Definition
These types of warehouses are often metaphorically termed "stacked warehouses" due to their efficient use of space for storing goods.
Automated Storage and Retrieval Systems (AS/RS) are revolutionary achievements in logistics technology, typically comprising high-rise shelves, aisle stackers, conveyors, control systems, and a Warehouse Management System (WMS). They enable the automated storage and retrieval of unit loads under the control of a computerized system.
Development History
The emergence and development of automated storage and retrieval systems (AS/RS) are the results of production and technological advancements. In the early 1950s, the U.S. saw the introduction of AS/RS using bridge cranes; by the late 1950s and early 1960s, driver-operated aisle cranes in AS/RS emerged; 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/RS has rapidly developed in the U.S. and Europe, forming a specialized discipline. In the mid-1960s, Japan began to develop AS/RS, with its pace accelerating, making it one of the countries with the most automated AS/RS 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 Mechanical Industry); in 1973, China began developing an AS/RS controlled by computers (15 meters tall, responsible by the Lifting Research Institute of the Ministry of Mechanical Industry), which was put into operation in 1980. As of now (2009), China has over 1,200 automated AS/RS. Due to their high space utilization, strong incoming and outgoing capabilities, computerized control and management, and their contribution to modern management, AS/RS have become an indispensable warehousing technology for enterprises, and are increasingly valued by businesses.
Application
Automated vertical storage systems have a wide range of applications, covering nearly all industries. In China, the main industries utilizing automated high-rise warehouses include machinery, metallurgy, chemicals, aerospace, electronics, libraries, 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 Bay Racking: A steel structure used for storing goods. Currently, there are two basic types: welded racking and assembled racking.
4.2 Pallet (Container): A device used for carrying goods, also known as a work station tool.
4.3 Conveyer Stacker: Equipment for automatic loading and unloading of goods. Divided into two basic types by structure: single-column and double-column; and into three basic types by service method: straight-line, curved-line, and transfer vehicle.
4.4 Conveyor System: A key peripheral equipment of the automated storage and retrieval system (AS/RS), responsible for transporting goods to or from the stacker. There are many types of conveyors, including roller conveyors, chain conveyors, lifting platforms, distribution carts, hoists, and belt conveyors, among others.
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 the various equipment of 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 vertical storage system. Currently, typical automated vertical storage systems all use large database systems (such as ORACLE, SYBA)Establish typical client/server architectures (such as se) that can be networked or integrated with other systems (like ERP systems).
Superiority
The advantages of automated vertical warehouses are multifaceted, and for businesses, they can be demonstrated in the following aspects:
Space Utilization
5.1 Enhance Space Utilization: The initial concept of early three-dimensional warehouses was centered around enhancing space utilization, fully conserving 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 treat the space utilization rate as a crucial indicator for evaluating the rationality and advancement of the system. The space utilization of a three-dimensional warehouse is closely related to its planning. Generally speaking, automated high-rise warehouses have a space utilization rate 2-5 times higher than that of ordinary flat warehouses, which is quite remarkable.
Logistics System
5.2 Facilitates the formation of advanced logistics systems and improves the management level of corporate production. Traditional warehouses are merely places for storing goods, with the function of preservation, representing a "static storage." Automated vertical warehouses utilize advanced automated material handling equipment, enabling not only the automatic storage and retrieval of goods within the warehouse as needed but also an organic connection with production processes outside the warehouse. Through computer management systems and automated material handling equipment, the warehouse becomes an important link in the corporate production logistics. The entry of externally purchased parts and self-manufactured production parts into the automated warehouse storage is a stage in the entire production process, with short-term storage intended to automatically output to the next production stage, thereby forming an automated logistics system. This is a "dynamic storage" and 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 (ranging from ordering, necessary design and planning, scheduling and production arrangement, manufacturing, assembly, testing, shipment, etc.). Establishing real-time connections between the logistics system and the corporate management system is another clear technical trend in the development of modern automated high-bay warehouses. Modern enterprises have higher requirements for management, and the "management generates 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, procurement of external equipment, product quality, cost estimation, and more. The automated elevated storage system serves as a central link in the production process, almost involved in the entire production management process.
Access pace
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-rise storage. It can swiftly and properly store goods in the high-rise storage (inventory), and also deliver the required parts and raw materials to the production line quickly, accurately, and automatically. 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 with automated aisle stackers for storing and retrieving goods, which is both quick and labor-saving. As workers do not need to enter the warehouse, the working environment is significantly improved. 2) Implementing a computerized management system for goods management, greatly enhancing management capabilities, making warehouse management scientific, and improving accuracy and reliability. Tasks like inventory management, inventory taking, and reporting become simpler and faster, significantly reducing labor intensity. 3) Supporting the system with auxiliary conveying equipment at the warehouse entrance, making inventory handling simpler and more convenient. 4) The automated three-dimensional warehouse system requires very few operators and system maintenance personnel, saving human and material resources, reducing costs, and improving the working environment, achieving multiple benefits with one move.
Excess inventory
5.4 Reducing Inventory Capital Tie-up After investigating some large enterprises, it has been found that due to historical reasons, management methods are outdated, material management is scattered, making it difficult to establish a tight connection between production management and production processes. To achieve expected production capacity and meet production requirements, sufficient raw materials and components must be prepared, which leads to a significant inventory tie-up issue. How to reduce inventory capital tie-up and fully meet production needs has become a major problem that large enterprises must face. The high-level storage system is one of the effective means to solve this problem. 1) A factory logistics system centered around an automated storage system addresses circulation issues 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 enables more timely and demand-matching procurement of raw materials and purchased components. 3) The establishment of a computer management system strengthens macro-control functions, making production quantities in various stages more responsive to actual needs. 4) Establishing finished product and semi-finished product warehouses helps address temporary discrepancies in market supply and demand, fully leveraging the company's production potential. 5.5 Symbol of Modernized Enterprises Modernized enterprises adopt an intensive large-scale production model, requiring close connections between all stages of production to form an organic whole. Production management must be scientific and practical, with decision-making being scientific. Therefore, establishing an automated high-level storage system is one of the effective measures. As previously mentioned, the automated logistics system has unparalleled advantages in maximizing space utilization, meeting production requirements, reducing labor intensity, improving production efficiency, strengthening production and material management, and reducing inventory capital tie-up. This aligns with what modernized 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 timely understand inventory information for the purpose of arranging production processes and improving efficiency. The Internet and Intranet provide a vast space and robust technical support for online connections with the outside world, breaking information bottlenecks, broadening horizons, and facilitating both external and internal integration. Overall, since the 1960s, large enterprises both domestically and internationally have gradually adopted automated logistics systems, which have become an indispensable part of corporate production management. According to relevant statistics, Japan has already established over 8,000 automated storage systems (logistics systems). Establishing an automated storage system has become one of the important symbols of modernized enterprises.
