STORAGE SYSTEMS OF THE FUTURE - ERIM
STORAGE SYSTEMS OF THE FUTURE - ERIM
STORAGE SYSTEMS OF THE FUTURE - ERIM
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3<br />
DEPARTMENT <strong>OF</strong> TECHNOLOGY AND INNOVATION MANAGEMENT<br />
<strong>STORAGE</strong> <strong>SYSTEMS</strong> <strong>OF</strong><br />
<strong>THE</strong> <strong>FUTURE</strong><br />
RENE DE KOSTER<br />
NOVEMBER 16, 2011<br />
MATERIAL HANDLING FORUM SEMINAR<br />
Without<br />
racking<br />
5<br />
Block<br />
stack<br />
1<br />
DE KEUZE VAN EEN (OPSLAG)SYSTEEM<br />
Het is net jam kopen in de winkel:<br />
Winkel 1: standaard jams<br />
Winkel 2: maatwerk jams<br />
Winkel 3: duurzame jams<br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
<strong>STORAGE</strong> <strong>SYSTEMS</strong><br />
Multi deep Single deep Multi deep Single deep<br />
With<br />
racking<br />
Drive-in<br />
racking<br />
- Drive-in racking<br />
- Drive-through<br />
racking<br />
Static Dynamic<br />
Without<br />
racking<br />
With<br />
racking<br />
Single deep Racks with<br />
block stack beams<br />
- Shelf racking<br />
- Pallet racking<br />
- Cantilever racking<br />
- Drawer racking<br />
- Cassette racking<br />
Compact<br />
storage<br />
racking<br />
With<br />
racking<br />
Flow-through<br />
racking<br />
- Satellites -Motorized<br />
- Highbay- -Gravity<br />
blockstack<br />
-Dynamic<br />
block stack<br />
(Autostore, etc)<br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
With<br />
racking<br />
Carousels AS/R System<br />
-Vertical<br />
carousel<br />
- Horizontal<br />
carousel<br />
On sorter/<br />
picking<br />
system<br />
- Miniload<br />
- AS/RS<br />
- Vertical<br />
carousel<br />
- Horizontal<br />
carousel<br />
- AVS/R System<br />
Mobile<br />
racking<br />
- Mobile rack<br />
- Kiva system<br />
2<br />
4<br />
Without<br />
racking<br />
6<br />
Block<br />
stack<br />
<strong>STORAGE</strong> <strong>SYSTEMS</strong> <strong>OF</strong> <strong>THE</strong> <strong>FUTURE</strong><br />
1. Overview Storage systems<br />
2. Conventional storage systems<br />
3. More advandced storage systems<br />
– AS/R systems<br />
– AVS/R systems<br />
– Compact/live-cube storage systems<br />
– Dynamic storage systems<br />
4. Wrap up<br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
DE KEUZE VAN EEN (OPSLAG)SYSTEEM<br />
Naar welke winkel moet je gaan?<br />
Welke jam is het best?<br />
• Smaak<br />
• Prijs<br />
• Kwaliteit<br />
• Duurzaam<br />
• Uiterlijk, CSR,…etc<br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
<strong>STORAGE</strong> <strong>SYSTEMS</strong><br />
Multi deep Single deep Multi deep Single deep<br />
With<br />
racking<br />
Drive-in<br />
racking<br />
- Drive-in racking<br />
- Drive-through<br />
racking<br />
Static Dynamic<br />
Without<br />
racking<br />
With<br />
racking<br />
Single deep Racks with<br />
block stack beams<br />
- Shelf racking<br />
- Pallet racking<br />
- Cantilever racking<br />
- Drawer racking<br />
- Cassette racking<br />
Compact<br />
storage<br />
racking<br />
With<br />
racking<br />
Flow-through<br />
racking<br />
- Satellites - Motorized<br />
- Highbay- -Gravity<br />
blockstack<br />
-Dynamic<br />
block stack<br />
(Autostore, etc)<br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
With<br />
racking<br />
Carousels AS/R System<br />
-Vertical<br />
carousel<br />
- Horizontal<br />
carousel<br />
11/16/2011<br />
On sorter/<br />
picking<br />
system<br />
- Miniload<br />
- AS/RS<br />
- Vertical<br />
carousel<br />
- Horizontal<br />
carousel<br />
- AVS/R System<br />
Mobile<br />
racking<br />
- Mobile rack<br />
-Kiva system<br />
1
Without<br />
racking<br />
7<br />
9<br />
Block<br />
stack<br />
With<br />
racking<br />
Drive-in<br />
racking<br />
