AUTOMATION IN MANUFACTURING (21ME735)

MODULE 4: MATERIAL STORAGE SYSTEMS

Material Storage Systems: Introduction to Storage systems, Storage system
performance, Conventional storge methods and Equipment, Automated Storage and
Retrieval Systems (AS/RS), AS/RS types, AS/RS applications, Components and
operating features of an AS/RS.

The function of a material storage system is to store materials for a period of time and to permit access
to those materials when required. Some production plants and storage facilities use manual methods for
storing and retrieving materials. The storage function is often accomplished inefficiently in terms of
human resources, factory floor space, and material control. More effective approaches and automated
methods are available to im prove the efficiency of the storage function.

INTRODUCTION TO STORAGE SYSTEMS:

Materials stored by a manufacturing firm include a variety of types, as indicated in Table.

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STORAGE SYSTEM PERFORMANCE:

The performance of a storage system in accomplishing its function must be sufficient to justify its
investment and operating expense.

Various measures used to assess the performance of a storage system include the following:

1. Storage capacity
2. Storage density
3. Accessibility
4. Throughput
5. Utilization
6. Reliability.

Storage capacity can be defined and measured in two ways: (1) as the total volumetric space available
or (2) as the total number of storage compartments in the system available to hold items or loads. In many
storage systems, materials are stored as unit loads that are held in standard-size containers (pallets, tote
pans, or other containers). The standard container can readily be handled, transported, and stored by the
storage system and by the material transport system that may be connected to it. Hence, storage capacity
is conveniently measured as the number of unit loads that can be stored in the system.

Storage density is defined as the volumetric space available for actual storage relative to the total
volumetric space in the storage facility. In many warehouses, aisle space and wasted overhead space
account for more volume than the volume available for actual storage of materials. Floor area is
sometimes used to assess storage density, because it is convenient to measure this on a floor plan of the
facility.

For efficient use of space, the storage system should be designed to achieve a high density. However, as
storage density is increased, accessibility, another important measure of storage performance, is
adversely affected. Accessibility refers to the capability to access any desired item or load stored in the
system. In the design of a given storage system, appropriate trade-offs must be made between storage
density and accessibility.

System throughput is defined as the hourly rate at which the storage system (1) receives and puts loads
into storage and/or (2) retrieves and delivers loads to the output station. In many factory and warehouse
operations, there are certain periods of the day when the required rate of storage and/or retrieval

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transactions is greater than at other times. The storage system must be designed for the maximum
throughput that will be required during the day.

System throughput is limited by the time to perform a storage or retrieval (S/R) transaction. A typical
storage transaction consists of the following elements:

(1) Pick up load at input station

(2) Travel to storage location
(3) Place load in storage location
(4) Travel back to input station.

A retrieval transaction consists of:

(1) Travel to storage location
(2) Pick up item from storage
(3) Travel to output station
(4) Unload at output station.

Each element takes time. The sum of the element times is the transaction time that determines throughput
of the storage system. Throughput can sometimes be increased by combining storage and retrieval
transactions in one cycle, thus reducing travel time; this is called a dual-command cycle. When either a
storage or a retrieval transaction alone is performed in the cycle, it is called a single-command cycle.

Utilization is defined as the proportion of time that the system is actually being used for performing S/R
operations compared with the time it is available. Utilization varies throughout the day, as requirements
change from hour to hour. It is desirable to design an automated storage system for relatively high
utilization, in the range 80–90%. If utilization is too low, then the system is probably overdesigned. If
utilization is too high, then there is no allowance for rush periods or system breakdowns.

Availability is a measure of system reliability, defined as the proportion of time that the system is capable
of operating (not broken down) compared with the normally scheduled shift hours. Malfunctions and
failures of the equipment cause downtime. Reasons for downtime include computer failures, mechanical
breakdowns, load jams, improper maintenance, and incorrect procedures by personnel using the system.
The reliability of an existing system can be improved by following good preventive maintenance
procedures and by having repair parts on hand for critical components. Backup procedures should be
devised to mitigate the effects of system downtime.
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STORAGE LOCATION STRATEGIES:

Several strategies can be used to organize stock in a storage system. These storage location strategies
affect the performance measures discussed above. The two basic strategies applied in warehousing
operations are
(1) Randomized storage
(2) Dedicated storage

Each item type stored in a warehouse is known as a Stock-Keeping-Unit (SKU). The SKU uniquely
identifies that item type. The inventory records of the storage facility maintain a count of the quantities
of each SKU that are in storage.

