DISEÑO DE SISTEMAS DE PRODUCCIÓN 2021

UNIVERSIDAD MILITAR NUEVA GRANADA

FACULTAD DE INGENIERIA
SECCIONAL VILLA ACADÉMICA
PROGRAMA DE INGENIERIA INDUSTRIAL
Work in Class No 3 - Part B
12 de noviembre de 2021

1. An AS/RS is to be designed for the storage of 60”X48” unit loads. The S/R machine will
travel horizontally at a speed of 500 fpm; simultaneously, it will travel vertically at a speed
of 80 fpm. The storage aisle will be 400’ long and 60’ tall. The pick-up and deposit station
will be located at the end of the aisle and will be elevated 20’ above floor level. Assume
randomized storage will be used and the storage region served by the S/R is a continuous,
rectangular region 400’X60’. The P/D time will be 0.30 minute.

a. Determine the single-command cycle time, including P/D times.

b. Determine the dual-command cycle time, including P/D times.
c. Suppose three classes of products are to be stored in the storage aisle. Fast movers will
be stored in a rectangular region defined by the following coordinates: (0,0), (0,40),
(125,40), and (125,0). Medium movers will be stored in an L-shaped region between the
fast and slow movers. Slow movers will be stored in a rectangular region defined by
(250,0), (250,60), (400,60), and (400,0). Fast movers represent 60% of the storage and
retrieval operations performed; medium movers account for 30% of the activity; slow
movers represent the balance. Determine the average single-command cycle time,
including P/D times.

2. In deriving the cycle time equations, the I/O point was assumed to be located at the lower
lefthand corner of the rack. Based on the particular type of hardware involved, however,
the exact location of the I/O point may not coincide with the lower lefthand corner of the
rack. In fact, suppose the I/O point is located 12’ from the lower lefthand corner of the rack,
as shown below:

Further assume that the storage rack is small-say, 150’ long and 30’ high. The S/R
machine travels at 400 fpm and 80 fpm in the horizontal and vertical directions,

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DISEÑO DE SISTEMAS DE PRODUCCIÓN 2021
respectively. Calculate the expected S/R machine travel time for single- and dual-
command cycles for the above case. Note: In traveling from the I/O point to a location in
the rack (and vice versa), the S/R machine is not required to pass through the lower
lefthand corner of the rack. Compare your results with the expected travel times obtained if
the I/O point is assumed to be located at the lower lefthand corner of the rack; show the
percent difference.

3. An AS/R system is being designed for 42”X48” unit loads that are 42” high. One of the
design alternatives involves eight aisles, no transfer cars, 1,100 openings per aisle, 11
levels and 50 columns of storage on each side of the aisle, and sprinklers. The S/R will
travel horizontally at an average speed of 300 fpm; simultaneously, it will travel vertically at
an average speed of 70 fpm. The time required for the shuttle to perform either a pickup
(P) or a deposit (D) operation is 0.35 minute. Each S/R will have to store and retrieve at a
rate of 18 storages per hour and 18 retrievels per hour. Due to the uncertainty concerning
the proportion of the operations that will be single command versus dual command, you
are to determine the maximum percentage of single command operations so that utilization
of the S/R does not exceed 85%. Also, the costs of the building, rack, and S/R machines
are to be determined. Assume 2,000 lb loads, off-board computer controls (but not a
central console), and a 20 USD/ft2 building cost for a 25’-high building.

4. An AS/RS is to be designed for a 40”X48” unit load that is 48” high. There are eight aisles;
each aisle is 12 loads high and 50 loads long. There are to be sprinklers and no transfer
cars. It takes 0.30 minute to perform a P/D operation. The S/R travels horizontally at a
speed of 300 fpm and travels vertically at a speed of 60 fpm. Thirty percent of the
retrievals and 30% of the storages are single-command operations.

a. How many storages per hour and retrievals per hour can each S/R handle without being
utilized more than 90%?
b. Estimate the cost of racks, S/R machines, and the building. Assume it costs 25USD/ft2
to build a 25’-high building, loads weigh 3,000 lb, there is a central console, and the
structure is conventional (not rack supported).

5. An AS/R system is to be designed to store approximately 12,000 loads. Due to space

limitations in the existing facility, it is known that the system will have eight tiers of storage.
The choice has been reduced to having either (a) 10 aisles, 75 openings long, (b) 9 aisles,
84 openings long, or (c) 8 aisles, 94 openings long. The S/R will travel horizontally at an
average speed of 450 fpm; simultaneously, it will travel vertically at an average speed of
80 fpm. 48”X40” unit loads, 44” high and weighing 2,500 lb, are to be stored. The I/O point
is located at the end of the aisle, at floor level. The time required to pick up (P) or to
deposit (D) a load is 0.30 minute. The throughput requirement on the system is to perform
a total of 180 storages per hour and 180 retrievals per hour. Randomized storage is used.
Forty percent single-command operations are anticipated. A maximum utilization of 95%
can be planned for an individual S/R. A central computer console is to be used to control
the S/Rs. Determine the least-cost alternative that satisfies the throughput constraint.
Consider only rack cost and S/R machine cost; do not consider building cost. (Assume
sprinklers and no transfer cars are to be used.)

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