Quantitative analysis of

AS/RS & Carousal Systems

• Sizing of storage structure
• Stress & load analysis of the structure
• Performance characteristics
 Sizing of the AS/RS structure
• Total storage capacity of one storage aisle
depends on---
– How many storage compartments are
arranged horizontally & vertically in the aisle.
– Refer figure 11.7
Sizing of the AS/RS structure
Sizing of the AS/RS structure
Sizing of the AS/RS structure
Sizing of the AS/RS structure
 AS/RS Throughput
• It is defined as the hourly rate of S/R
transmissions that the AS system can perform.
• Transaction:
– Depositing a load into storage or retrieving a load
from storage.
• Single command cycle
– Either one of the transactions alone is accomplished
• Dual command cycle
– Accomplishes both transaction types in one cycle
– Throughput is increased in dual command cycle
(reduces travel time per transaction)
 AS/RS Cycle time
• Several methods available
• Method recommended by Material Handling Institute is
presented
• Assumptions:
– Randomized storage of loads in the AS/RS
– Storage compartments are equal in size
– P&D stations are located at the base and end of aisle
– Constant horizontal & vertical speeds of S/R machine
– simultaneous horizontal & vertical travel
– for a single command cycle, the load to be entered or retrieved is
assumed to be located at the centre of the rack structure.
• So, S/R machine must travel half the length and half the height of the
AS/RS.
– for a dual command cycle: travel to center of the rack to deposit
and ¾ length and height for retrieval
AS/RS Cycle time-single & Dual command cycle

Two P&D times reqd per cycle representing load transfers to and from the
S/R machine.
AS/RS Cycle time-single & Dual command cycle
 System Throughput
• Throughput per hour depends on the relative number of
single & dual command cycles performed by the system
per hour.
Rcs  number of single command cycles performed per hour
Rcd  number of dual command cycles performed per hour
U  system utilization per hour

• Amount of time spent in performing single & dual

command cycles per hour is,

• 60U=total number of minutes of operation per hour

 Total hourly cycle rate
• The relative proportions of RCS and RCd
must be determined or assumed
• Then, the total hourly cycle rate is,
Total number of transactions per hour
Example: AS/RS Throughput analysis
Solution
Solution
Solution
 Example
• A 10-aisle automated storage/retrieval system is
located in an integrated factory-warehouse
facility. The storage racks in each aisle are 18 m
high and 95 m long. The S/R machine for each
aisle travels at a horizontal speed of 2.5 m/s and
a vertical speed of 0.5 m/s. Pick and deposit
time = 20 s. Assume that the number of single
command cycles per hour is one-half the
number of dual command cycles per hour and
that the system operates at 80% utilization.
Determine the throughput rate (loads
moved/hour) of the AS/RS.
 Solution

 0.5(95) 0.5(18) 
Tcs = 2 Max  ,  + 2(20) = 78 s/cycle = 1.30 min/cycle
 2.5 0.5 
 0.75(95) 0.75(18) 
Tcd = 2 Max  ,  + 4(20) = 137 s/cycle = 2.283 min/cycle
 2.5 0.5 
1.3 Rcs + 2.283 Rcd = 60(0.80) = 48.0 min
Given Rcs = 0.5 Rcd, 1.3(0.5 Rcd) + 2.283 Rcd = 2.933 Rcd = 48 Rcd = 16.36 cycles/hr
Rcs = 0.5 Rcd = 0.5(16.36) = 8.182 cycles/hr
Rt = Rcs + 2Rcd = 8.182 + 2(16.36) = 40.91 transactions/hr
With 10 aisles, Rt = 10(40.91) = 409.1 transactions/hr
 Carousal storage systems
• A typical carousal system is likely to have higher
throughput rates than AS/RS
 Storage capacity
• Individual bins or baskets are suspended
from carriers that revolve around the
carousal oval rail.
• The circumference of the rail is,
Storage capacity
Storage capacity
 S/R Cycle time
• Assumptions:
– Only single command cycles are performed. A bin is
accessed in the carousal either to put items into storage or to retrieve
one or more items from storage.
– The carousal operates with a constant speed.
Acceleration deceleration effects are ignored.
– Random storage is assumed
– Carousal can move in either direction. So, Bidirectional
movement.
– Mean travel distance between load/unload station and
a bin randomly located in the carousal is C/4.
S/R Cycle time & number of transactions
Example
Solution
Solution