In randomized storage, items are stored in any available location in the storage system. In the usual
implementation of randomized storage, incoming items are placed into storage in the nearest available
open location. When an order is received for a given SKU, the stock is retrieved from storage according
to a first-in-first-out policy so that the items held in storage the longest are used to make up the order.

In dedicated storage, SKUs are assigned to specific locations in the storage facility. This means that
locations are reserved for all SKUs stored in the system, and so the number of storage locations for each
SKU must be sufficient to accommodate its maximum inventory level. The basis for specifying the
storage locations is usually one of the following:
➢ Items are stored in part number or product number sequence
➢ Items are stored according to activity level, the more active SKUs being located closer to the
input/output station
➢ Items are stored according to their activity-to-space ratios, the higher ratios being located closer
to the input/output station.
When comparing the benefits of the two strategies, it is generally found that less total space is required
in a storage system that uses randomized storage, but higher throughput rates can usually be achieved
when a dedicated storage strategy is implemented based on activity level.

CONVENTIONAL STORGE METHODS AND EQUIPMENT:

A variety of storage methods and equipment are available to store the various materials. The choice of
method and equipment depends largely on the materials to be stored, the operating philosophy of the
personnel managing the storage facility, and budgetary limitations. The storage methods are as follows:
❖ Bulk Storage

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 ❖ Rack systems
❖ Shelving and bins
❖ Drawer storage

Bulk storage: Bulk storage is the storage of stock in an open floor area. The stock is generally contained
in unit loads on pallets or similar containers, and unit loads are stacked on top of each other to increase
storage density. The highest density is achieved when unit loads are placed next to each other in both
floor directions, as in Figure (a). However, this provides very poor access to internal loads. To increase
accessibility, bulk storage loads can be organized into rows and blocks, so that natural aisles are created
between pallet loads, as in Figure (b). The block widths can be designed to provide an appropriate balance
between density and accessibility. Depending on the shape and physical support provided by the items
stored, there may be a restriction on how high the unit loads can be stacked. In some cases, loads cannot
be stacked on top of each other, either because of the physical shape or limited compressive strength of
the individual loads. The inability to stack loads in bulk storage reduces storage density, removing one
of its principal benefits.

Rack systems: Rack systems provide a method of stacking unit loads vertically without the need for the
loads themselves to provide support. One of the most common rack systems is the pallet rack, consisting
of a frame that includes horizontal load supporting beams, as illustrated in Figure. Pallet loads are stored
on these horizontal beams. Alternative storage rack systems include

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• Cantilever racks, similar to pallet racks except the supporting horizontal beams are cantilevered from
the vertical central frame. Elimination of the vertical beams at the front of the frame provides unobstructed
spans, which facilitates storage of long materials such as rods, bars, and pipes.

• Flow-through racks. In place of the horizontal load-supporting beams in a conventional rack system, the
flow-through rack uses long conveyor tracks capable of supporting a row of unit loads. The unit loads are
loaded from one side of the rack and unloaded from the other side, thus providing first-in-first-out stock
rotation. The conveyor tracks are inclined at a slight angle to allow gravity to move the loads toward the
output side of the rack system.

Shelving and Bins: Shelves represent one of the most common storage equipment types. A shelf is a
horizontal platform, supported by a wall or frame, on which materials are stored. Steel shelving sections
are manufactured in standard sizes, typically ranging from about 0.9 to 1.2 m (3 to 4 ft) long (in the aisle
direction), from 0.3 to 0.6 m (12 to 24 in) wide, and up to 3.0 m (10 ft) tall. Shelving often includes bins,
which are containers or boxes that hold loose items.

Drawer storage: Finding items in shelving can sometimes be difficult, especially if the shelf is either far
above or far below eye level for the storage attendant. Storage drawers, Figure 11.4, can alleviate this
problem because each drawer pulls out to allow its entire contents to be readily seen. Modular drawer

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storage cabinets are available with a variety of drawer depths for different item sizes and are widely used
for storage of tools and maintenance items.

