Definition

Due to their ability to fully utilize space for storing goods, these warehouses are often metaphorically referred to as "three-dimensional warehouses."

Automated Storage and Retrieval Systems (AS/RS) represent a revolutionary achievement in logistics technology. Typically comprising high-rise racks, aisle stackers, conveyors, control systems, and a Warehouse Management System (WMS), they enable the automated storage and retrieval of unit loads under computer system control.

History of Development

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 advent of AS/RS using bridge cranes; by the late 1950s and early 1960s, driver-operated aisle cranes for AS/RS 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. Subsequently, AS/RS automated systems rapidly expanded in the U.S. and Europe, evolving into a specialized field. In the mid-1960s, Japan began to develop AS/RS, with increasing speed, and became one of the countries with the most AS/RS in the world. China's research and development of AS/RS and material handling equipment did not lag behind; in 1963, a bridge crane was developed (by the Beijing Research Institute of Lifting and Transportation Machinery of the Ministry of Machinery); in 1973, China began to develop an AS/RS controlled by computers (15 meters tall, responsible by the Lifting Machinery Research Institute of the Ministry of Machinery), 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 inbound and outbound capabilities, and computerized control management, AS/RS have become an indispensable warehousing technology for corporate logistics and production management, and are increasingly valued by businesses.

Application

Automated vertical storage systems are widely applied across almost all industries. In China, the main industries utilizing automated elevated warehouses include machinery, metallurgy, chemicals, aerospace, electronics, books, food processing, tobacco, printing, distribution centers, airports, and ports.

Basic Composition

The automated vertical warehouse 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 racks and assembled racks.

4.2 Pallet (Container): A device used to carry 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 structures; and into three basic types of service methods: straight, curved, and transfer car.

4.4 Conveying System: The main peripheral equipment of the vertical storage system, 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: Automatic 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 of the automated storage and retrieval system. Currently, fieldbus-based control mode is predominantly 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-scale database systems (such as ORACLE, SYbase).Build typical client/server architectures (e.g., SE) that can be networked or integrated with other systems (e.g., 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 and fully conserving the limited yet valuable land. In some developed countries in the West, the idea of improving space utilization has taken on a broader and more profound meaning, where conserving land is linked with energy conservation, environmental protection, and more. Some even treat space utilization as a key indicator for assessing the rationality and advancement of a 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 ordinary flat warehouses, which is quite remarkable.

Logistics System

5.2 Facilitates the development 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 being their primary role, a "static storage" method. 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 organic connections with production processes outside the warehouse. Through computer management systems and automated material handling equipment, the warehouse becomes a crucial link in the corporate production logistics. The storage of externally purchased parts and self-manufactured production components in an automated warehouse is a part of the entire production process, with short-term storage intended for automatic transfer to the next production stage, thereby forming an automated logistics system. This is a "dynamic storage" method and represents a clear technical trend in the development of 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 arrangement, manufacturing, assembly, testing, dispatch, etc.). Establishing real-time connections between the logistics system and the corporate management system is another clear technical trend in the development of 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 corporate management, encompassing product planning, production organization, logistics planning, external procurement, product quality, cost estimation, and more. As a central element in the production process, the automated high-bay storage system is almost involved in the entire production management process.

Withdrawal and deposit rhythm

5.3 Accelerate the pace of goods handling, reduce labor intensity, and enhance production efficiency. Establish a logistics system centered around an automated multi-level warehouse, which boasts superiorities such as the rapid intake and output capabilities of the automated high-rise storage. It can swiftly and properly store goods in the high-rise storage (intake) and also deliver the required parts and raw materials to the production line quickly, timely, and automatically. This feature is unattainable by conventional flat warehouses. Additionally, the implementation of an automated multi-level warehouse is a typical example of reducing labor intensity. This reduction is comprehensive, including: 1) Replacing manual storage and retrieval with automated aisle stackers, which is both quick and labor-saving. As workers do not need to enter the warehouse, the working environment is significantly improved. 2) Using a computer management system to manage goods greatly enhances management capabilities, making warehouse management scientific, with improved accuracy and reliability. Tasks like intake/output management, inventory, and reporting become simpler and faster, significantly reducing labor intensity. 3) The multi-level storage system is supplemented by auxiliary conveying equipment at the warehouse entrance, simplifying and facilitating intake/output operations. 4) The automated multi-level warehouse system requires few operators and system maintenance personnel, saving both human and material resources, conserving funds, and improving the working environment, achieving multiple benefits with one move.

Excess Inventory

5.4 Reducing Inventory Capital Tie-Up Through investigations of some large enterprises, it has been found that due to historical reasons, management methods are outdated and 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, an adequate supply of raw materials and components is necessary. This leads to significant inventory tie-up. How to reduce inventory capital tie-up and fully meet production needs has become a major challenge 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 circulation and supply-demand conflicts in various production stages, ensuring that the supply of raw materials and the production of components meet optimal values. 2) The establishment of a computer network system enables more timely and demand-matching procurement of raw materials and components. 3) The establishment of a computer management system strengthens macro-control functions, allowing production stages to better meet actual demands. 4) The establishment of finished goods and semi-finished goods warehouses addresses temporary inconsistencies in market supply and demand, fully utilizing the company's production potential. 5.5 The Symbol of a Modern Enterprise Modern enterprises adopt an intensive, large-scale production model, which requires close connections between all stages of production to form an integrated whole. Production management must be scientific and practical, with decision-making being scientifically based. To achieve this, establishing an automated high-bay storage system is one powerful measure. As previously mentioned, automated logistics systems offer unparalleled advantages in maximizing space utilization, meeting production demands, reducing labor intensity, enhancing production efficiency, strengthening production and material management, and reducing inventory capital tie-up. This aligns with what modern enterprises require and pursue. With 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 optimal production process planning and efficiency improvement. The Internet and enterprise Intranet provide extensive space and robust technical support for online connectivity, breaking through information bottlenecks, broadening horizons, and promoting external and internal integration. Looking at large enterprises globally, since the 1960s, the gradual adoption of automated logistics systems has become an indispensable part of corporate production management. According to statistics, Japan has already established over 8,000 automated high-bay warehouses (logistics systems). The establishment of an automated high-bay storage system has become one of the important symbols of a modern enterprise.