Professional Documents
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MANUFACTURING
1.0 HISTORICAL DEVELOPMENT OF AUTOMATED STORAGE AND
RETRIEVAL SYSTEM (ASRS)
Automated storage and retrieval systems (AS/RS) are inventory management systems
that are widely used in distribution centres and warehouses throughout the United States and
the world. AS/RS systems generally consist of machines that move up and down one or
multiple parallel storage aisles, storing and retrieving products and materials
for dissemination to internal and external destinations alike. The advantages of these systems
are numerous. 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;
storage density is important because of space constraints; no value adding content is present
in this process; accuracy is critical because of potential expensive damages to the load. They
provide users with increased inventory control and tracking, including greater flexibility to
accommodate changing business conditions. Indeed, these systems are comprised of modular
subsystems that can be easily replaced to minimize downtime and extend the service life of
the overall system. AS/RS systems also reduce labour costs, lowering
necessary workforce requirements, increasing workplace safety, and removing personnel
from difficult working conditions (such as cold food storage environments). Perhaps most
significantly, however, AS/RS systems can produce major savings in inventory storage costs,
as vastly improved warehouse space utilization—both vertically and horizontally—creates
greater storage density.
There are some various makers or vendors of ASRS in Malaysia. The following table
below shows the details of the companies that were provided ASRS:
ALPHA MASTER (M) SDN BHD Alpha Master (M) Sdn. Bhd. is a leading supplier in
Plot 108 & 109, Lorong Perusahaan Utama Malaysia automation industry, supplying automation
2, Prai Industrial Estate 4, system & Machines. It is also a well known
Bukit Tengah, 14000 Bukit Mertajam, Electrical Switch Board manufacturer in Malaysia
Penang, Malaysia. metal fabrication industry. Since it’s incorporated in
Tel: 604-507 7811 1991, Alpha Master utilizes its state of the art
Fax 604-507 2150, 508 2728 facility and dedicated staff to provide our customers
Website: http://www.alphamaster.com.my with the highest quality equipment and service
E-mail: alphamaster@myjaring.net possible.
Products & Services: ASRS, Sheet Metal Work,
Electrical Switch Board, Machining Works,
Machine Framework Structure, Conveyor System,
Trolleys, Racks Tables & Benches, Ovens, Jigs and
Fixtures, Pneumatic Actuator and AGV Transport.
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Jalan Lompat Tinggi 13/33 supplies, newspapers, magazines, general inventory,
Sekysen 13, sporting equipment, personal effects, clothes, to
40100,Shah Alam artefacts of historical significance, weapons, and
Selangor Darul Ehsan,Malaysia criminal evidence. You name it, and a Dexion
Tel: 60-60 3 5511 1688 product is storing it somewhere.
Website: http://www.compactus.com.my Products & Services: Pallet Handling Systems,
Rack Accessories, Integrated Systems, Specialists
Racks, Raised Storage Areas, Carton Live Storage,
Drawer Systems, Binning and Shelving, Static
Shelving, Storwall and Lockers
SEE HAU GLOBAL SDN BHD See Hau Global Sdn. Bhd. is a leading
80 JALAN PAHANG, manufacturer and marketer of high quality plastic
53000, WILAYAH PERSEKUTUAN, pallets. Established in 1994, they started with only
KUALA LUMPUR, Malaysia one melding machine. Today, their total annual
Tel: 60-3-40421355 production capacity comes close to one million
Fax: 60-3-40423407 pieces, making the company the largest
Website: http://www.intracopallet.com manufacturer in Malaysia and this region.
Products & Services: ASRS, Super Hygiene Pallets,
Medium Duty Pallets, Cargo Pallets, Top Frame,
and Plastic Bins.
SSI SCHAEFER SYSTEMS (M) SDN Since its inception in 1937, SSI SCHAEFER has
BHD been an owner-operated, German family company.
No. 2, Jalan TP5, With over 50 subsidiaries worldwide, SSI
Taman Perindustrian UEP Subang Jaya SCHAEFER is a strong and reliable partner.
47600 Subang Jaya, Whether in industry, trade, commerce or public
Selangor Darul Ehsan. organisations, our products are in use on all
Tel: 60-603 8024 6373 continents and fulfil your tasks efficiently and
Fax: 603-56211013 competently.
Website: http://www.ssi-schaefer.com/ Products & Services: ASRS, Modular Shelving,
Double Deep Pallet Racking, Automatic-order
picking systems, Storage and Transport Containers,
Semi-Open Front Storage, Shelf Containers, etc.
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Automated Storage & Retrieval System (AS/RS) is to ensure smooth flow of
materials and efficient use of labour in manufacturing and warehousing facilities.