AUTOMATED STORAGE AND RETRIEVAL SYSTEMS (AS/RS):

The storage equipment described in the preceding section requires a human worker to access the items in
storage. The storage system itself is static. Mechanized and automated storage systems are available that
reduce or eliminate the amount of human intervention required to operate the system. The level of
automation varies. In less automated systems, a human operator is required to handle each
storage/retrieval transaction. In highly automated systems, loads are entered or retrieved under computer
control, with no human participation except to input data to the computer. Table 11.2 lists the advantages
and disadvantages as well as typical applications of automated storage systems.

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An automated storage system represents a significant investment, and it often requires a new and different
way of doing business. Companies have a variety of reasons for automating the storage function.

List of possible objectives and reasons behind company decisions to automate their storage
operations.

➢ To increase storage capacity

➢ To increase storage density
➢ To recover factory floor space presently used for storing work-in- process
➢ To improve security and reduce pilferage
➢ To improve safety in the storage function
➢ To reduce labor cost and/or increase labor productivity in storage operations
➢ To improve control over inventories
➢ To improve customer service
➢ To increase throughput

AS/RS CATEGORIES:
Automated storage systems divide into two general categories:
(1) Fixed-aisle automated storage/retrieval systems
(2) Carousel storage systems.
A fixed-aisle AS/RS consists of a rack structure for storing loads and a storage/retrieval machine whose
motions are linear (x–y–z motions.
A carousel system uses storage baskets attached to a chain-driven conveyor that revolves around an oval
track loop to deliver the baskets to a load/unload station. Both types include horizontal and vertical
structures, with the horizontal configuration being much more common in both cases

FIXED-AISLE AUTOMATED STORAGE/RETRIEVAL SYSTEMS:

A fixed-aisle automated storage/retrieval system (AS/RS) is a storage system consisting of one or more
aisles of storage racks attended by storage/retrieval machines, usually one S/R machine per aisle. The
system performs storage and retrieval operations with speed and accuracy under a defined degree of
automation. The S/R machines are used to deliver materials to the storage racks and to retrieve materials
from the racks. Each AS/RS aisle has one or more input/output stations where materials are delivered into
the storage system and withdrawn from it. The input/ output stations are called pickup-and-deposit
stations (P&D stations) in AS/RS terminology. P&D stations can be manually operated or interfaced to
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some form of automated transport system such as a conveyor or an AGVS (automated guided vehicle
system).

Figure shows one aisle of an AS/RS that handles and stores unit loads on pallets. At the most sophisticated
level, the operations are computer controlled and fully integrated with factory and/or warehouse
operations. At the other extreme, human workers control the equipment and perform the storage/retrieval
transactions. Fixed-aisle automated storage/ retrieval systems are custom-designed for each application,
although the designs are based on standard modular components available from each respective AS/RS
supplier.

AS/RS TYPES:
Several important categories of fixed-aisle automated storage/ retrieval system can be distinguished. The
following are the principal types:
❖ Unit load AS/RS
❖ Deep lane AS/RS
❖ Miniload AS/RS
❖ Man-on-board S/RS
❖ Automated item retrieval system
❖ Vertical lift modules (VLM)
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Unit load AS/RS:
The unit load AS/RS is typically a large automated system designed to handle unit loads stored on pallets
or in other standard containers. The system is computer controlled, and the S/R machines are automated
and designed to handle the unit load containers.

Deep-lane AS/RS:
The deep-lane AS/RS is a high-density unit load storage system that is appropriate when large quantities
of stock are stored, but the number of separate stock types (SKUs) is relatively small. Instead of storing
each unit load so that it can be accessed directly from the aisle (as in a conventional unit load system), the
deep-lane system stores ten or more loads in a single rack, one load behind the next. Each rack is designed
for “flow-through,” with input on one side and output on the other side. Loads are picked up from one
side of the rack by an S/R-type machine designed for retrieval, and another machine inputs loads on the
entry side of the rack.

