AUTOMATIC STORAGE AND

RETRIEVAL SYSTEM
PRESENTED AS PART OF COMPUTER INTEGRATED MANUFACTURING
COURSE
FUNCTIONS OF STORAGE SYSTEMS AND
DEFINITION OF AS/RS
1. Definition- AS/RS by material handling Institute as
“ A combination of equipment and controls which handles, stores, and
retrieves materials with precision, accuracy and speed under a defined
degree of automation.”
2. AS/RS perform a basic set of operations without human
intervention:
1. Automatic removal of an item from a storage location
2. Transportation of this item to a specific processing or interface point
3. Automatic storage of an item in a predetermined location, having received
an item from a processing or interface point.
AS/RS COMPONENTS AND TERMINOLOGY
USED
• An automated storage and retrieval system comprises
the following:
• A series storage aisles having storage racks
• Storage and retrieval machines, normally one machine per
aisle, to store and retrieve materials
• One or more pickup and delivery stations where materials
are delivered for entry to the system and materials are
picked up from the system.
 AS/RS COMPONENTS AND TERMINOLOGY
USED
1. Storage space- 3-D space
in the storage racks that is
normally required to store
a single load unit of
material.
2. Bay- Vertical stack of
storage locations from
floor to the ceiling.
3. Row- A series of bays
placed side by side.
4. Aisle- The space between
two rows for the AS/RS
machine operations
5. Aisle unit- Aisle space and
racks adjacent to an aisle
constitute an aisle unit.
AS/RS COMPONENTS AND TERMINOLOGY
USED
6. Storage racks- A structure entity comprising storage locations,
bays, and rows.
7. Storage structure- A storage structure comprises storage racks
and is used to store inventory items.
8. Storage/retrieval machine- An S/R machine moves items in and
out of inventory.
9. Storage modules- Storage modules are used to hold the
inventory items. The modules may be pallets, bins, wire baskets,
pans, or other containers.
[Link] and deposit stations- To allow inventory into the system,
it is necessary to have pickup and deposit (P/D) stations. These
are generally placed at the end of the aisles so that they can be
WHY AN AS/RS ?
• Reasons for selecting AS/RS include:
1. An AS/RS is highly space efficient.
2. Increased storage capacity to meet long range plans.
3. Improved inventory management and control.
4. Quick response time to locate, store, and retrieve items.
5. Reduced shortage of inventory items due to real-time
information and control.
6. Reduced labor cost due to automation.
7. Improved stock rotation.
WHY AN AS/RS ?
8. Improved security and reduced pilferage because of closed
storage area.
9. Flexibility in design to accommodate a wide variety of loads.
10. Flexibility in interfacing with other systems such as AGVS,
FMS, and inspection systems such as coordinate measuring
machines.
[Link] scrap and rework due to automatic handling of
parts.
[Link] operating expenses for light, power and heat.
13. Helps in implementing JIT concepts by getting the right
parts, tools, pallets, and fixtures to the right place at the right
 TYPE OF AS/RS
• Several types of ASRS are
distinguished based on certain
features and applications. Some
of the important categories
include:
1. Unit Load ASRS
2. Miniload ASRS
3. Person-on-board ASRS
4. Deep-lane ASRS
5. Automated item retrieval
system
UNIT LOAD ASRS

• It is used to store and retrieve loads that are palletized or

stored in standard-sized containers.
• The system is computer controlled.
• The S/R machines are automated and designed to handle
the unit load containers.
• Usually, a mechanical clamp mechanism on the S/R
machine handles the load.
• However, there are other mechanisms such as a vacuum or
a magnet-based mechanism for handling sheet metal.
• The loads are generally over 200 Kgs per unit.
MINILOAD ASRS

• This system is designed to handle small loads such as

individual parts, tools, and supplies that are contained in
bins or drawers in the storage system.
• This system is applicable where the availability of space is
limited.
• Also useful where the volume is too low for a full-scale unit
load system and too high for a manual system.
• A mini load AS/RS is generally smaller than a unit load
AS/RS and is often enclosed for security of items stored.
PERSON-ON-BOARD ASRS

