AS/RS - EXERCISES

1. Each aisle of a six –aisle Automated Storage/Retrieval System is to contain 50 storage

compartments in the length direction and eight compartments in the vertical direction. All
storage compartments will be the same size to accommodate standard size pallets of
dimensions: x= 36in and y = 48in. The height of a unit load z = 30in. Using the allowances, a=
6in, b =8in, and c=10in, determine:
(a) how many unit loads can be stored in the AS/RS and
(b) the width, length, and height of the AS/RS. The rack structure will be built 18in in above
floor level

2. A unit load AS/RS is being designed to store 1000 pallet loads in a distribution center located
next to the factory. Pallet dimensions are x= 1000 mm, y = 1200mm, and the maximum height
of a unit load =1300mm. The following is specified:
(1) the AS/RS will consist of two aisles with one S/R machine per aisle,
(2) length of the structure should be approximately five times its height, and
(3) the rack structure will be built 500 mm above floor level. Using allowances, a= 150 mm,
b=200 mm, and c= 250mm, determine the width, length and height of the AS/RS rack structure

3. The length of the storage aisle in an AS/RS 240ft and its height = 60ft. Suppose horizontal
and vertical speed of the S/R machine are 300ft/min and 60ft/min, respectively. The S/R
machine requires 18 sec to accomplish a pick-and-deposit operation. Find
(a) the single command and dual command cycle time per aisle and
(b) throughput for the aisle under the assumption that storage system utilization = 85% and the
numbers of single command and dual command cycle are equal.

4. Consider the AS/RS is to contain 60 storage compartments in the length direction and 12
compartments vertically. The length of storage aisle = 280ft and its height =46 ft. supposes
horizontal and vertical speed of S/R machine are 200ft/ min and 75ft/ min respectively. The
S/R machine requires 20 sec to accomplish a P&D operation. Find
(a) the single command and dual command cycle time per aisle, and
(b) through put per aisle under the assumptions that storage system utilization = 90% and the
number of single command and dual command cycle are equal

5. An AS/RS is used for work-in-process storage in a manufacturing facility. The AS/SR has
five aisles, each aisle being 120 ft long and 40 ft heigh. The horizontal and vertical speed of
S/R machine is 400 ft/min and 500 ft/min, respectively. The S/R machine requires 21 sec to
accomplish pick and deposit operation. The number of single commands cycles used is equal
to dual commands cycles. If the requirement is that the AS/RS must have a throughput rate of
200 S/R transactions /hr during periods of peak activity, will the AS/RS satisfy this
requirement? If so, what is the utilization of the AS/RS during peak hours?
6. An automated storage/retrieval system installed in a warehouse has five aisles. The storage
racks in each aisle are 30 ft high and 150 ft long. The S/R machine for each aisle travels at a
horizontal speed of 350ft/min and vertical speed of 60 ft/min. The pick-and-deposit time = 0.35
min. Assume that the number of single command cycles per hr is equal to the number of dual
command cycle per hr and that the system operates at 75%
utilization. Determine the throughput rate (load moved per hr) of the AS/RS.

7. A unit load AS/RS for work-in-process storage in a factory must be designed to store 2000
pallets loads, with an allowance of no less than 20% additional storage compartments for peak
period and flexibility. The unit load pallet dimensions are: depth (x) = 36 in and width (y) = 48
in. Maximum height of unit load = 42 in. It has been determined that the AS/RS will consist of
four aisles with one S/R machine per aisle. The maximum height (interior) of the building
permitted by local ordinance is 60 ft. so the AS/RS must fit within this height limitation. The
rack level will be made 2ft above floor level. And the clearance between the rack structure and
the ceiling of the building must be at least 18 in. determine the dimension (height, length, and
width) of the rack structure

8. An automated storage/retrieval system for work-in-process has six aisles. The storage racks
in each aisle are 12 m high and 60 m long. The S/R machine for each aisle travels at a horizontal
speed of 3.0 m/sec and a vertical speed of 0.5 m/sec. Pick-and-deposit time = 20 sec. Assume
that the number of single-command cycles/hr is equal to three times the number of dual-
command cycles/hr and that the system operates at 80% utilization. Determine the throughput
rate (loads moved/hr) of the AS/RS.

9. The length of one aisle in an AS/RS is 80 m and its height is 16 m. Horizontal travel speed
is 3.0 m/sec. The vertical speed is specified so that the storage system is “square in time,” which
means that L/vy = H/vz. The pick-and-deposit time is 15 sec. Determine the expected
throughput rate (transactions/hr) for the aisle if the expected ratio of the number of transactions
performed under single-command cycles to the number of transactions performed under dual-
command cycles is 3:1. The system operates continuously during the hour.

10. A single carousel storage system is located in a factory making small assemblies. It is 12
m long and 0.5 m wide. The pick – and – deposit time is 0.15 min. The speed at which the
carousel operates is 0.5 m/sec. The storage system has a 80% utilization. Determine the hourly
throughput rate.

11. A storage system serving an electronics assembly plant has six storage carousels, each with
its own manually operated pick- and -deposit station. The pick-and-deposit time is 0.20min.
Each carousel is 60 ft long and 3 ft wide. The speed at which the system revolves is 75 ft/min.
Determine the throughput rate of the storage system.

12. A single carousel storage system has an oval rail loop that is = 60 ft long and 2 ft wide.
Sixty carriers are equally spaced around the oval. Suspended from each carrier are four bins.
Each bin has a volumetric capacity = 1 ft^3. Carousel speed = 150 ft/min. Average pick-and-
deposit time for a retrieval = 15 sec. Determine
a) Volumetric capacity of the storage system and
b) Hourly retrieval rate of the storage system.