Miniload AS/RS:
This storage system is used to handle small loads (individual parts or supplies) that are contained in bins
or drawers in the storage system. The S/R machine is designed to retrieve the bin and deliver it to a P&D
station at the end of the aisle so that individual items can be withdrawn from the bins. The P&D station
is usually operated by a human worker. The bin or drawer must then be returned to its location in the
system. A miniload AS/RS is generally smaller than a unit load AS/RS and is often enclosed for security
of the items stored.

Man-on-board S/RS:
A man-on-board (also called man-aboard) storage/retrieval system represents an alternative approach to
the problem of retrieving individual items from storage. In this system, a human operator rides on the
carriage of the S/R machine. Whereas the miniload system delivers an entire bin to the end-of-aisle pick
station and must return it subsequently to its proper storage compartment, with the man-on-board system
the worker picks individual items directly at their storage locations. This offers an opportunity to increase
system throughput.

Automated item retrieval system:

These storage systems are also designed for retrieval of individual items or small product cartons;
however, the items are stored in lanes rather than bins or drawers. When an item is retrieved, it is pushed
from its lane and drops onto a conveyor for delivery to the pickup station. The supply of items in each
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lane is periodically replenished, usually from the rear of the system so that there is flow-through of items,
thus permitting first-in/first-out inventory rotation.

Vertical lift modules (VLM):

All of the preceding AS/RS types are designed around a fixed horizontal aisle. The same principle of
using a center aisle to access loads is used in a VLM except that the aisle is vertical. The structure consists
of two columns of trays that are accessed by an S/R machine (also called an extractor) that delivers the
trays one-by-one to a load/unload station at floor level. Vertical lift modules, some with heights of 10 m
(30 ft) or more, are capable of holding large inventories while saving valuable floor space in the facility.

AS/RS APPLICATIONS:
Most applications of fixed-aisle automated storage/retrieval systems have been associated with
warehousing and distribution operations, but they can also be used to store raw materials and work-in-
process in manufacturing.

Three application areas can be distinguished:

(1) Unit load storage and handling
(2) Order picking
(3) Work-in-process storage.
Unit load storage and retrieval applications are represented by the unit load AS/RS and deep-lane storage
systems. These kinds of applications are commonly found in warehousing for finished goods in a
distribution center, but rarely in manufacturing. Deep-lane systems are used in the food industry.
Order picking involves retrieving materials in less than full unit load quantities. Miniload, man-on-board,
and item retrieval systems are used for this application area.
Work-in-process (WIP) storage is a more recent application of automated storage technology. While it is
desirable to minimize the amount of work-in-process, WIP is unavoidable and must be effectively
managed.

Various AS/RS applications in both the manufacturing and distribution industries are:
Manufacturing
❖ Raw material storage
❖ Parts storage and supply to assembly lines
❖ Work-in-progress buffer
❖ Aging-process management
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 ❖ Finished product storage
❖ Improved product security
❖ Production tool storage such as dies and molds
❖ Service parts storage and order preparation
Distribution
❖ A temporary buffer of received products from suppliers
❖ Automatic inventory supply to order picking lines
❖ Sequencing or grouping of shipping items

Reasons that justify the installation of automated storage systems include the following:

Buffer storage in production: A storage system can be used as a buffer storage zone between two
processes whose production rates are significantly different.

Support of just-in-time delivery: Just-in-time (JIT) is a manufacturing strategy in which parts required
in production and/or assembly are received immediately before they are needed in the plant. This results
in a significant dependency of the factory on its suppliers to deliver the parts on time for use in production.
To reduce the chance of stock-outs due to late supplier deliveries, some plants have installed automated
storage systems as storage buffers for incoming materials.

Kitting of parts for assembly: The storage system is used to store components for assembly of products
or subassemblies. When an order is received, the required components are retrieved, collected into kits
(tote pans), and delivered to the production floor for assembly.

Compatible with automatic identification systems: Automated storage systems can be readily
interfaced with automatic identification devices such as bar code readers. This allows loads to be stored
and retrieved without needing human operators to identify the loads.

Computer control and tracking of materials: Combined with automatic identification, an automated
WIP storage system permits the location and status of work-in process to be known.

