Storage Systems

Sections:
1. Storage System Performance and Location Strategies
2. Conventional Storage Methods and Equipment
3. Automated Storage Systems
4. Engineering Analysis of Storage Systems
 Storage Systems

Function to store materials (e.g., parts, work-in-process,

finished goods) for a period of time and permit retrieval
when required

Used in factories, warehouses, distribution centers,

wholesale dealerships, and retail stores

Important supply chain component

Automation available to improve efficiency
 Storage Systems

Types of materials typically stored in a factory

Raw Materials
Purchased Parts
Work in Process
Finished product
Rework and scrap
Refuse
Tooling
Spare Parts
Office supplies
Plant records
 Storage System Performance

Performance measures for storage systems:

Storage capacity - two measures:
Total volumetric space
Total number of storage compartments (e.g., unit loads)
Storage density - volumetric space available for storage
relative to total volumetric space in storage facility
Accessibility - capability to access any item in storage
System throughput - hourly rate of storage/retrieval
transactions
Utilization and availability (reliability)
 Storage Location Strategies

Two strategies: 1. Randomized, and 2. Dedicated

Randomized storage
. Incoming items are stored in any available location
. Usually means nearest available open location
Dedicated storage
Incoming items are assigned to specific locations in the storage facility
Typical bases for deciding locations:
Items stored in part number sequence
Items stored according to activity level
Items stored according to activity-to-space ratios
 Comparison of Storage Strategies

Less total space is required in a storage system that uses a

randomized storage strategy
Dedicated storage requires space for maximum inventory level of
each item
Higher throughput rates are achieved in a system that uses dedicated
storage strategy based on activity level
The most active items can be located near the input/output point
Compromise: Class-based dedicated storage
Items divided into classes according to activity level
Random storage strategy used within each class
 Conventional Storage Methods

Bulk storage - storage in an open floor area

Problem: achieving proper balance between storage
density and accessibility
Rack systems - structure with racks for pallet loads
Permits vertical stacking of materials
Shelving and bins - horizontal platforms in structural
frame
Steel shelving comes in standard sizes
Finding items can be a problem
Drawer storage - entire contents of each drawer can be
viewed
 Bulk Storage

Bulk storage arrangements:

(a) high-density bulk storage provides low accessibility,
(b) bulk storage with loads forming rows and blocks for improved accessibility
(c) Low cost per sq meter
 Conventional Storage Methods

Bulk storage - storage in an open floor area

Problem: achieving proper balance between storage
density and accessibility
Rack systems - structure with racks for pallet loads
Permits vertical stacking of materials
Shelving and bins - horizontal platforms in structural
frame
Steel shelving comes in standard sizes
Finding items can be a problem
Drawer storage - entire contents of each drawer can be
viewed
 Pallet Rack System

Pallet loads placed on racks

in multi-rack structure
(a) Low cost
(b) Good stroge density
(c) Good accessibility

Other Rack System

Cantilever racks
Portable racks
Flow through racks
Flow through racks
 Conventional Storage Methods

Bulk storage - storage in an open floor area

Problem: achieving proper balance between storage
density and accessibility
Rack systems - structure with racks for pallet loads
Permits vertical stacking of materials
Shelving and bins - horizontal platforms in structural
frame
Steel shelving comes in standard sizes
Finding items can be a problem
Drawer storage - entire contents of each drawer can be
viewed
Shelving and bins
 Conventional Storage Methods

Bulk storage - storage in an open floor area

Problem: achieving proper balance between storage
density and accessibility
Rack systems - structure with racks for pallet loads
Permits vertical stacking of materials
Shelving and bins - horizontal platforms in structural
frame
Steel shelving comes in standard sizes
Finding items can be a problem
Drawer storage - entire contents of each drawer can be
viewed
 Drawer Storage

Contents easily visible

Good accessibility
Relatively high cost

Small items (tools,

repair parts, etc.)
 Automated Storage Systems

Mechanized and automated storage equipment to reduce the

human resources required to operate a storage facility

Significant investment

Level of automation varies

In mechanized systems, an operator participates in each
storage/retrieval transaction
In highly automated systems, loads are entered or retrieved
under computer control
 Objectives and Reasons for
Automating Storage Operations
To increase storage capacity
To increase storage density
To improve security and reduce pilferage
To reduce labor cost and/or increase productivity
To improve safety
To improve inventory control
To improve stock rotation
To improve customer service
To increase throughput
 Types of Automated Storage System

1. Automated Storage/Retrieval System (AS/RS)

Rack system with mechanized or automated crane to
store/retrieve loads
2. Carousel Storage System
Oval conveyor system with bins to contain individual
items
 AS/RS

Unit load on
pallet AS/RS
with one aisle
 AS/RS Types

Unit load AS/RS - large automated system for pallet loads

Deep-lane AS/RS High density Storage System uses
flow-through racks and fewer access aisles
Miniload AS/RS - handles small loads contained in bins or
drawers to perform order picking
Man-on-board AS/RS - human operator rides on the
carriage to pick individual items from storage
Automated item retrieval system - picks individual items
Vertical lift storage modules (VLSM) - uses a vertical
aisle rather than a horizontal aisle as in other AS/RS types
Deep-lane AS/RS
 AS/RS Applications

