3]

5.4.2 The Physical Design of an AS/RS There are two main points in physical design [3]. System choice: The AS/RS type is chosen. System configuration: According to the ASRS type; number of aisles, rack dimensions etc. are determined. Some of the criteria behind the configuration decisions for physical design are presented below [19]: Historical data Forecasted data Product characteristics Available budget Required throughput

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Storage space needed Space available

It is a hard process to decide on the right configuration of the system. For example deciding on the number of aisles, rack height and length depends on the total space available and capacity. We cannot change the given and needed capacity. The mathematical product of the rack height, length, and number of aisles is constant. N=nyz Where, n: number of aisles y: rack length (number of tiers) z: rack height N: the number of total space available. This can be in meter square, or in unit measures such as pallet size. This equation proves that if we increase one property we have to decrease one or two of the others. Thus, having more aisles result in reducing rack length and/or rack depth which leads to less response time. If we have decided on aisle captive AS/RS we will have to have a crane for each aisle, which will increase the throughput, but will also increase the costs. Rack designs are generally of equal size, which is not suitable every time. Each product is not the same in size, so for better customer service the racks may be designed to be able to store different size items. Table 1 shows the system configurations and other problems in a table. The travel time of the AS/RS is another point to notice. Cranes can travel simultaneously, which means that while going horizontally they are also able to travel vertically. The actual travel time is thus the highest of these times (Chebyshev distance metric). If the time needed to reach to highest rack is equal to the time to reach the furthest rack, this is called square in time rack, otherwise rectangular in time rack. (5.1)

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Horizontal speeds (3 m2) are more than the vertical speeds (0.75 m2), so good design of optimal or near optimal rack length and height will reduce travel times [8]. This concept will be discussed under the engineering analysis part of the thesis. The table below provides an overview of design decisions for an AS/RS.
TABLE 5.2. Overview of design decisions for AS/RS [3]

5.4.3 The Control of an AS/RS Control policies form the underlying policies and methods of how the AS/RS operates. Storage assignment policy: determines which items to go to which locations. Dwell point policy: the position where the idle crane will wait. Sequencing policy: assigning the crane for storing or retrieving such that total time is minimized with some delays in some orders, or the total tardiness is minimized (due dates are met) with an increase in total time.

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Batching policy: combination policies for different customers, or for different orders of one customer in order to maximize utilization and/or minimize response time.

The software used for controlling form another important part of AS/RS control [20]. The trade off is to use an efficient program which fits with the warehouse and with the lowest cost possible.

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CHAPTER 6

IMPLEMENTATION OF THE AUTOMATION SYSTEM

In the beginning of spring 2008, Fatih University together with some other research facilities regarding automation, mechanics, robotics, and electronics invited me and a group of students to participate in the initiation of the automation lab. Located in the engineering faculty of the university, the CIM (Computer Integrated Manufacturing) lab already possessed the milling and turning machines which were brand new and operational. The pictures of the present situation can be seen in the figures below.

FIGURE 6.22. Turn and Milling Machines in the CIM lab

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FIGURE 6.23. Front view of the lab. The new structures will be installed to the behind of these machines

FIGURE 6.24. The robot arm that will pick the parts and take them to the machines. In the middle the buffer zone is shown.

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However, there was something missing in the CIM lab: something that would widen the horizons of the industrial engineering students as well as electrical engineering students, something that would serve both the university and the industry. This was automation, and the university executive board decided to implement an automation project which would benefit the academia as well as the industry. So starting at the beginning of the semester we tried our best to accomplish this goal. First of all we formed our group. Two students from industrial engineering MS, and two students from industrial engineering BS including me were chosen for the project. Then we divided the tasks to be done by each person. My part was to design the AS/RS in the automation lab. After that we came together every week having meetings about what we had done during last week and decided on what to do during next week. At the very beginning none of us knew virtually anything about the concepts of this project. But during the weeks to come the knowledge accumulated and the project came to life. We started with what the concepts were. I made a research about AS/RS. My friends did research about the SCADA systems, servo motors, relays, PLC, and conveyor systems. Then we shared our knowledge with each other. The preliminary designs of the lab were made which can be seen in the diagram below. In these designs we focused on what equipment to buy, and how to facilitate them. The diagram below shows us the top view of the future lab. Another key issue was the cost. We had to stay in the limits that were assigned for the lab. So we had to make good use of the money by buying the right things ate the right price.