Without<br />
racking<br />
With<br />
racking<br />
Single deep Racks with<br />
block stack beams<br />
<strong>STORAGE</strong> <strong>SYSTEMS</strong><br />
Multi deep Single deep Multi deep Single deep<br />
- Drive-in racking<br />
- Drive-through<br />
racking<br />
2<br />
Static Dynamic<br />
- Shelf racking<br />
- Pallet racking<br />
- Cantilever racking<br />
- Drawer racking<br />
- Cassette racking<br />
Compact<br />
storage<br />
racking<br />
With<br />
racking<br />
Flow-through<br />
racking<br />
- Satellites -Motorized<br />
- Highbay- -Gravity<br />
blockstack<br />
-Dynamic<br />
block stack<br />
(Autostore, etc)<br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
CONVENTIONAL <strong>STORAGE</strong> <strong>SYSTEMS</strong><br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
With<br />
racking<br />
Carousels AS/R System<br />
-Vertical<br />
carousel<br />
- Horizontal<br />
carousel<br />
On sorter/<br />
picking<br />
system<br />
- Miniload<br />
- AS/RS<br />
- Vertical<br />
carousel<br />
- Horizontal<br />
carousel<br />
- AVS/R System<br />
Mobile<br />
racking<br />
- Mobile rack<br />
- Kiva system<br />
Without<br />
racking<br />
8<br />
Block<br />
stack<br />
With<br />
racking<br />
Drive-in<br />
racking<br />
Without<br />
racking<br />
With<br />
racking<br />
Single deep Racks with<br />
block stack beams<br />
<strong>STORAGE</strong> <strong>SYSTEMS</strong><br />
Static Dynamic<br />
Multi deep Single deep Multi deep Single deep<br />
- Drive-in racking<br />
- Drive-through<br />
racking<br />
- Shelf racking<br />
- Pallet racking<br />
- Cantilever racking<br />
- Drawer racking<br />
- Cassette racking<br />
Compact<br />
storage<br />
racking<br />
With<br />
racking<br />
Flow-through<br />
racking<br />
- Satellites - Motorized<br />
- Highbay- -Gravity<br />
blockstack<br />
-Dynamic<br />
block stack<br />
(Autostore, etc)<br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
11 R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
12<br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
10<br />
With<br />
racking<br />
Carousels AS/R System<br />
-Vertical<br />
carousel<br />
- Horizontal<br />
carousel<br />
11/16/2011<br />
On sorter/<br />
picking<br />
system<br />
Mobile<br />
racking<br />
- Miniload - Mobile rack<br />
- AS/RS -Kiva system<br />
- AVS/R System<br />
2
Without<br />
racking<br />
Block<br />
stack<br />
13<br />
15<br />
17<br />
With<br />
racking<br />
Drive-in<br />
racking<br />
Without<br />
racking<br />
With<br />
racking<br />
Single deep Racks with<br />
block stack beams<br />
<strong>STORAGE</strong> <strong>SYSTEMS</strong><br />
Static Dynamic<br />
Multi deep Single deep Multi deep Single deep<br />
- Drive-in racking<br />
- Drive-through<br />
racking<br />
- Shelf racking<br />
- Pallet racking<br />
- Cantilever racking<br />
- Drawer racking<br />
- Cassette racking<br />
Compact<br />
storage<br />
racking<br />
With<br />
racking<br />
Flow-through<br />
racking<br />
- Satellites -Motorized<br />
- Highbay- -Gravity<br />
blockstack<br />
-Dynamic<br />
block stack<br />
(Autostore, etc)<br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
1. AS/RS OPERATED WAREHOUSE<br />
With<br />
racking<br />
Carousels AS/R System<br />
-Vertical<br />
carousel<br />
- Horizontal<br />
carousel<br />
On sorter/<br />
picking<br />
system<br />
Mobile<br />
racking<br />
- Miniload - Mobile rack<br />
- AS/RS - Kiva system<br />
- AVS/R System<br />
Main components: racks, cranes, aisles, I/O-points, and pick positions<br />
Source: http://www.daifukuamerica.com<br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
VARIOUS CONFIGURATIONS IN AS/RS<br />
• Single unit-load aisle-captive AS/RS<br />
• The most basic version of an AS/RS<br />
