On sorter/ picking system. Without racking. With racking. racking. racking. Compact storage racking. Mobile. Drive-in racking. Block stack.
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1 OF THE FUTURE DEPARTMENT OF TECHNOLOGY AND INNOVATION MANAGEMENT OF THE FUTURE 1. Overview Storage s 2. Conventional s 3. More advandced s AS/R s AVS/R s /live-cube s s 4. Wrap up RENE DE KOSTER NOVEMBER 16, 2011 MATERIAL HANDLING FORUM SEMINAR 2 1 DE KEUZE VAN EEN (OPSLAG)SYSTEEM Het is net jam kopen in de winkel: Winkel 1: standaard jams Winkel 2: maatwerk jams Winkel 3: duurzame jams DE KEUZE VAN EEN (OPSLAG)SYSTEEM Naar welke winkel moet je gaan? Welke jam is het best? Smaak Prijs Kwaliteit Duurzaam Uiterlijk, CSR, etc 3 4 out out out out - - Shelf - Pallet - Cantilever - Drawer - Cassette - Satellites -Motorized - -Vertical - Miniload - rack - AS/RS - Kiva - Horizontal - Vertical - Horizontal - AVS/R System - - Shelf - Pallet - Cantilever - Drawer - Cassette - Satellites - Motorized - -Vertical - Miniload - rack - AS/RS -Kiva - Horizontal - Vertical - Horizontal - AVS/R System 5 6 1
2 out out out out - - Shelf - Pallet - Cantilever - Drawer - Cassette - Satellites -Motorized - -Vertical - Miniload - rack - AS/RS - Kiva - Horizontal - Vertical - Horizontal - AVS/R System - - Shelf - Pallet - Cantilever - Drawer - Cassette - Satellites - Motorized - -Vertical - Miniload - rack - AS/RS -Kiva - Horizontal - AVS/R System 7 8 CONVENTIONAL
3 MORE ADVANCED SYSTEMS out out 3 1. Single-deep s: Traditional: Miniload AS/RS Carousels Advanced: AVS/R s Kiva: movable racks 2. Multi-deep (compact) s Traditional: Satellites Advanced: Satellites and lifts Autostore Live-cube - - Shelf - Pallet - Cantilever - Drawer - Cassette - Satellites -Motorized - -Vertical - Miniload - rack - AS/RS - Kiva - Horizontal - AVS/R System AS/RS OPERATED WAREHOUSE CRANE-BASED AS/RS (OPERATIONS) Rack Crane I/O Point Main components: racks, cranes, aisles, I/O-points, and pick positions Typically one crane captive to an aisle Cranes have one or multiple load carriers (also known as shuttles; typically one shuttle/crane) Simultaneous) movement of the crane in the y and z directions IO Point Storage/ Retrieval Side view of a rack Source: VARIOUS CONFIGURATIONS IN AS/RS One of the best researched areas in MH literature (estimate >500 papers), studying every aspect. What is known (f.e.): 1. Crane cycle time (depending on rack size, strategy, etc.) 2. Optimal shape of the rack 3. Optimal ABC zone shape and size (for given demand Pareto curve) 4. Optimal number of ABC classes Single unit-load aisle-captive AS/RS The most basic version of an AS/RS has one crane in each aisle, which cannot leave its designated aisle (aisle-captive) and can transport only one unit-load at a time (single shuttle) 17 Source: Roodbergen and Vis,
4 Pallet rack (side view). Rack length=height = 20 sec crane travel time. Random. What is the average travel time to go to a rack location and back to the (neglect acceleration/deceleration)? Travel time: = 27 sec H=20 sec =20 sec L =20 sec =20 sec Pallet rack (side view). Height 20 m. Optimal length? 2. Pallet rack (side view). Height 20 m. Optimal length? H=20 m H=20 m L?? L?? Pallet rack (side view). Height 20 m. Optimal length? 3. Optimal shape and size of the ABC area? Minimize crane travel time Example overhead crane for carpet rolls Constraint: rack must have given capacity Answer: rack must be square in time = Since crane drives about 4 times faster than it lifts: L 80 m
5 3. Optimal shape and size of the ABC area? 3. Optimal shape and size of the ABC area? AN AVS/RS OPERATED WAREHOUSE 4. Optimal number of classes? Travel time with the 20%/90% ABC curve Yu et al Source: Savoye Logistics (savoye.com) COMPACT STORAGE 3. LIVE-CUBE COMPACT STORAGE
6 ENVIRONMENTAL IMPACT LIVE STORAGE Parking type Live-cube Traditional parking car park Average (fossil fuel-based) CO2 emission (gram/car) Q1: What is the performance (response time) of the, given layout, configuration, and strategy Q2: How to optimize live-cube dimensions yielding minimum response times Total electrical (lighting, vent, moving) energy (kwh/car) In addition: 40%-50% smaller footprint area (smaller building) for the same number of parking slots (Hyundai Elevator, 2011) Q1: What is the performance (response time) of the, given layout, configuration, and strategy Q1: What is the performance (response time) of the, given layout, configuration, and strategy Q2: How to optimize live-cube dimensions yielding minimum response times Q2: How to optimize live-cube dimensions yielding minimum response times Method: mathematical model: min E[ RT ] Method: mathematical model: min E[ RT ] Such that l w h V Such that l w h V A: Zaerpour et al., 2011: cubic in time is nearly optimal KIVA GOODS TO MAN SYSTEMS Q: Lift in the middle (same capacity)? A: 20% reduction in response time compared to a with lift at the corner Q: based on duration of stay? A: 25% shorter travel time for a 20/70 curve
7 4. KIVA GOODS TO MAN SYSTEMS Q: To which rack should we allocate products? Q: To which rack should we allocate orders? Q: How to schedule orders and racks? Q: how many AGVs do we need? Q: how to schedule the AGVs? WRAP UP Er is veel keuze op het gebied van geautomatiseerde opslagen Veel wetenschappelijke resultaten bekend. Vooral van AS/R en. Veel nieuwe en op de markt die nog nauwelijks onderzocht zijn Nog nauwelijks tools beschikbaar voor gestructureerde afweging van en met meerdere criteria Q: Where to store the racks? 37 Q: Should one picker pick complete orders, or only a part? Etc. 38 WRAP UP Er is veel keuze op het gebied van geautomatiseerde opslagen Veel wetenschappelijke resultaten bekend. Vooral van AS/R en. Veel nieuwe en op de markt die nog nauwelijks onderzocht zijn Nog nauwelijks tools beschikbaar voor gestructureerde afweging van en met meerdere criteria Kortom, er is veel te beleven op het gebied van opslagen Veel keuze en nog veel uit te zoeken! 39 7
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