AS/RS improves productivity of transporting, buffering and sequencing of standard and non-
standard loads. Also, its high-rise storage capabilities make optimal use of available floor
space. It is built around racks, pallets, containers, and machines and is specifically designed
to fit products and processes. This flexibility enables the system to meet your unique storage
control and handling needs.
As a top company in industry, they need an Automated Storage and Retrieval System
(AS/RS or ASRS) that helps to reduce inventory, shipping and labour costs. Require a
supplier who will truly partner and develop an automated warehousing solution.
Automated Storage & Retrieval Systems (ASRS) increase warehousing efficiency by:
System Types
a) AS/RS Inquiries
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Inquire about your automated storage and retrieval system
A mini-load automatic storage and retrieval system handles loads that are typically
contained in small containers, cartons, or totes with load weights typically falling in a range
of 100 to 500 pounds. The capacity range can go to 750 to 1000 pounds on the high end. A
mini-load system lets you store more material in less space, especially material in totes. It can
also handle these totes with much more velocity than conventional static, manual methods.
Despite that speed, Mini-load systems tend to run quieter than other methods. Mini-load
systems offer a variety of load handling methods, depending on the application. Some
possibilities include single or dual shuttle, frame, robotic arm, or extractor load transfer
methods. Speed options can vary from manufacturer to manufacturer, model to model, as can
dimensional variables. One key feature of mini-load AS/RS is that it maximizes the cube,
saving space while increasing throughput. Systems can range from 10' to 50' (or even higher
in some cases). Mini-load can offer a narrow footprint, as well, saving space horizontally.
Unit Load Automated Storage and Retrieval Systems: AS/RS for Palletized Loads
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Automated storage & retrieval for unit loads
Unit load is the material handling term for any configuration of materials that allow it
to be moved by material handling equipment as a single unit. Typically, this means pallet
loads, but can apply to containerized loads.
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STV's feature onboard microprocessor control with no complex programming
functions. Simply define the layout to the controller and it directs the STV where to
go and what to do.
• Flexible layout options
STV's give your flexibility using a straight or L-shaped layout, or as a single- or
multi-vehicle continuous loop. Standard modular components can be easily
configured to meet a variety of building layout, space, and performance requirements.
What's more, several independent STV systems can be controlled using the same
controller, even on separate floors.
• Ready for expansion
STV systems are designed to grow right along with you. As your operating volume
increases, simply add STV's to the system to increase capacity. You can also expand
your STV layout using the existing modular power supply and connecting new
components to the existing track and input/output stations as needed.
• Efficient sortation
STV's can sort loads to different delivery stations without the complex conveyor
intersections that can hamper throughput. And because STV's are bi-directional, they
can receive loads as well as deliver them.
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AGVs offer a variety of flexible
configurations for nearly any material
handling function
Ultimately, value is created when facility or warehouse processes are made more
efficient or eliminated altogether by the type of storage method employed. When comparing
automated pallet handling methods such as AS/RS (automated storage/retrieval systems) or
HDDS (high-density dynamic storage systems) to standard rack or drive-in rack methods, the
entire discussion is typically reduced to a capital basis. Little or no consideration is given to
the ongoing operating costs or potential capital avoidance.
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A reason people like to use 'cost per position' when discussing storage methods may
be that it is easier to talk about equipment as a simple unit of measure. However, using 'cost
per position' is not always a complete measurement. What needs to be considered is the entire
operation using a total system view, taking into account all the process elements incorporated
and their associated costs.
A significant area in a comparison between the automated pallet handling and manual
methods is the one-time facility costs of the land and building. It can be argued that the
capital avoidance in the building footprint and related costs such as land purchase can be as
much as 50%, depending on the automated pallet handling technology employed. In addition,
equipment such as fork trucks and dock doors can also be reduced by as much as 50%.
Operating costs have a similar relationship to value creation, and the potential to
increase the productivity of shipping and receiving activities via automation can be as high as
300%. The manual storage, replenishment and staging functions in many cases can be
completely eliminated. Other pertinent operating savings exist; reduced damage from
multiple handling, lower utilities including the high cost of refrigeration in freezers, and even
ancillary areas such as drop-lot costs can be reduced in the faster-turn automated
environment.
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Automated Storage and Retrieval Systems (ASRS) 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.
Benefits of ASRS:
• Reducing product loses from handling damage, locations errors, and theft.
• 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.
• Provides real-time inventory control with instant reports. With near 100% accuracy
and real time information about the inventory on hand, achievable commitment can be
made.
• Bringing material to the operator cutting cycle time by eliminating wait, walk, and
search time.
• Minimize downtime and extend the service life of the overall system.