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FIGURE 6.25. Top view of the projected CIM lab

When doing the research we also made use of the industry. We organized a field trip to Arelik A.. Grundig electronics manufacturing plant. There we analyzed the AS/RS. It was a huge system with 15 aisles wide, 20 storage shelves high and 50 bays deep making up a 30000 pallet storage capacity. The S/R cranes capacity was 2 pallets (twin shuttle AS/RS) next to each other. It did not move until two pallets arrived. After the arrival of two pallets it moved to its destination, stored the pallets, and waited there until retrieval orders arrived. So the system worked on a dual order basis. Not only the AS/RS but the whole system was totally automated. The pallets came to the AS/RS by conveyors which moved automatically when pallets arrived. When pallets arrived at the depot location the S/R knew it by the sensors. Then loading was made. After that the destination was determined automatically by the system, because it already knew the stored and empty locations. The system was working on a random storage policy in which the pallets were stored to the next available location closest to the depot. The pictures of AS/RS below are taken with the permission of Grundig Electronics at the manufacturing plant in Istanbul. lviii

FIGURE 6.26. Pallets are moving on the conveyors

FIGURE 6.27. The conveyors take the pallets to the available S/R crane

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FIGURE 6.28. The S/R cranes are waiting for orders

FIGURE 6.29. A pallet is being loaded to the S/R crane

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FIGURE 6.30. S/R crane is taking the pallets to the storage area

The field trip to Grundig electronics manufacturing plant helped us a lot in experiencing the system in a real manufacturing environment. We understood the concept of AS/RS, and the benefits of it. After doing this we got into the details of our project at the CIM lab. I got into the details of the AS/RS size, rack size, drawings of the AS/RS, technical and scientific knowledge of AS/RS, the design of AS/RS and how the system works.

6.1

AUTOMATED STORAGE AND RETRIEVAL SYSTEM IN THE LAB I tried to explain the AS/RS concept in chapter 5. Here Im going to tell about the

AS/RS and the parts of it we used in the lab. The AS/RS consists of: Parts to be machined Pallets Racks S/R crane

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6.1.1 Aluminum Bar The aluminum bars are the parts to be machined in either the turn machine or the milling machine. They are 4 cm in diameter, and 6 cm high. They will not be carried on an individual basis. The parts will be carried on small pallets.

FIGURE 6.31. Aluminum part

6.1.2 Pallet The pallet will be used for the storage of parts. The parts will be set as two layers: One on top the other. The pallets will be square shaped and there will be three parts next to each other. So the size will be: 15cm wide- 15cm deep- 2cm high from the ground and 14 cm in total.

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FIGURE 6.32. Pallet

6.1.3 Rack Structure The racks provide locations for the pallets to be stored. The racks will be 6 levels high, and five pallets will be put next to each other, with some distance left between each other. There will be two rack structures facing each other, with the S/R crane in between. The sizes of each rack structure will be: Height= 125cm, Width= 150cm, Depth= 30cm. The drawings of the rack structure can be seen in the diagrams below.

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FIGURE 6.33. Rack structure and its sizes

FIGURE 6.34. Rack structure together with S/R crane in between

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6.1.4 S/R Crane S/R crane or S/R machine is the machine that does storage and retrieval. It moves in three directions: Either up and down or back and forth. When it reaches the target location, it does the storage and retrieval by using the mini slide. There is a servo motor for each motion. The drawings can be seen in the below diagrams.

