Definition
Due to their ability to maximize space for storing goods, these warehouses are often metaphorically referred to as "stacked warehouses."
The Automated Storage and Retrieval System (AS/RS) is a revolutionary achievement in logistics technology, typically comprising high-rise racks, aisle stackers, conveyors, control systems, and a Warehouse Management System (WMS). It facilitates the automated storage and retrieval of unit loads under the control of a computer system.
Development History
The emergence and development of automated storage and retrieval systems (AS/RS) are the result of production and technological advancements. In the early 1950s, the United States saw the birth of AS/RS using bridge cranes; by the late 1950s to early 1960s, driver-operated aisle cranes were introduced. In 1963, the U.S. was the first to adopt computer control technology in high-bay warehouses, establishing a computer-controlled AS/RS. Since then, AS/RSs have rapidly developed in the U.S. and Europe, forming a specialized field. In the mid-1960s, Japan began to develop AS/RSs, with increasing speed, becoming one of the countries with the most AS/RSs in the world today. China's research and development of AS/RS and material handling equipment did not start late; in 1963, a bridge crane was developed (by the Beijing Research Institute of Lifting and Transportation Machinery of the Ministry of Machinery), and in 1973, China started developing an automated AS/RS under computer control (15 meters tall, responsible by the Lifting Institute of the Ministry of Machinery). This system was put into operation in 1980. As of now (2009), China has over 1,200 automated AS/RSs. AS/RSs, with their high space utilization, strong inventory handling capabilities, and computerized control management, are essential for modern management in enterprises and are increasingly valued.
Applied
Automated vertical warehouse applications are widespread, covering nearly all industries. In our country, the main industries utilizing automated high-bay warehouses include machinery, metallurgy, chemicals, aerospace, electronics, books, food processing, tobacco, printing, distribution centers, airports, and ports.
Basic Components
The automated vertical storage system is essentially composed of the following parts:
4.1 High-rack storage: Steel structure used for storing goods. Currently, there are mainly two basic types: welded shelves and assembled shelves.
4.2 Pallet (Container): A device used for carrying goods, also known as a work station tool.
4.3巷道堆垛机: Equipment for automatic storage and retrieval of goods. Divided into two basic types: single-column and double-column, and three basic types of service methods: straight, curved, and transfer vehicle.
4.4 Conveying System: A primary peripheral equipment of the立体仓库, responsible for transporting goods to or from the stacker. There are numerous types of conveyors, commonly including roller conveyors, chain conveyors, lift platforms, distribution vehicles, hoists, belt conveyors, and more.
4.5 AGV System: Automated Guided Vehicle. Divided into inductive guided vehicles and laser guided vehicles based on their guidance methods.
4.6 Automatic Control System: The automatic control system for driving various equipment in the automated storage and retrieval system. Currently, fieldbus-based control mode is primarily used.
4.7 Inventory Information Management System (WMS): Also known as the Central Computer Management System. It is the core of a fully automated three-dimensional storage system. Currently, typical automated three-dimensional storage systems all use large database systems (such as ORACLE, SYbase).Build a typical client/server architecture with SEs (etc.), which can be networked or integrated with other systems (such as ERP systems).
Superiority
The advantages of an automated vertical warehouse are multifaceted, and for businesses, they can be reflected in the following aspects:
Space utilization
5.1 Enhance Space Utilization: The initial concept of early vertical warehouses was fundamentally centered around enhancing space utilization, aiming to fully conserve the limited and valuable land. In some developed countries in the West, the idea of improving space utilization has taken on a broader and deeper meaning, with land conservation being linked to energy conservation, environmental protection, and more. Some even consider the space utilization rate as a crucial indicator for evaluating the rationality and advancement of the system. The space utilization of a vertical warehouse is closely related to its planning. Generally speaking, automated high-rise warehouses have a space utilization rate that is 2-5 times higher than that of conventional flat warehouses, which is quite remarkable.
