Automated Storage & Retrieval Systems (AS/RS)

Automated Storage and Retrieval Systems (AS/RS) are typically used in applications where there is a very high volume of loads being moved into and out of storage where storage density is important because of space constraints, and where no value adding content is present in this process. They are used widely in both Manufacturing and Distribution operations to hold and buffer the flow of material moving through the process to the ultimate end user. Most systems operate in a fully automated mode with little or now human involvement in the handling of material except at the controlled input and output stations to the system. This results in extremely high inventory accuracy.

AS/RS benefits include:

• Bringing material to the operator cutting cycle time by eliminating wait, walk, and search time.
• Reduces work-in-progress inventory. Better inventory accuracy and better responsiveness to need result in reduction or elimination of “safety stock” in the overall inventory model. This has the net effect of inventory reduction.
• Dramatically increases operator productivity. The “Part to Picker” model of order fulfillment is 3 to 5 times more productive that having the picker travel to the part to complete the fulfillment .
• Provides real-time inventory control with instant reports. With near 100% accuracy and real time information about the inventory on hand, achievable commitments can be made to your customer – as opposed to “best efforts promises”.
• Improves product quality and productivity. Real time information, faster response to a need, physical protection, and traceability of material access all contribute to a better process where time can be spent on improving the quality of the process instead of on expediting material to a point of use.

Bastian offers the following Automated Storage and Retrieval System (AS/RS) families:

AS/RS Tunnel Concept

AS/RS Tunnel concept is a unique concept for the purpose of removing non-value added labor. AS/RS Tunnel concept is a proven AS/RS technology that can be coupled with more traditional tools like gravity flow lanes allowing more flexible and efficient opportunities for warehouses in the future.

AS/RS Tunnel Concept Features

• Used to replenish carton flow lanes
• Satellite load handling device able to store totes or cases above flow lanes so that maximum density is achieved
• Used in Unit Load and Mini Load systems

 

High Speed Sorting Box Buffer

This technology has the ability to accept a random variety of carton sizes, store them and then send them back out in a new, customer specific sequence to build the final order. The system uses a unique high performance design that makes the buffer ideal for high-volume box handling and sorting operations. This type of application is often found where “Store Ready” or “Rainbow” pallet orders are being created. As a result of the speed of this technology, the need for accumulation conveyor lanes can be eliminated thus saving space, system complexity, and expense.

Also described as a 3-dimensional buffering sorter, the Sorting Box buffer saves valuable floor space with its compact foot print and heights up to 50 ft. tall, Likewise, the units are relatively modular, making expansion simple. Additional modules can be added as needed to increase the capacity of this high-density storage buffer.

This technology is designed with variable speeds in all axis which Bastian Engineers will match your throughput requirements. Servo and vector drives support vertical, horizontal, and shuttle movement or smooth, precise load control that prevents damage. Despite its high speed, the equipment is remarkably quiet, operating at typical office sound levels.

AS/RS High Speed Buffer Features:

• Controls – The high speed sorting buffer contains end-of-aisle controls using the latest processors and user-friendly menus guiding operators to quickly diagnose any errors.
• Multiple Speed Options - multiple speed options are available allowing you to pick the machine that matches your requirements. This includes high-speed order picking.
• Multiple Heights – Allows you to maximize the use of your overhead space, from 10’ to 50’ high.
• Small Footprint – Each module has a footprint as narrow as 7’ and is easily installed close to the factory or warehouse use point.
• Easy maintenance – Designed with modular construction and built-in diagnostics simplify installation and maintenance.
• Space Efficient – This AS/RS provides easy access to totes, multiple items per tote and likewise permits computerized location tracking for thousands of SKUs.
• Designed for integration - The system is easily integrated with conveyor or ergonomic order picking workstations.

AS/RS Mini Load

The unique compact design of the Mini Load AS/RS allows you to store more material in less space. This AS/RS is designed with strong, lightweight alloys making the mini load less expensive to install, operate, and maintain. More specifically, the lightness of these alloys allow for much faster performance, making these machines significantly more productive than their technical ancestors.

The most common usage of this class of AS/RS is for small parts storage and management for picking and order fulfillment. Often paired with a hybrid combination of carousels, flow lanes and static racks or shelves, the Miniload provides the best solution for those SKUs that represent the mid-range of activity.

In this configuration, pans of parts are stored in the system in random order. Each pan may have multiple SKUs located loosely in the pan, or in specifically segmented and labeled partitions within the pan. The computer system knows where every part is in the system, and on request, brings the pan containing the needed SKU to the operator picking station.

The design of the front end of the Mini-Load allows for work to be “in-queue” for the picking operator. Application and design methodologies are used by Bastian engineers to carefully balance the capability of the Mini-Load with the ability of the operator to perform the picking and fulfillment process. This balancing is designed to optimize the system, but also to insure that a significant degree of scaleability is built into the design – allowing productive use of the technology during low as well as high activity periods.