FIGURE 6.35. S/R crane and its sizes

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FIGURE 6.36. S/R crane

6.2

KEY ELEMENTS IN THE OPERATION OF THE AUTOMATION SYSTEM To understand how the system works, we have to know some key elements of

automation. These are from the up to down: Warehouse management system (WMS) SCADA systems Programmable Logic Controller (PLC) Relays Servo motors

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6.2.1 Warehouse Management System (WMS) WMS or warehouse management system is a system which is used to control all the transactions in a warehouse. The transactions can be classified as follows: Control the movement and storage of materials Shipping Receiving Picking

The primary purpose of a WMS is to control the movement and storage of materials within a warehouse. Warehouse management system makes use of auto ID data capture technology. These can be classified as follows: Barcode scanners Mobile computers Wireless LANs RFID

Warehouse management systems can be stand alone systems or modules of an ERP system or supply chain execution suite. In this system first of all data should be collected. After the data has been collected, the data is transferred to central database by either a batch synchronization or real time wireless transmission method. Now with the updated database, the place, type, and quantity of goods are known exactly. After this action is taken. This could be retrieval, storage etc. 6.2.2 SCADA Systems Supervisory control and data acquisition or SCADA is an industrial control system which functions across a wide area. SCADA systems include input-output signal hardware, controllers, human-machine interfacing (HMI), networks, communications,

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databases, and software. It is a centralized system which monitors and controls entire sites, or complexes of systems spread out over large areas (on the scale of kilometers or miles). For example you could use SCADA to control the room temperature, but you could also use to monitor the status of an entire nuclear power plant. Most site control is performed automatically by remote terminal units (RTUs) or by programmable logic controllers (PLCs). Data is taken at the RTU or PLC level. It includes meter readings and equipment status reports that are communicated to SCADA as required. Data is then compiled and formatted in such a way that a control room operator using the HMI can make supervisory decisions to adjust or override normal RTU (PLC) controls. Thus though the PLC controls the system, SCADA may allow operators to interfere. The feedback control loop passes through the RTU or PLC, while the SCADA system monitors the overall performance of the loop.

FIGURE 6.37. Interaction between the PLCs and the SCADA system [26]

In the figure above we see an example of how SCADA system works. The measured flow and level from PLC1 and PLC2 are sent to the SCADA, combined, processed and then the set points are sent back to the PLCs. Now the PLCs act according to the set points, and send the new information to the SCADA. This loop goes on like this. The importance of SCADA system is that it combines the information from the PLCs and other controllers and with the help of HMI presents this data to the operator. So

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the operator easily understands what is going on and makes some changes if needed any. The PLC alone does provide this opportunity. However, because it is separated all over the site it is very hard to gather data manually. So the SCADA system by gathering and combining data, it provides great easiness. Components of SCADA System: 1. Remote Terminal Units RTU RTU connects to the physical equipment. Now it is able to read and transfer data. Status data such as whether the switch or valve is open or closed, or measurement data such as pressure, flow, voltage or current is read. After that data is sent to the SCADA system. When signals are sent to the equipment RTU can control the equipment by opening or closing the switch or valve, or setting the flow quantity. 2. Master Station Master station is the computer, server, and software systems that communicate with the field equipment such as RTU, PLC etc. and then with the control room HMI. Smaller SCADA systems may have a single computer, while larger systems may be composed of several PCs and servers. 3. Communication Infrastructure SCADA systems use radio or modem and direct serial connections to meet communication requirements. Ethernet and IP are also used at large sites like power stations. As any communication system, SCADA has also some standard protocols. These are Modbus, RP-570, IEC 60870-5-101 or 104, IEC 61850, Profibus, and DNP3. These communication protocols are standardized and recognized by all major SCADA vendors. 6.2.3 PLC A programmable logic controller (PLC) or programmable controller is a digital computer used for automation of industrial processes, such as control of machinery on factory assembly lines. A PLC is a real time system. The inputs are processed in a certain time where time is limited to seconds and milliseconds, and outputs are sent to proper places such as the machine and the upper hierarchy systems such as SCADA. If not