Logistics System
5.2 Facilitates the formation of advanced logistics systems, enhancing corporate production management levels. Traditional warehouses are merely places for storing goods; preserving goods is their function, a form of "static storage." Automated vertical warehouses utilize advanced automated material handling equipment, enabling not only automatic storage and retrieval of goods within the warehouse as needed but also organic connections with production processes outside the warehouse. Through computerized management systems and automated material handling equipment, the warehouse becomes a crucial component of the company's production logistics. The storage of externally purchased parts and self-manufactured production parts in an automated warehouse is a stage in the entire production process. Short-term storage is to automatically output to the next production stage, thereby forming an automated logistics system, a "dynamic storage" that is also a clear technical trend in the development of modern automated warehouses. The aforementioned logistics system is also a subsystem of the overall corporate production management system (from ordering, necessary design and planning, scheduling and production arrangements, manufacturing, assembly, testing, shipment, and more). Establishing real-time connections between the logistics system and the company's large-scale system is another clear technical trend in the development of modern automated high-bay warehouses. Modern enterprises demand higher management standards, and the "management creates benefits" mindset has become a consensus among most modern corporate managers.
Production management is a crucial component of enterprise management, encompassing product planning, production organization, logistics planning, outsourced equipment, product quality, cost estimation, and more. As a central part of the production process, the automated high-bay storage system is virtually involved in the entire production management process.
Deposit and withdrawal rhythm
5.3 Accelerate the pace of goods handling, reduce labor intensity, and enhance production efficiency. Establish a logistics system centered around an automated three-dimensional warehouse, which boasts superiorities such as the rapid incoming and outgoing capabilities of the automated high-rack storage. It can swiftly and properly store goods in the high-rack storage (inventory), as well as promptly and automatically deliver the required components and raw materials to the production line. This feature is unattainable by conventional flat warehouses. Additionally, the implementation of an automated three-dimensional warehouse is a typical example of reducing labor intensity. This reduction is comprehensive, including: 1) Replacing manual handling of goods with automated aisle stackers, which is both quick and labor-saving. Since workers do not need to enter the warehouse, the working environment is greatly improved. 2) Using a computer management system for goods management, significantly enhancing management capabilities and making warehouse management scientific, with substantial improvements in accuracy and reliability. Tasks such as inventory management, inventory taking, and reporting become simpler and quicker, greatly reducing the labor intensity. 3) Supporting the three-dimensional storage system with auxiliary conveying equipment at the warehouse entrance, making incoming and outgoing operations more straightforward and convenient. 4) The automated three-dimensional warehouse system requires minimal personnel for operation and system maintenance, saving both labor and resources, as well as conserving funds. It also improves the working environment, achieving multiple benefits with a single move.
Excess inventory
5.4 Reducing Inventory Capital Pressure Through investigations of some large enterprises, it has been found that due to historical reasons, management methods are outdated, material management is scattered, and the close connection between production management and production processes is difficult to achieve. To reach the expected production capacity and meet production requirements, sufficient raw materials and components must be prepared, leading to significant inventory accumulation. How to reduce inventory capital pressure and fully meet production needs has become a major issue for large enterprises. The high-bay racking system is one effective means to address this issue. 1) A factory logistics system centered around automated storage solves the circulation problems and supply-demand conflicts in various production stages, allowing the supply of raw materials and the production of components to reach an optimal value. 2) The establishment of a computer network system makes the procurement of raw materials and purchased components more timely and meets actual demand. 3) The establishment of a computer management system strengthens macro-control functions, making production quantities in various stages more responsive to actual demand. 4) Establishing finished product and semi-finished product warehouses addresses temporary inconsistencies in market supply and demand, fully leveraging the company's production potential. 5.5 Symbol of Modern Enterprises Modern enterprises adopt an intensive large-scale production model, requiring close connections between all stages of production to form an integrated whole. Production management must be scientific and practical, with decision-making being scientific. Establishing an automated high-bay warehouse system is one powerful measure to achieve this. As previously mentioned, an automated logistics system offers unparalleled advantages in maximizing space utilization, meeting production requirements, reducing labor intensity, improving production efficiency, strengthening production and material management, and reducing inventory capital pressure. This aligns with what modern enterprises require and pursue. Due to the adoption of computer management and network technology, it is now possible for corporate leaders to quickly grasp various material information and for engineers, production managers, and technical staff to promptly understand inventory information to arrange production processes and improve efficiency. The Internet and enterprise intranet provide a vast space and robust technical support for online connections, breaking information bottlenecks, broadening horizons, and promoting external and internal integration. Looking at large enterprises domestically and internationally, since the 1960s, the gradual adoption of automated logistics systems has become an indispensable part of enterprise production management. According to statistics, Japan has already built over 8,000 automated high-bay warehouses (logistics systems). Establishing an automated high-bay warehouse system has become one of the important symbols of modern enterprises.