• This system allows storage of items in less than unit load quantities.
• Human operator rides on the carriage of the S/R machine to pick up
individual items from a bin or drawer.
• The system permits individual items to be picked directly at their
storage locations.
• This provides an opportunity to increase system throughput.
• The operator can select the items and place them in a module.
• It is then carried by the S/R machine to the end of the aisle or to a
conveyor to reach its destination.
DEEP-LANE ASRS

• This is a high-density unit load storage system that is appropriate for

storing large quantities of stock.
• The items are stored in multi deep storage with up to 10 items in a
single rack, one load behind the next.
• Each rack is designed for flow-through, with input and output on the
opposite side.
• Machine is used on the entry side of the rack for input load and loads
are retrieved from other side by an S/R- type machine.
• The S/R machines are similar to unit load S/R machine except that it
has specialized functions such as controlling rack-entry vehicles.
AUTOMATED ITEM RETRIEVAL SYSTEM

• This system is designed for retrieval of individual items or small

product cartoons.
• The items are stored in lanes rather than bins or drawers.
• When an item is retrieved from the front by use of a rear-
mounted pusher bar, it is delivered to the pickup station by
pushing it from its lane and dropping onto a conveyor.
• The supply of items in each lane is periodically replenished and
thus permitting first-in/first-out inventory rotation.
• After moving itself to the correct lane, the picking head activates
DESIGN OF AS/RS
• Bozer and White(1980) and the 4. Determining the system
Material Handling Institute provide throughput and number of
a list of user and supplier related S/R machines
issues that must be considered 5. Determining the size
while designing an automated parameters of storage and
storage and retrieval system. Here retrieval system
we will discuss following important
• Determining the number of
issues related to the layout and rows and number of bays in
design of AS/RS: each row
1. Determining load sizes • Determining bay width , rack
length, system length, bay
2. Determining the dimension of an depth, aisle unit, and system
individual storage space width
3. Determining the storage space 6. Determining single and
considering dual command cycle times
• Dedicated storage 7. Determining utilization of
• Randomized storage
DETERMINING LOAD SIZES

