Automated storage and retrieval system
An automated storage and retrieval system (ASRS or AS/RS) consists of a variety of computer-controlled systems for automatically placing and retrieving loads from defined storage locations. 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 is added in this process (no processing, only storage and transport) Accuracy is critical because of potential expensive damages to the load An AS/RS can be used with standard loads as well as nonstandard loads, meaning that each standard load can fit in a uniformly-sized volume; for example, the film canisters in the image of the Defense Visual Information Center are each stored as part of the contents of the uniformly sized metal boxes, which are shown in the image. Standard loads simplify the handling of a request of an item. In addition, audits of the accuracy of the inventory of contents can be restricted to the contents of an individual metal box, rather than undergoing a top-to-bottom search of the entire facility, for a single item. They can also be used in self storage places. == Overview == AS/RS systems are designed for automated storage and retrieval of parts and items in manufacturing, distribution, retail, wholesale and institutions. They first originated in the 1960s, initially focusing on heavy pallet loads but with the evolution of the technology the handled loads have become smaller. The systems operate under computerized control, maintaining an inventory of stored items. Retrieval of items is accomplished by specifying the item type and quantity to be retrieved. The computer determines where in the storage area the item can be retrieved from and schedules the retrieval. It directs the proper automated storage and retrieval machine (SRM) to the location where the item is stored and directs the machine to deposit the item at a location where it is to be picked up. A system of conveyors and or automated guided vehicles is sometimes part of the AS/RS system. These take loads into and out of the storage area and move them to the manufacturing floor or loading docks. To store items, the pallet or tray is placed at an input station for the system, the information for inventory is entered into a computer terminal and the AS/RS system moves the load to the storage area, determines a suitable location for the item, and stores the load. As items are stored into or retrieved from the racks, the computer updates its inventory accordingly. The benefits of an AS/RS system include reduced labor for transporting items into and out of inventory, reduced inventory levels, more accurate tracking of inventory, and space savings. Items are often stored more densely than in systems where items are stored and retrieved manually. Within the storage, items can be placed on trays or hang from bars, which are attached to chains/drives in order to move up and down. The equipment required for an AS/RS include a storage & retrieval machine (SRM) that is used for rapid storage and retrieval of material. SRMs are used to move loads vertically or horizontally, and can also move laterally to place objects in the correct storage location. The trend towards Just In Time production often requires sub-pallet level availability of production inputs, and AS/RS is a much faster way of organizing the storage of smaller items next to production lines. The Material Handling Institute of America (MHIA), the non-profit trade association for the material handling world, and its members have categorised AS/RS into two primary segments: Fixed Aisle and Carousels/Vertical Lift Modules (VLMs). Both sets of technologies provide automated storage and retrieval for parts and items, but use different technologies. Each technology has its unique set of benefits and disadvantages. Fixed Aisle systems are characteristically larger systems whereas carousels and Vertical Lift Modules are used individually or grouped, but in small to medium-sized applications. A fixed-aisle AS/R machine (stacker crane) is one of two main designs: single-masted or double masted. Most are supported on a track and ceiling guided at the top by guide rails or channels to ensure accurate vertical alignment, although some are suspended from the ceiling. The 'shuttles' that make up the system travel between fixed storage shelves to deposit or retrieve a requested load (ranging from a single book in a library system to a several ton pallet of goods in a warehouse system). The entire unit moves horizontally within an aisle, while the shuttles are able to elevate up to the necessary height to reach the load, and can extend and retract to store or retrieve loads that are several positions deep in the shelving. A semi-automated system can be achieved by utilizing only specialized shuttles within an existing rack system. Another AS/RS technology is known as shuttle technology. In this technology the horizontal movement is made by independent shuttles each operating on one level of the rack while a lift at a fixed position within the rack is responsible for the vertical movement. By using two separate machines for these two axes the shuttle technology is able to provide higher throughput rates than stacker cranes. Storage and Retrieval Machines pick up or drop off loads to the rest of the supporting transportation system at specific stations, where inbound and outbound loads are precisely positioned for proper handling. In addition, there are several types of Automated Storage & Retrieval Systems (AS/RS) devices called Unit-load AS/RS, Mini-load AS/RS, Mid-Load AS/RS, Vertical Lift Modules (VLMs), Horizontal Carousels and Vertical Carousels. These systems are used either as stand-alone units or in integrated workstations called pods or systems. These units are usually integrated with various types of pick to light systems and use either a microprocessor controller for basic usage or inventory management software. These systems are ideal for increasing space utilization up to 90%, productivity levels by 90%, accuracy to 99.9%+ levels and throughput up to 750 lines per hour/per operator or more depending on the configuration of the system. == Horizontal carousels == Robotic Inserter/Extractor devices can be used for horizontal carousels. The robotic device is positioned in the front or rear of up to three horizontal carousels tiered high. The robot grabs the tote required in the order and often replenishes at the same time to speed up throughput. The tote(s) are then delivered to a conveyor, which routes it to a work station for picking or replenishing. Up to eight transactions per minute per unit can be done. Totes or containers up to 36" x 36" x 36" can be used in a system. On a simplistic level, horizontal carousels are also often used as "rotating shelving". With simple "fetch" command, items are brought to the operator and otherwise wasted space is eliminated. AS/RS Applications: Most applications of AS/RS technology have been associated with warehousing and distribution operations. An AS/RS can also be used to store raw materials and work in process in manufacturing. Three application areas can be distinguished for AS/RS: (1) Unit load storage and handling, (2) Order picking, and (3) Work in process storage. Unit load storage and retrieval applications are represented by unit load AS/RS and deep-lane storage systems. These kinds of applications are commonly found in warehousing for finishing goods in a distribution center, rarely in manufacturing. Deep-lane systems are used in the food industry. As described above, order picking involves retrieving materials in less than full unit load quantities. Minilpass, man-on board, and items retrieval systems are used for this second application area. Work in process 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. Automated storage systems, either automated storage/retrieval systems or carousel systems, represent an efficient way to store materials between processing steps, particularly in batch and job shop production. In high production, work in process is often carried between operations by conveyor system, which this serve both storage and transport functions. === Inventory Category-specific AS/RS === Each inventory category—raw materials, work-in-process, and finished goods—requires its own specialized Automated Storage and Retrieval System (AS/RS). Particularly for work-in-process (WIP) inventories, due to variations in manufacturing processes, the AS/RS systems are significantly different in design and function, tailored specifically to match unique handling, storage, and retrieval requirements === Installed applications === Installed applications of this technology can be wide-ranging. In some librarie
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