Support of factory-wide automation: Given the need for storage of work-in-process in batch
production, an appropriately sized automated storage system can be an important subsystem in a fully
automated factory.
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COMPONENTS AND OPERATING FEATURES OF AN AS/RS:
Virtually all of the fixed aisle automated storage/retrieval systems described earlier consist of the
following components:
(1) Storage structure
(2) S/R machine
(3) Storage modules (e.g., pallets for unit loads)
(4) One or more pickup-and-deposit stations.
In addition, a control system is required to operate the AS/RS.

The storage structure is the rack framework, made of fabricated steel, which supports the loads contained
in the AS/RS. The individual storage compartments in the structure must be designed to hold the storage
modules used to contain the stored materials. The rack structure may also be used to support the roof and
siding of the building in which the AS/RS resides. Another function of the storage structure is to support
the aisle hardware. This hardware includes guide rails at the top and bottom of the structure as well as
end stops and other features required for safe operation.

The S/R machine is used to accomplish storage transactions, delivering loads from the input station into
storage, and retrieving loads from storage and delivering them to the output station. To perform these
transactions, the storage/retrieval machine must be capable of horizontal and vertical travel to align its
carriage (which carries the load) with the storage compartment in the rack structure. The S/R machine
consists of a rigid mast on which is mounted an elevator system for vertical motion of the carriage. Wheels
are attached at the base of the mast to permit horizontal travel along a rail system that runs the length of
the aisle.

The storage modules are the unit load containers of the stored material. These include pallets, steel wire
baskets and containers, plastic tote pans, and special drawers (used in miniload systems). The storage
modules are a standard size that is designed to fit in the storage compartments of the rack structure and
can be handled automatically by the carriage shuttle of the S/R machine.

The pickup-and-deposit station is where loads are transferred into and out of the AS/RS. It is generally
located at the end of the aisle for access by the external handling system that brings loads to the AS/RS
and takes loads away. Pickup stations and deposit stations may be located at opposite ends of the storage
aisle or combined at the same location. This depends on the origin of incoming loads and the destination
of output loads. A P&D station must be compatible with both the S/R machine shuttle and the external
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handling system. Common methods to handle loads at the P&D station include manual load/unload,
forklift truck, conveyor (e.g., roller), and AGVS.

CAROUSEL STORAGE SYSTEMS:

A carousel storage system consists of a series of bins or baskets attached to a chain-driven conveyor that
revolves around an oval track loop to deliver the baskets to a load/unload station, as depicted in Figure.
The purpose of the chain conveyor is to position bins at a load/unload station at the end of the oval. Most
carousels are operated by a human worker at the load/unload station. The worker activates the powered
carousel to deliver a desired bin to the station. One or more parts are removed from or added to the bin,
and then the cycle is repeated. Some carousels are automated by using transfer mechanisms at the
load/unload station to move loads into and from the carousel.

CAROUSEL APPLICATIONS:

Carousel storage systems provide a relatively high throughput and are often an attractive alternative to a
miniload AS/RS in manufacturing operations where their relatively low cost, versatility, and high
reliability are recognized.
Typical applications of carousel storage systems include
(1) Storage and retrieval operations
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 (2) Transport and accumulation
(3) Work-in-process
(4) Specialized uses

Storage and retrieval operations can be efficiently accomplished using carousels when individual items
must be selected from groups of items in storage. Sometimes called “pick and load” operations, these
procedures are common in order-picking of tools in a toolroom, raw materials in a stockroom, service
parts or other items in a wholesale firm, and work-in-process in a factory.

In transport and accumulation applications, the carousel is used to transport and/or sort materials as they
are stored. One example of this is in progressive assembly operations where the workstations are located
around the periphery of a continuously moving carousel, and the workers have access to the individual
storage bins of the carousel. They remove work from the bins to complete their own respective assembly
tasks, then place their work into another bin for the next operation at some other workstation.

Carousel storage systems often compete with automated storage and retrieval systems for applications
where work-in-process is to be temporarily stored. Applications of carousel systems in the electronics
industry are common.

One example of specialized use of carousel systems is electrical testing of products or components, where
the carousel is used to store the item during testing for a specified period of time. The carousel is
programmed to deliver the items to the load/unload station at the conclusion of the test period.

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