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processed in time the outputs will be too late, sometimes resulting in some severe conditions like tunnel fires, power plant explosions etc. Features of PLC PLCs are different than other computers in ways of endurance and I/O points. They are well armored so that they can bear severe conditions of the working environment. This includes heat, cold, moisture, pressure, dust, electrical noise, magnetic waves, vibration etc. PLCs have extensive input output arrangements which connect to sensors and actuators. PLCs read switches, analog process variables such as temperature and pressure, positions of complex positioning systems. A PLC consists of a power supply, controller, and relays for input and output. These parts can be seen in the figure below.

FIGURE 6.38. Control panel with PLC (grey elements in the center). The unit consists of separate elements, from left to right; power supply, controller, relay units for in- and output

PLCs operate the actuators. The actuators can be electric motors, pneumatic or hydraulic cylinders, magnetic relays or solenoids, or analog outputs. The input/output arrangements for these actuators may be built into a simple PLC, or the PLC may have

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external I/O modules attached to a computer network that plugs into the PLC. The input/ output arrangements can be seen in the figure below.

FIGURE 6.39. PLC with many inputs and outputs [27]

PLCs have developed a lot since the first invention. They were invented to replace hundreds of relays, timers, drum sequencers etc. Now they include sequential relay control, motion control, process control, distributed control systems and networking. PLCs are well-adapted to a range of automation tasks. Generally these industrial processes have high cost of maintenance and development compared to the investment cost of the automation. PLC provides a good automation control both effective and low cost in that they are highly customizable. The communication is done via signals. Digital or discrete signals behave like binary switches. 1 or True for On, and 0 or False for Off. Examples of equipment creating digital signals are push buttons, limit switches, and photoelectric sensors. Discrete signals could be sent either using voltage or current. For instance, a voltage of 20V DC or higher could be used for ON, values below 2V DC could be used for OFF, and intermediate voltage undefined. 6.2.4 Relay A relay is an electrical switch that opens and closes under the control of another electrical circuit. The first relay was invented by Joseph Henry in 1835. Relay operates by an electro magnet, which opens or closes the switch according to the current passing through the wire.

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Operation of a relay The current flows through the wire which is wrapped like a coil. This flow of current creates a magnetic field. This magnetic field attracts an armature. The armature which is linked to a contact mechanically moves the contact. So this movement has two possible results. It can either make or break a connection with a fixed contact. When the current stops flowing or is turned off, the armature turns to its relaxed position by a force half as strong as the magnetic field force [21]. Relay Types In the application of automation relays play a vital role. There are many kinds of relays. I will just mention about the types of relays without going into detail while this issue is out of our scope. Latching relay Reed relay Mercury-wetted relay Polarized relay Machine tool relay Contactor relay Solid state contactor relay Buchholz relay Forced-guided contacts relay Solid-state relay Overload protection relay

6.2.5 Servo Motor A servomotor (servo) is a small electromechanical device. It is used to position the armature of a motor by the help of an electrical input. Servos have a wide range of lxxii

application areas from airplanes to ships, from radio controlled cars to puppets and robots. Servo motors are very useful in robotics due to their size and effectiveness. They are not only small but also very powerful compared to their size. Thus servos have become one of the most essential parts in robotics industry. Servo motors are electrical devices some of which are partially electronic. The electrical energy is transformed to mechanical energy. They operate on the basis of negative feed back. Negative feedback means that the computer reads the position of the motor and controls the power applied to the motor. Any difference between the real position and the wanted position which can be named as error and this error is used (feedback) and acted accordingly. If more power is required then more power is supplied, if less power is needed then the power is cut down. The science of control theory works on this kind of problems. Generally the servo motors are used for angular or rotary movement. However, linear motion servo motors are also used, which provide vertical or horizontal motion. The first application area of servo motors was in military. They were used for fire control, marine navigation and aircraft navigation. Today they are used nearly everywhere. The automatic machines such as washing machine, dish washer etc. work with servo motors. Autofocus cameras use servo motors to focus on the picture to be taken. Radio controlled devices such as toy cars; toy helicopters use servo motors to make the necessary movement. Satellite tracking antennas perform the needed motion by the help of servo motors.