– has one crane in each aisle, which cannot leave its designated aisle<br />
(aisle-captive) and can transport only one unit-load at a time (single<br />
shuttle)<br />
Source: Roodbergen and Vis, 2009<br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
Rack<br />
Crane<br />
I/O Point<br />
14<br />
16<br />
18<br />
3<br />
MORE ADVANCED <strong>SYSTEMS</strong><br />
1. Single-deep systems:<br />
Traditional:<br />
– Miniload<br />
– AS/RS<br />
– Carousels<br />
Advanced:<br />
– AVS/R systems<br />
– Kiva: movable racks<br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
CRANE-BASED AS/RS (OPERATIONS)<br />
•Typically one crane captive<br />
to an aisle<br />
•Cranes have one or multiple<br />
load carriers (also known as<br />
shuttles; typically one<br />
shuttle/crane)<br />
•Simultaneous) movement of<br />
the crane in the y and z<br />
directions<br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
AS/RS RESEARCH<br />
2. Multi-deep (compact)<br />
systems<br />
Traditional:<br />
– Satellites<br />
– Block stack<br />
Advanced:<br />
– Satellites and lifts<br />
– Autostore<br />
– Live-cube<br />
IO Point<br />
Storage/ Retrieval<br />
Side view of a rack<br />
One of the best researched areas in MH literature (estimate >500<br />
papers), studying every aspect.<br />
What is known (f.e.):<br />
1. Crane cycle time (depending on rack size, storage strategy,<br />
etc.)<br />
2. Optimal shape of the rack<br />
3. Optimal ABC zone shape and size (for given demand Pareto<br />
curve)<br />
4. Optimal number of ABC storage classes<br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
11/16/2011<br />
3
19<br />
21<br />
23<br />
H=20 sec<br />
H=20 m<br />
AS/RS RESEARCH<br />
Pallet storage rack (side view). Rack length=height = 20 sec crane<br />
travel time. Random storage.<br />
What is the average travel time to go to a rack location and back to<br />
the I/O point (neglect acceleration/deceleration)?<br />
I/O point<br />
I/O point<br />
L =20 sec<br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
AS/RS RESEARCH<br />
2. Pallet storage rack (side view). Height 20 m. Optimal length?<br />
L ??<br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
AS/RS RESEARCH<br />
Pallet storage rack (side view). Height 20 m. Optimal length?<br />
Minimize crane travel time<br />
Constraint: rack must have given capacity<br />
Answer: rack must be square in time =<br />
Since crane drives about 4 times faster than it lifts: L≈80 m.<br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
20<br />
22<br />
24<br />
=20 sec<br />
H=20 m<br />
I/O point<br />
I/O point<br />
AS/RS RESEARCH<br />
Travel time: = 27 sec<br />
=20 sec<br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
AS/RS RESEARCH<br />
2. Pallet storage rack (side view). Height 20 m. Optimal length?<br />
L ??<br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
AS/RS RESEARCH<br />
3. Optimal shape and size of the ABC storage area?<br />
Example overhead crane for carpet rolls<br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
11/16/2011<br />
4
25<br />
27<br />
AS/RS RESEARCH<br />
3. Optimal shape and size of the ABC storage area?<br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
AS/RS RESEARCH<br />
I/O point<br />
4. Optimal number of storage classes?<br />
Travel time with the 20%/90% ABC curve<br />
Yu et al. 2011<br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
3. COMPACT <strong>STORAGE</strong><br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
29 R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
26<br />
28<br />
30<br />
AS/RS RESEARCH<br />
3. Optimal shape and size of the ABC storage area?<br />
I/O point<br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
2. AN AVS/RS OPERATED WAREHOUSE<br />