• The variety and volume of parts types and the type of

production system used essentially determine the overall
workflow, that is, the movement frequency of parts, tools,
fixtures, pallets, and other supplies.
• The work flow information is required to determine load size,
which is the most important element in the design AS/RS.
• The load size refers to depth, width and height.
• The dimensions of the unit loads with approximate clearances
provide the individual storage space dimensions.
DETERMINING THE DIMENSION OF AN
INDIVIDUAL STORAGE SPACE
• Height of a storage space= h+c1.
• Length of a storage space= l+c2.
• Width of individual storage space= u(w+c3).
• Normally, the storage space depth(width) is up to maximum of
three unit loads(u=3).
Where h = Height of unit load
l = Length of unit load
w = Width of unit load
c1, c2, c3 = height, length and width clearances required for the unit load
respectively.
u = storage depth in number of unit loads
DETERMINING THE STORAGE SPACE
CONSIDERING
1. Considering Dedicated Storage (fixed slot storage) Policy-
In this policy, a particular set of storage slots or locations is assigned
to a specific product. Therefore, the number of slots required to store
the products equals the sum of the maximum inventory levels for all
the products.
2. Considering Randomized Storage (floating-slot storage) Policy-
In this, each empty storage slot is equally likely to be selected for
storage when a storage operation is performed. Likewise, each unit of
a particular product is equally likely to be retrieved when a retrieval
operation is performed.
DETERMINING THE SYSTEM THROUGHPUT
AND NUMBER OF S/R MACHINES
• The system throughput refers to the number of loads to be stored
and number of loads to be retrieved per hour. These numbers are of
course, a function of production activity. Factors that influence the
throughput include:
1. Speed of S/R machine
2. Mix of single- and dual-cycle transactions
3. Percent utilization of the storage racks
4. Arrangement of stored items
5. AS/RS control system speed
6. Speed and efficiency of the material- handling equipment such
as AGVs, conveyors, and forklifts used to move loads to the
input and removal loads from the output
DETERMINING THE SYSTEM THROUGHPUT
AND NUMBER OF S/R MACHINES
• To carry out the production activity efficiently, the calculation
of the number of S/R machines should be based on the
maximum number of loads out per hour.
• The number of S/R machines are determined as follows:
𝑠𝑦𝑠𝑡𝑒𝑚 𝑡ℎ𝑟𝑜𝑢𝑔ℎ𝑝𝑢𝑡
Number of S/R machines=
𝑠|𝑟 𝑚𝑎𝑐ℎ𝑖𝑛𝑒 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝑖𝑛 𝑐𝑦𝑐𝑙𝑒𝑠 𝑝𝑒𝑟 ℎ𝑜𝑢𝑟
DETERMINING THE SIZE PARAMETERS OF
STORAGE AND RETRIEVAL SYSTEM
• 𝐵𝑎𝑦 𝑤𝑖𝑑𝑡ℎ = 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑠𝑡𝑜𝑟𝑎𝑔𝑒 𝑠𝑝𝑎𝑐𝑒 + 𝑐𝑒𝑛𝑡𝑟𝑒 𝑡𝑜 𝑐𝑒𝑛𝑡𝑟𝑒 𝑟𝑎𝑐𝑘 𝑠𝑢𝑝𝑝𝑜𝑟𝑡 𝑤𝑖𝑑𝑡ℎ
• 𝐵𝑎𝑦 𝑤𝑖𝑑𝑡ℎ =l+C2+C4 ,where c4 is center to center rack support width
• Rack length=bay width*number of bays
• System length= rack length+ clearance for S/R machine run-out+ clearance for
the P/D area
• Bay depth= width of individual storage space+ bay side support allowance
• Bay depth=u(w+c3)+c5 , where c5 is bay side support allowance
• Aisle unit=aisle width+(2*bay depth)
• System width= aisle unit*desired number of aisles
DETERMINING SINGLE AND DUAL
COMMAND CYCLE TIMES
• In Single Command cycle either a storage or a retrieval
operation is performed, but not both. To determine cycle time,
a storage cycle is assumed to begin with the S/R machine at the
P/D station.
• Dual command cycle is assumed to begin with the S/R machine
at the P/D station. The machine picks up a load, travels empty
to the retrieval location and retrieves a load from there, travels
back to P/D station, and deposits the load.
DETERMINING SINGLE AND DUAL
COMMAND CYCLE TIMES
• Single Command Cycle Time
𝑄2
𝑇𝑠𝑐 = 𝑇 + 1 + 2𝑇𝑝𝑑
3
• Double Command Cycle Time
𝑇
𝑇𝑑𝑐 = 40 + 15𝑄2 − 𝑄3 + 4𝑇𝑝𝑑
30
Where T= max(th, tv)
Q= min(th/T, tv/T)
Tpd= time to perform either a pick up or deposit
th= time required to travel full horizontal aisle distance
tv= time required to travel full vertical aisle distance
DETERMINING UTILIZATION OF S/R
MACHINES
• Suppose the system throughput (ST) for an AS/RS is known.
Remember, the system throughput is defined as the number of
loads to be stored and number of loads to be retrieved per
hour. Suppose each aisle is served by one S/R machine and
there are N S/R machines. Then the number of transections per
S/R machine per hour is
𝑆𝑇
nt =
𝑁
DETERMINING UTILIZATION OF S/R
MACHINES

• Assuming the number of storages and retrievals are equal in the long
run, 𝑊𝑜𝑟𝑘𝑙𝑜𝑎𝑑 𝑝𝑒𝑟 𝑚𝑎𝑐ℎ𝑖𝑛𝑒 = 𝛼𝑛𝑡. 𝑇𝑠𝑐 + 𝛽 𝑛𝑡 2 𝑇𝑑𝑐 𝑚𝑖𝑛 ℎ
• Where 𝛼 and β are the percentages of operations done by single and dual
command cycles, respectively and (𝛼 +β=1)
REFERENCES
• Systems approach to computer-integrated design and
manufacturing Author Nanua Singh, Publisher Wiley, 1996 ISBN
9788126530410
• Random sources has been used to acquire relevant images for
the presentation using Google image searches

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