There are several types of Automated Storage and Retrieval Systems that are used in distribution and warehousing operations. These automated storage systems are designed to handle different types of unit loads such as pallets, cases and totes. Common to all of these systems are the benefits gained such as reduced staffing, increased productivity, improved accuracy and a higher density of storage or cube utilization.
Automated storage systems like Horizontal and Vertical Carousels as well as Mini-Load systems are typically tasked with order picking operations for small parts or small item picks. The method for these order fulfillment systems is called “part-to-picker” and typically results in very high productivity work zones. In the case of carousels, this is usually accomplished by having several carousels nested together. As an example, an operator can pick product from Carousel A while the other Carousels, B & C, rotate so that parts will be ready to be picked when the operator is finished picking from Carousel A. When the operator notifies the system the pick is complete from Carousel A, the picker will then start picking the next item from Carousel B. Then, Carousel A will start to rotate in order to present the next part or item to be picked from that carousel.
A well designed Mini-Load system also presents the “part-to-picker” at an order picking station. Mini-Load systems typically use pans that have adjustable dividers to store the items being picked. This allows for several SKUs to be stored in one pan. After a pan is dropped off at the order picking station, it takes a pan that product has been already picked from and returns it to its proper storage location before retrieving the next pan with product to be picked. This efficient design prevents wasted empty trips on the Mini-Load.
AS/RS systems that handle pallet loads are typically fully automated systems that require little human intervention. These systems are controlled by Warehouse Control Systems (WCS) that direct the storage and retrieval of the pallet loads. The cranes that are used to store and retrieve the pallets are designed to operate at very high speeds that far exceed the capability of lift trucks. Typically pallet handling AS/RS systems also have better cube utilization since they operate in very narrow aisles and have more levels of storage than lift truck system designs. Incorporating pallet flow rack with your AS/RS design further increases your space utilization as well as reduces the number of aisles and cranes required by the system.
Carousels and Mini-Load Systems are often installed in existing warehouse and distribution facilities. Because of the nature of a pallet handling AS/RS design, which typically incorporates the use of very high storage bays with extremely level floors, these systems are commonly associated with new building construction. In fact, the storage rack of the system is usually the method for supporting the building structure, which is often dubbed “rack supported building”.
Because of the initial capital costs associated with these types of systems, doing the design phase properly is critical to ensuring the project’s success and the money was well spent. Product Slotting and a Needs Analysis are musts as well as System Simulations in order to determine the most cost effective design that meets your specifications.
TriFactor offers facility design layout services for those companies in the planning stages for the construction of a new storage facility or the reconfiguration of their existing operations. Our engineers collaborate with architecture or construction firms to determine the proper pallet rack configuration when developing the overall warehouse and production layout and design. Regardless of the material handling situation, TriFactor has developed a solution process over the past 20 years which is now called the TriFactor Edge. If you’re looking for an Edge on your competition, call TriFactor today at 1-800-507-4209 to get us started solving your warehouse and distribution center needs.
For additional information on Product Slotting, Distribution Center Planning, Choosing a Conveyor System and other material handling issues go to the TriFactor Learning Center.
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