Source: Savoye Logistics (savoye.com)<br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
3. LIVE-CUBE COMPACT <strong>STORAGE</strong><br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
11/16/2011<br />
5
31<br />
33<br />
35<br />
ENVIRONMENTAL IMPACT LIVE <strong>STORAGE</strong><br />
Parking type Live-cube<br />
parking<br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
Traditional<br />
car park<br />
Average (fossil fuel-based) CO2 emission (gram/car) 96 3897<br />
Total electrical (lighting, vent, moving) energy<br />
(kWh/car)<br />
0.12 9.60<br />
In addition: 40%-50% smaller footprint area (smaller building) for the same<br />
number of parking slots (Hyundai Elevator, 2011)<br />
RESEARCH QUESTIONS<br />
Q1: What is the performance (response time) of the<br />
system, given layout, configuration, and storage<br />
strategy<br />
Q2: How to optimize live-cube storage system<br />
dimensions yielding minimum system response<br />
times<br />
Method: mathematical model: min E[ RT ]<br />
Such that<br />
lwhV R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
RESEARCH QUESTIONS<br />
Q: Lift in the middle (same system<br />
capacity)?<br />
A: 20% reduction in response time<br />
compared to a system with lift at the<br />
corner<br />
Q: storage based on duration of stay?<br />
A: 25% shorter travel time for a 20/70<br />
curve.<br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
32<br />
34<br />
RESEARCH QUESTIONS<br />
Q1: What is the performance (response time) of the<br />
system, given layout, configuration, and storage<br />
strategy<br />
Q2: How to optimize live-cube storage system<br />
dimensions yielding minimum system response<br />
times<br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
RESEARCH QUESTIONS<br />
Q1: What is the performance (response time) of the<br />
system, given layout, configuration, and storage<br />
strategy<br />
Q2: How to optimize live-cube storage system<br />
dimensions yielding minimum system response<br />
times<br />
Method: mathematical model:<br />
Such that<br />
lwhV A: Zaerpour et al., 2011: cubic in time is nearly<br />
optimal<br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
min E[ RT ]<br />
4. KIVA GOODS TO MAN <strong>SYSTEMS</strong><br />
36 R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
11/16/2011<br />
6
37<br />
4. KIVA GOODS TO MAN <strong>SYSTEMS</strong><br />
Q: To which rack should we allocate products?<br />
Q: To which rack should we allocate orders?<br />
Q: How to schedule orders and racks?<br />
Q: how many AGVs do we need?<br />
Q: how to schedule the AGVs?<br />
Q: Where to store the racks?<br />
Q: Should one picker pick complete orders, or only a part?<br />
Etc.<br />
R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
WRAP UP<br />
• Er is veel keuze op het gebied van geautomatiseerde<br />
opslagsystemen<br />
• Veel wetenschappelijke resultaten bekend. Vooral van<br />
AS/R systemen.<br />
• Veel nieuwe systemen op de markt die nog nauwelijks<br />
onderzocht zijn<br />
• Nog nauwelijks tools beschikbaar voor gestructureerde<br />
afweging van systemen met meerdere criteria<br />
Kortom, er is veel te beleven op het gebied van<br />
opslagsystemen<br />
Veel keuze en nog veel uit te zoeken!<br />
39 R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
WRAP UP<br />
• Er is veel keuze op het gebied van geautomatiseerde<br />
opslagsystemen<br />
• Veel wetenschappelijke resultaten bekend. Vooral van<br />
AS/R systemen.<br />
• Veel nieuwe systemen op de markt die nog nauwelijks<br />
onderzocht zijn<br />
• Nog nauwelijks tools beschikbaar voor gestructureerde<br />
afweging van systemen met meerdere criteria<br />
38 R. de Koster, MHF 16 nov, Opslagmethoden en technieken<br />
11/16/2011<br />
7
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