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FIGURE 6.40. The grey/green cylinder is the brush-type DC motor. The black section at the bottom contains the planetary reduction gear, and the black object atop the motor is the optical encoder for position feedback. This is the steering actuator of a large robot vehicle [26].

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6.2.5.1

How Does A Servo Motor Work?

FIGURE 6.41. A servo motor disassembled [28]

The servo motor has some control circuits and a potentiometer (a variable resistor, aka pot). The potentiometer is connected to the output shaft. The picture above shows the pot on the right side of the circuit board. This pot allows the control circuitry to monitor the current angle of the servo motor. If the shaft is at the correct angle, then the motor shuts off. If the circuit finds that the angle is not correct (negative feedback), it will turn the motor the correct direction until the angle is correct. The output shaft of the servo is capable of travelling somewhere around 180 degrees. A normal servo is used to control an angular motion of between 0 and 180 degrees. A normal servo is mechanically not capable of turning any farther due to a mechanical stop built on to the main output gear. How is the angle to be turned, communicated to the servo motor? The servo motor is controlled by three wires: ground (usually black/orange), power (red) and control (brown/other color). The control wire (which can be seen in the above picture with the brown color) is used for this purpose. The duration of the electrical pulse determines how much to turn. Every 20 milliseconds a pulse is given to the motor. If this lasts for 1.5 ms the servo motor will turn 90 degrees. If more than 1.5 ms the servo motor will turn the shaft closer to 180 degrees. If less than 1.5 ms, the servo will turn the shaft closer to 0 degrees. Though we have to consider that these time settings may change from

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manufacturer to manufacturer. This concept is illustrated below. The duration of the pulse dictates the angle of the output shaft which is shown as circles.

FIGURE 6.42. Motion of the servo motor according to the duration of the current [28]

Below we see the general overview of how the system works.

FIGURE 6.43. General control diagram of the system

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6.3

HOW DOES THE SYSTEM WORK? In our system we use the concepts, parts, and systems mentioned above. The parts

to be machined are taken from racks by the S/R machine. The motion in vertical and horizontal direction is done by the servo motors. This motion is controlled by relays which act as a switch. Of course the relays have to take order when to pass the current, and when to stop from something else. The PLC does this. The information from multiple PLCs are combined and processed accordingly by the SCADA system. The parts which are on the pallets are then put on the conveyor. The conveyor brings the pallet to the machine center. A robot takes the pallet from the conveyor and leaves it at the buffer storage between the turning machine and milling machine. When the machines are finished with their jobs and are ready for the next parts to be machined, another robot arm situated on the front of the machines takes the parts from the pallets and brings them to the machines one by one. The robot arm properly sets the part in the machine. Now the machine is ready for machining. Because they are CNC turning and CNC milling the steps of the process is already defined and stored in the machines. They will start and process according to this program. Finally when finished, a signal will be sent to the SCADA system. The SCADA will inform the robot arm, and the robot arm will come and take the part out of the machine. Then, it will bring the finished part to the buffer storage area and put it on the pallet. When the pallet is full with 18 parts, the robot arm will take pallet and put it on the conveyor. The conveyor will bring the pallet to the AS/RS system. A signal will be sent to the SCADA, the SCADA will inform the S/R machine PLCs to move to the proper point. The PLCs will let enough current to flow to the relays which will start the servo motors to move the S/R machine. After the S/R machine has reached the pallet on the conveyor, it will take the pallet and again by the control of PLCs it will reach an empty place in the racks. By the movement of the mini slide it will put the pallet in the rack. The S/R machine may be left in that position, or if a dwell point is defined it will move to this dwell point. If of course another storage or retrieval order has arrived, it will perform the necessary job. Now the process is finished.