1. Unit load storage and retrieval

Warehousing and distribution operations
AS/RS types: unit load, deep lane (food industry)
2. Order picking
Item retrieval
AS/RS types: miniload, man-on-board,
3. Work-in-process storage
Helps to manage WIP in factory operations
Buffer storage between operations with different production rates
Supports JIT manufacturing strategy
Kitting of parts for assembly
 Carousel Storage Systems
A carousel storage system consists of a series of bins or baskets suspends
from an over head chain conveyor that revolves around a long oval rail
system.
Most carousel are operated by a human worker located at load/unload
station.
Some carousal are automated by using transfer mechanism at the
load/unload station to move loads into and from carousal.
 Carousel Storage Systems

Horizontal
Operation is similar to overhead conveyor system used
in dry cleaning establishments
Items are stored in bins suspended from the conveyor
Lengths range between 3 m and 30 m
Horizontal is most common type
Vertical
Operates around a vertical conveyor loop
Less floor space required, but overhead room must be
provided
 Horizontal Carousel Storage System

Manually operated
horizontal
carousel storage
system
 Carousel Applications

1. Storage and retrieval operations

Order picking
Kitting of parts for assembly
Order picking of tools in a tool room
2. Transport and accumulation
Progressive assembly with assembly stations located
around carousel
3. Work-in-process
WIP applications in electronics industry are common
4. Unique applications
Example: testing of electrical products
 Engineering Analysis of
Automated Storage Systems

1. Automated Storage/Retrieval Systems

Sizing the AS/RS
AS/RS throughput analysis
2. Carousel storage systems
Storage capacity
Throughput analysis
 Ex. 1
Each aisle of a four aisle As/Rs is to contain 60 storage compartments in
the length direction and 12 compartments vertically. All storage
compartments will be same size to accommodate size of pallets of
dimensions x=42 in, y=48 in and z= 36 in. a=6 in , b= 8 in. c=10 in.
Determine the (a) How many unit loads can be stored in AS/RS. (b) W , L
, H of AS/RS.

Ex. 2
Consider the AS/RS from above examples, in which an S/R machine is
used fro each aisle. The length of the storage aisle=280 ft and its height =
46 ft. Suppose horizontal and vertical speeds of the S/R machine are 200
ft/min and 75 ft/min, respectively. The S/R machine requires 20 sec to
accomplish a P & D operation. Find (a) the single command and dual
command cycle times per aisle, and (b) throughput per aisle under the
assumptions that storage system utilization = 90 % and the number of
single command and dual command cycles are equal.
 Ex. 3 Consider the AS/RS from previous examples, in which an S/R
machine is used for each aisle. The length of the storage aisle=280 ft and
its height = 46 ft. Suppose horizontal and vertical speeds of the S/R
machine are 200 ft/min and 75 ft/min, respectively. The S/R machine
requires 20 sec to accomplish a P & D operation.
The system used a class based dedicated storage system. The more
active stock stored in the half of the rack system that is located closest to
the input/output station, and the less-active stock is stored in the other
half of the rack system farther away from the input/output station.
Within each half of the rack system random storage is used. The more
active stocks accounts for 75% of transaction and less active stocks
account for remaining 25%.
Find (a) the single command and dual command cycle times per aisle,
and (b) throughput per aisle under the assumptions that storage system
utilization = 90 %
(c) Throughput for complete AS/RS.
The number of single command and dual command cycles are equal.
 Ex. 4
A unit load AS/RS is being designed to store 1000 pallet loads in a
distribution center located next to the factory. Pallet dimensions
are: x = 1000 mm, y = 1200 mm; and the maximum height of a
unit load = 1300 mm. The following is specified:
(1) the AS/RS will consist of two aisles with one S/R machine per
aisle, (2) length of the structure should be approximately five
times its height, and (3) the rack structure will be built 500 mm
above floor level. Using the allowances a = 150 mm, b = 200 mm,
and c = 250 mm, determine the width, length, and height of the
AS/RS rack structure.
 Ex. 5
An AS/RS is used for work-in-process storage in a manufacturing facility. The
AS/RS has five aisles, each aisle being 120 ft long and 40 ft high. The
horizontal and vertical speeds of the S/R machine are 400 ft/min and 50
ft/min, respectively. The S/R machine requires 12 sec to accomplish a pick
and deposit operation. The number of single command cycles equals the
number of dual command cycles. If the requirement is that the AS/RS must
have a throughput rate of 200 S/R transactions per hour during periods of
peak activity, will the AS/RS satisfy this requirement? If so, what is the
utilization of the AS/RS during peak hours.
 Ex. 6
An automated storage/retrieval system installed in a warehouse has five
aisles. The storage racks in each aisle are 30 ft high and 150 ft long. The S/R
machine for each aisle travels at a horizontal speed of 350 ft/min and a
vertical speed of 60 ft/min. The pick and deposit time = 0.25 min. Assume
that the number of single command cycles per hour is equal to the number
of dual command cycles per hour and that the system operates at 75%
utilization. Determine the throughput rate (loads moved/hour) of the AS/RS.