BMFA 3443 INDUSTRIAL AUTOMATION SEM 2, 2015/2016

Tutorial 2: Storage Systems

Sizing the AS/RS Rack Structure

1. Each aisle of a six-aisle Automated Storage/Retrieval System is to contain 50 storage compartments in the
length direction and 8 compartments in the vertical direction. All storage compartments will be the same
size to accommodate standard size pallets of dimensions: x = 36 in and y = 48 in. The height of a unit load z
= 30 in. Using the allowances a = 6 in, b = 8 in, and c = 10 in, 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 18
in above floor level.
Answer: a) 4800 loads b) 63 ft, 233.33 ft, 28.167 ft.

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 = 1200 mm; and the maximum height of a unit load = 1300
mm. 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 the allowances a = 150 mm, b = 200 mm, and c = 250 mm, determine the
width, length, and height of the AS/RS rack structure.
Answer: W = 6.9 m, L = 50.4 m, H = 11.35 m

3. Given the rack structure dimensions computed in Problem 11.2. Assuming that only 75% of the storage
compartments are occupied on average, and that the average volume of a unit load per pallet in storage =
0.90 m3, compute the ratio of the total volume of unit loads in storage relative to the total volume occupied
by the storage rack structure.
Answer: 18.03%

AS/RS Throughput Analysis

4. The length of the storage aisle in an AS/RS = 240 ft and its height = 60 ft. Suppose horizontal and vertical
speeds of the S/R machine are 400 ft/min and 60 ft/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 times per
aisle, and (b) throughput for the aisle under the assumptions that storage system utilization = 85% and the
number of single command and dual command cycles are equal.
Answer: a) 1.6 min/cycle, 2.7 min/cycle b) 35.58 S/R transactions/hr

5. An AS/RS is used for work-in-process storage in a manufacturing facility. The AS/RS has five aisles, each
aisle being 120 ft long and 40 ft high. The horizontal and vertical speeds of the S/R machine are 400 ft/min
and 50 ft/min, respectively. The S/R machine requires 12 sec to accomplish a pick and deposit operation. The
number of single command cycles equals the number of dual command cycles. If the requirement is that the
AS/RS must have a throughput rate of 200 S/R transactions per hour 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.
Answer: 281.25 S/R transactions/hr, 71.1%

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 350

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BMFA 3443 INDUSTRIAL AUTOMATION SEM 2, 2015/2016

ft/min and a vertical speed of 60 ft/min. The pick and deposit time = 0.25 min. Assume that the number of
single command cycles per hour is equal to the number of dual command cycles per hour and that the system
operates at 75% utilization. Determine the throughput rate (loads moved/hour) of the AS/RS.
Answer: 245.5 transactions/hr

7. A 10-aisle automated storage/retrieval system is located in an integrated factory-warehouse facility. The

storage racks in each aisle are 20 m high and 110 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 = 15 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.
Answer: 441.7 transactions/hr

8. An automated storage/retrieval system for work-in-process has five aisles. The storage racks in each aisle are
10 m high and 50 m long. The S/R machine for each aisle travels at a horizontal speed of 2.0 m/s and a
vertical speed of 0.4 m/s. Pick and deposit time = 15 s. Assume that the number of single command cycles
per hour is equal to three times the number of dual command cycles per hour and that the system operates at
90% utilization. Determine the throughput rate (loads moved/hour) of the AS/RS.
Answer: 308.5 transactions/hr

Carousel Storage Systems

9. A single carousel storage system is located in a factory making small assemblies. It is 25 m long and 1.0 m
wide. The pick and deposit time is 0.25 min. The speed at which the carousel operates is 0.5 m/s. The storage
system has a 90% utilization. Determine the hourly throughput rate.
Answer: 88.7 transaction/hr

10. A storage system serving an electronics assembly plant has three storage carousels, each with its own
manually operated pick and deposit station. The pick and deposit time is 0.30 min. Each carousel is 60 ft
long and 2.5 ft wide. The speed at which the system revolves is 85 ft/min. Determine the throughput rate of
the storage system.
Answer: 272.2 transaction/hr

11. A single carousel storage system has an oval rail loop that is = 30 ft long and 3 ft wide. Sixty
carriers are equally spaced around the oval. Suspended from each carrier are 5 bins. Each bin has a
volumetric capacity = 0.75 ft3. Carousel speed = 100 ft/min. Average pick and deposit time for a retrieval =
20 sec. Determine (a) volumetric capacity of the storage system and (b) hourly retrieval rate of the storage
system.
Answer: a) 225 ft3 (b) 122.1 transaction/hr

12. A carousel storage system is to be designed to serve a mechanical assembly plant. The specifications
on the system are that it must have a total of 400 storage bins and a throughput of at least 125 storage and
retrieval transactions per hour. Two alternative configurations are being considered: (1) a one-carousel
system and (2) a two-carousel system. In either case, the width of the carousel is to be 4.0 ft and the spacing
between carriers = 2.5 ft. One picker-operator will be required for the one-carousel system and two picker-
operators will be required for the two-carousel system. In either system vc = 100 ft/min. For the convenience
of the picker-operator, the height of the carousel will be limited to 5 bins. The standard time for a pick and
deposit operation at the load/unload station = 0.4 min if one part is picked or stored per bin and 0.6 min if
more than one part is picked or stored. Assume that 50% of the transactions will involve more than one
component. Determine (a) the required length of the one-carousel system and (b) the corresponding
throughput rate; (c) the required length of the two-carousel and (d) the corresponding throughput rate. (e)
Which system better satisfies the design specifications?
Answer: a) 97.7 ft b) 60 transactions/hr c) 47.7 ft d) 160 transactions/hr

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