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• Improving operator productivity
• Saving energy
• Removing personnel from difficult working conditions ( such as cold food storage
environments )
Limitations of ASRS:
B. APPLICATIONS
There are various ASRS concept that may be combined to achieve cost effective
solutions within the framework of the objective that have been established for the application.
ASRS concepts incorporate the following primary functions:
Storage
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Input/output
Function Order Picking
Function
i) Storage Function
Dell Inc.
Within 20 years, Dell became the computer industry leader; build desktop computer
models “OptiPlex” and “Dimension”, specifically to meet customer requirements ate the rate
of 15,000 to 20,000 computers each day. So that, the ASRS system are using to sorts
completed products to be transported from the build, test and boxing area to either direct-ship
or to staging in the ASRS Buffer, in the case of a multi-unit order. The Automated
Storage/Retrieval System buffers about 3000 system cases in 6 twin-shuttle S/R machines.
ARUP Laboratories
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sciences Centre. The rapid increase in demand for esoteric specimen testing has pushed
ARUP’s annual growth rate from 1994-2003 up to 18 percents. With growth expected to
reach 50,000 specimens by the year 2012, automation has played a key role in ARUP’s
ability to keep up with industry growth, which is expected to continue for the next decade or
two. After that, they are decided to use automated transport and sorting system transport and
sort 22-26,000 new specimens a day. An additional 80 percents of that volume is returned to
the track each day to route for additional test or for storage on the Motoman Storage
AutoSorters, bringing the total daily volume on the track system to 40-45,000. After
implement ASRS system the track has a capacity of 7,000 new tubes/hour or >10,000/day.
Besides, the Storage AutoSorters can each store > 1,100 tube per hours. Now, ASRS
retrieval time for any single tube is < 2.5 minutes. So that, ASRS system has achieved highly
significant improvements in TAT, quality, and efficiency from the application of automation.
Before implementing an ASRS, the following things that a company should be considered
are:
• Description of operations
• Architectural/Engineering consideration
And below is the explanation about all the following things that have been showed before;
Handling of the load outside and within the ASRS must be considered. Overall
dimensions and weight of each load configuration must be defined first. The essential
characteristics of the load are can be transferrable by the SR Machine, storable in the ASRS
racks, and transportable outside the ASRS System. Although SR Machines may handle more
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than one load configuration, commonality of load base configuration leads not only to
simplicity of equipment and controls, but also to efficiency of space utilization. Commonality
may be achieved through the use of slave pallets or containers to provide a uniform base
where uniformity might otherwise be unobtainable.
The number of loads to be stored, or the storage capacity, must include current
requirements and future growth. Cube utilization or packing densities for the proposed
system must be considered before implementing an ASRS.
Material flow description should include a definition of all sources and destinations of
materials, the average and peak rates of movement, and description of operator tasks and
times. Discontinuities, points of congestion and any queues must be considered in detail.
4. Description of operations
The next logical steps are to describe the operations needed to accomplish the desired
material flow. This also should include the essential elements of the record keeping system.
Operations involving human operations are often the most critical and very careful
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description of these tasks is a key element of successful system design. Besides, it is
important to define equipment control and data processing tasks at the earliest possible time.
The element that ties all system components together to perform as one entity is SYSTEM
CONTROL. System control not only refers to the control of equipment, but to the control of
materials and also its flow. The correlation of equipment control and also information control
is the key to material control. Material control means knowing exactly where material is
located, knowing status, and being able to get it where it is needed exactly when it is needed.
The achievement of improved material control is one of the most important objectives
served by ASRS. And to achieve effective system operation equipment reliability, operator
malfunctions and interruptions is related operations that must be considered. Back-up modes
of operations including detection and correction of multifunction are very important.
Automatic control should be designed for the highest level of reliability and should be backed
up by emergency levels of control including manual operation. The selection of back-up
modes of operations requires a very careful consideration of the real ability of a given option,
particularly its relationship with record keeping system. Besides, it is very important to
consider equipment reliability, to anticipate operator and equipment multifunction, their
detection and correction, and planned up modes of operation.
5. Architectural/Engineering consideration
The useful life of ASRS systems may substantially exceed the predictable range of
business forecasting. Therefore, decision for upgrading or expanding the system should be
included not only in physical layout, but also in the controls of information systems. An
important aspect of any expansion or upgrading plan should be consideration of the logistics
of integration of the expansion into existing operations with minimum disruption or loss of
production. Many existing ASRS systems have been upgraded without expansion of physical
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facilities to incorporate new control and record keeping technology after several years of
service. Changing technology, therefore, need to not be viewed as a factor leading to rapid
obsolescence of an ASRS system, but as a future benefit that may be incorporated at a
fraction of the cost of new equipment when the technology appears.
Rack Structures
Our group are agreeing to make estimation for rack consists of 15 bays and 15 tiers.