The AS/RS Mini Load is available in seven horizontal and eight vertical speeds to match your requirements. In addition, variable acceleration rates ensure load stability. Despite the AS/RS’s high speed, the machine remarkably quiet, operating at usual office sound levels.

For maintenance efficiency, AS/RS Mini Load’s drives and components have been carefully placed for easy access and quick repairs making installations simpler and faster.

AS/RS Mini Load Features

• Material for the picking operator is presented at an ergonomically ideal position for operator interface. These locations can be at the end of an aisle, or along the sides of the system allowing multiple operators to be served by a single aisle of equipment.
• Picking instructions are normally integrated into the Human/Machine Interface at the picking station, significantly reducing the complexity for a picking operator, and reducing the learning curve a new operator must complete in order to be fully productive
• Variety of Load Handling Methods – Including a single or dual shuttle, frame, robotic arm, or extractor load transfer methods. This flexibility allows you to choose the method that best fits your needs.
• Multiple Speed Options – This AS/RS is available with multiple horizontal and vertical speeds allowing you to pick the machine that matches your requirements; high-speed order picking included.
• Multiple Heights – Allows you to maximize the use of overhead space, from 10’ to 50’ in height, and even higher is some specialty applications.
• Easy Maintenance – Designed with modular construction and built-in diagnostics simplify installation and maintenance of the AS/RS Mini Load.
• Small Footprint – The Mini Load has a footprint as narrow as 7’ and is easily installed close to the factory or warehouse use point.
• Space Efficient – This AS/RS provides easy access to totes, multiple items per tote and likewise permits computerized location tracking for thousands of SKUs.
• Available Enclosures – Allow you to secure your materials. A variety of enclosure styles and colors are available.

AS/RS Unit Load

The AS/RS Unit Load technology designed to handle unitized loads into and out of very high density storage. While sometimes used to replenish picking locations with palletized commodities, the most common application of this equipment is for the buffering of supply chain deliveries, storing and controlling the inventory until it has been released from QC, or is requested out for use in downstream processes. This would include the buffering of palletized finished goods waiting for distribution to the end user.

The first AS/RS Unit Load systems were built in the late 1960’s, and were heavy, slow, and very complicated to service. Today’s technology is engineered with reliability, speed, and cost effectiveness as primary design criteria. The equipment regularly operates in 24/7 applications with unparalleled performance when compared with more manual high density storage methods.

The AS/RS Unit Load is available with a variety of horizontal and vertical speed options. As a result, it’s easy to pick the right machine for your application. Likewise, today’s lightweight cranes with their modern electronics allow for variable acceleration rates ensure the fastest speeds are possible while maintaining load stability. Despite the AS/RS’s speed, the machines offered by Bastian are remarkably quiet, operating at what is often described as “office quiet” sound levels.

AS/RS Unit Load Features

• Controls – The Unit Load systems have interfaces to plant level warehouse control systems, but they also have end-of-aisle controls for Human Machine Interface (HMI) These systems offer user-friendly touch screens guiding operators through the process of accessing the system, and instructing the operator as to what action to perform on loads delivered to him at that location. These systems also monitor operations, notify the operator or maintenance operation as to problems or PM procedures that need to be performed, and support the quick diagnosis and recovery from any potential error.
• Narrow, Precise Shuttles (Single or Dual) – Provides fast, accurate load transfers while reducing space requirements.
• Ergonomic Workstations - A variety of ergonomic workstations are available with access at end-of-aisle or the side.
• Easy Maintenance – Designed with modular construction and built-in diagnostics simplify installation and maintenance of the AS/RS Mini Load.
• Full Complement of Safety Devices – The AS/RS Unit load has the best in equipment and operator safety devices. The devices available include: redundant lift carriage chains/cables, freefall brakes, safety fences, automatic load alignment and sizing detection, and more.
• Optical Communications – To reduce the likelihood of lost data and ensure constant communication even in the event of power surges.
• Special Loads – With the AS/RS Unit Load, special loads can be accommodated. This includes long or bulky materials, freezer and hazardous material applications, and very low noise environments.

AS/RS Unit Load Deep Lane

A really unique approach to the use of AS/RS in a high density environment is being offered in the form of a hybrid design that uses control intelligence to provide variable lane depth for pallet storage. In addition to a unique design that supports the direct storage of less than perfect pallets, software and dynamic adjustment of the system rules for storage assignments has created a very attractive solution.

AS/RS Unit Load Deep Lane Features

• Allows for multi-deep storage
• Pallets can be delivered at rates upwards of 80 per hour
• Used in food and pharmaceutical industries
• Ability to enforce strict First-In, First-Out consumption
• No load constraints