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CHAPTER 7

CONCLUSIONS

The concept of warehousing has been given at the very beginning of the thesis. After the definitions, processes regarding warehouses, major warehousing activities such as storage and orderpicking were analyzed. These were the basics in order to understand the automated storage and retrieval systems. After that AS/RS is analyzed thoroughly. Finally the underlying concepts and the planning and implementation phases of the automation project at the computer integrated manufacturing lab of Fatih University were given. The lab will be a great asset for both the students and professors. It will serve as an application area for the theories learned at the classes. This will make the classes more attractive and the students will also be able to take this knowledge to the industry while doing their interns, or while working full time after graduation. The experienced graduates will be of greater interest to the industry rather than a graduate who knows nothing about application. Another benefit for the industry will be the realization of automation and the benefits of it. Thus this lab will be a win- win situation. Some recommendations of mine are that the lab should go on being a priority for the university in the future as it is now. New facilities, machines should be added. New equipment should be installed if necessary. A class or classes concerning the programming of the AS/RS, PLC, and SCADA system should be added. Computer Numeric Control (CNC) programming is another important class to fulfill the gap of automatic manufacturing. Another great move could be opening a mechanical engineering department. This department together with electrical engineering could initiate new application areas such as mechatronics. Thus, there are many opportunities to improve this project. The project should not be like a started and

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finished project in a time frame. Rather it should be regarded as a long run, with lots of opportunities for continuous improvement.

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REFERENCES

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14. Roodbergen, K.J., Layout And Routing Methods For Warehouses, Ph.D. thesis, RSM Erasmus University, the Netherlands, 2001. 15. Zollinger, H., AS/RS application, Benefits And Justification In Comparison To Other Storage Methods: A White Paper, Automated Storage Retrieval Systems Production Section of the Material Handling Industry of America, 1999. 16. Eldemir F., Analytical Concepting Of Material Handling Systems, PhD Thesis, RPI, 2003. 17. Ashayeri, J., Gelders, L., Van Wassenhove, L., A Microcomputerbased Optimization Model For The Design Of Automated Warehouses, International Journal of Production Research 23 (4), pp. 825839, 1985. 18. Bozer, Y.A., White, J.A., Travel-Time Models For Automated Storage/Retrieval Systems, IIE Transactions 16 (4), pp. 329338, 1984. 19. Allen, S.L., A Selection Guide To AS/R Systems, Industrial Engineering, 24 (3), pp. 2831, 1992. 20. Fohn, S.M., Greef, A.R., Young, R.E., OGrady, P.J., A Constraint System Shell To Support Concurrent Engineering Approaches To Design Artificial Intelligence in Engineering 9 (1), pp. 117,1994. 21. Vladimir Gurevich Electrical Relays: Principles and Applications, CRC Press (Taylor & Francis group), London - New York, 2005. 22. Eldemir, F., Graves, R.J., Malmborg, C.J., New Cycle Time And Space Estimation Models For Automated Storage And Retrieval System Conceptualization, International Journal of Production Research 42 (22), pp. 47674783, 2004. 23. http://www.diamondphoenix.com/page.php?page=storage-retrieval-machines 24. http://www.diamondphoenix.com/images/storage-retrievalmachine/cranes2_lg.jpg 25. http://www.diamondphoenix.com/images/storage-retrieval-machine/family_lg.jpg 26. http://www.bastiansolutions.com/products/automated-storage-and-retrievalsystems/default.asp 27. http://en.wikipedia.org/wiki/SCADA 28. http://en.wikipedia.org/wiki/Programmable_logic_controller 29. http://www.seattlerobotics.org/guide/servos.html 30. http://www.mhia.org/psc/PSC_Products_StorageRetrieval.cfm

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