Cells are single deep and are designed for 40’ containers. Each cell has a width of 44’, a
height of 12’, and a depth of 11’. Each aisle is 10’ wide, and a P/D stand is located at the end
of aisle.
The total net area required for each module is less than 15000 square feet while it can
store 300 forty feet containers. Given such a system, the space utilization key variables are
measured as follows:
However, the actual cost data are not available. The rough-cut cost estimate is around
RM11 million for each module.
There have a lot of competing demands that using the limited capital investment
dollars in business environment. Analysis of economic justification is the key to management
acceptance for any project. ASRS consistently received their funding approval in a wide
range of business by showing favourable return on investment.
The details of the justifications process are peculiar to each corporation and may vary
among divisions. However, there have many common data which is should be considered for
each alternative approach. Capital benefits of ASRS arise from significant reductions in floor
area and often from construction economics found in rack supported structures.
The ability to plan for extended economic life of equipment beyond the six years
common to other material handling equipment must also be considered. Many ASRS have
been refitted with new controls and rebuilt machines after ten years of services at a fraction of
the cost of new equipment while yielding the benefits of new technology.
Other than that, the variable and continuing annual costs need to be measured for each
alternative are include but not limited to:
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4. taxes and depreciation
5. maintenance costs
This cost should include not only wages but also fringe benefits which may amount to 1/3 of
wages or more. The reduction of direct labour will influence the indirect labour for example
data processing, accounting and others. The automation of storage and retrieval operations
may permit a significant reduction in paper work.
The efficiency of building occupancy means conversation of energy as well as intensives use
of floor area available for adding value to product. Continuing benefits may be measured by
rents not paid for off-site facilities by increased value of sales per square foot of plant
occupied and by investment deferred because unproductive space is reclaimed for expansion
of productive effort.
Studies indicate that average carrying costs of inventory are about 30% of value on an annual
basis. Perhaps the most dramatic savings are to be realized from a simple reduction of
inventory value. Carrying cost may range as high as 43% of value per year. Excess
inventories include inventories on hand considerably in advance of need, investors segregated
for manufacture considerably in advance of need, inventories known to be received but not
locatable, inventories inaccessible because paperwork is not process, inventory in excess of
that needed for insurance against shrinkage and inventory of partially completed products due
to material shortages.
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Taxes and depreciation
The intimate relationship between rack structure and machines is likely to allow the whole
system to be depreciated as machinery rather than as a building. Even the wall panels and
roof of rack supported buildings may qualify for these tax incentives. Depreciation cash flow
multiplied by the basis income tax rate may be use to estimate savings.
Maintenance cost
The maintenance skills required by ASRS are common to those required for high technology
manufacturing equipment. The reliability of ASRS and related equipment, even severest duty
cycles is a proven positive factor. Careful assessment of relative maintenance costs of
competitive technical approaches to storage solutions is vital to justifications analysis.
There have some benefit for the company that using the ASRS. One of the benefit is
the company can reduce their work in progress inventory because as we known the better
inventory accuracy, the better responsiveness that we need in result reduction and elimination
of ‘safety stock’ in the overall inventory model. This has been effect of inventory reduction.
Other than that, the benefit that companies get is it can increase the productivity of
operator. The ‘part to picker’ model of order fulfilment is from 3 to 5 times be more
productive that having the picker travel to the part to complete the fulfilment.
ASRS also include the benefit of improving the product quality and the productivity.
The real time information and the faster response to be need, physical protection, and
traceability of material access all contribute to a better process where the time can be spent on
improving the quality of the process instead of an expediting material to a point of use.
Besides that, ASRS benefit also includes to provide a real time inventory control with
instant report. With near 100% accuracy and real time information are about the inventory on
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hand, achievable commitments can be made to customer as opposed to ‘best efforts
promises’.
REFERENCES
http://www.jervisbwebb.com/Categories/AutoStorRetr.aspx?cid=4
http://www.cisco-eagle.com/material-handling-systems/asrs-systems
http://www.answers.com/topic/automated-storage-and-retrieval-system#ixzz1JFbJShMO
http://www.wikipedia.com
http://www.aw-systems.com/automated-storage.htm
http://invsee.asu.edu/srinivas/spheresmod/determination.html
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MINUTES MEETING
1st Meeting
2nd Meeting
3rd Meeting
4th Meeting
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• Date/Day - 05/04/2011 (Tuesday)
• Matters Discuss - Try to help group members that is not understand about their
part.
5th Meeting
• Matters Discuss - Meet Advance Manufacturing lecturer, Mr. Farid, to ask him
- Siti Salwah asks about how to find the estimated cost for
ASRS.
6th Meeting
• Matters Discuss - Combine all the work from each group members.
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