Overview
With the increasing popularity of automated equipment, and the current situation of rising labor costs, tight land use and high land prices, more and more warehouses are introducing automated equipment to participate in warehouse operations in order to reduce costs and improve operational efficiency.
The development of automation technology in the warehousing field (including main warehouses) is generally considered to have gone through five stages: manual warehousing, mechanized warehousing, automated warehousing, integrated warehousing, and intelligent automated warehousing. For a considerable period to come, intelligent automated warehousing will be the main direction of automation technology development.
Below, I will briefly talk about the ASRS and DPS systems.
ASRS system
Brief description
ASRS is short for Automated Storage and Retrieval System, whose core components are stacker cranes and high-rise automated storage and retrieval systems. It is a self-contained system that interacts with WMS (Warehouse Management System) and other similar systems through open interfaces.
Stacker cranes, in China, are generally aisle-type stacker cranes, which typically include columns, a loading platform, and a control system (some manufacturers' equipment includes a control console or control compartment). The main body of the equipment is shown in the figure below.
Stacker cranes operate on tracks between racks. Upon receiving an instruction, the stacker crane positions itself at the designated storage location and uses the raising, lowering, extending, and retracting of the forks on the loading platform to retrieve and store goods (using neatly arranged pallets or tote boxes) from the storage location.
Because stacker cranes use sensors for positioning and addressing, ASRS systems have strict technical requirements for racking, such as the accuracy requirements for storage location specifications, load-bearing capacity, shock resistance, and ground level. Even the operational strategies need special consideration (such as prioritizing lower storage locations and storing items evenly on both sides).
ASRS also includes some auxiliary facilities, such as loading and unloading platforms and conveyor systems.
Typically, one stacker crane is configured per aisle (rail-guided passageway between racks), corresponding to one inbound/outbound port. However, the aisles, stacker cranes, inbound and outbound ports can be flexibly configured according to warehouse planning and process design. For example, if multiple stacker cranes operate in multiple aisles but use only one inbound (outbound) port, a transfer trolley can be used to move the stacker crane between the inbound (outbound) port and the aisle; alternatively, a transfer trolley can be used to move one stacker crane between multiple aisles (this method has a cost advantage if the design efficiency meets the warehouse operation requirements).
Advantages
Space utilization : The biggest advantage of the ASRS system is its ability to greatly improve warehouse utilization. Case studies show that warehouse racking heights can reach 40 meters, with tens of thousands or even more usable storage locations, resulting in a significant increase in space utilization.
Work efficiency : Replacing manual labor with mechanical automation reduces the intensity of manual labor, resulting in improved work efficiency and accuracy.
Special environments : ASRS has a great advantage in certain special situations, such as darkness, toxicity, and low temperature.
Ø Limitations
High initial investment: ASRS systems require a significant initial investment, including equipment and facilities.
High requirements : The warehouse has high requirements, including the floor level, load-bearing capacity, fire protection, and even the reliability of the power supply. High requirements are also placed on the personnel responsible for the mechanical and electrical maintenance of the equipment.
Planning First : The construction of ASRS requires rigorous and scientific preliminary analysis, planning, and design. Once completed, any subsequent modifications will be a major headache.
Ø Applicable
ASRS is applicable to industries such as tobacco, food, and pharmaceuticals. It is particularly suitable for situations involving full pallet handling, high-frequency operations, and heavy goods. Additionally, ASRS can be used in high-risk warehouse environments.
DPS system
Brief description
DPS is short for Digital Picking System. Its core component is the electronic tag.
Similarly, it is a self-contained system that interacts with WMS and other systems through open interfaces.
The electronic tag includes a display screen, confirmation button, and function buttons. When the electronic tag is in operation, the indicator light illuminates, and the display screen shows the current quantity being picked. After the operator completes the task (picking or distributing), they press the confirmation button, and the system automatically updates the picking task status. When there is a shortage or lack of stock, the function buttons can be used to adjust the actual picking quantity (the display screen updates synchronously). The actual electronic tag is shown in the image below:
In the picking area, each storage unit is equipped with an electronic tag, connected by cable trays to form rows, which in turn connect to the control center. Each row is equipped with a row operation indicator (e.g., three-color indicator or electronic tag), and each area has an area operation indicator. Depending on the specific workflow design, the row and area indicators use different statuses (three-color indicator light, buzzer sound, electronic tag numbers, etc.) to indicate the current operational status of the rack row and rack area, guiding operators in their work.
DPS is a fully visual operation that can greatly improve operational efficiency and accuracy, while also reducing the warehouse's reliance on operator experience.
ØWork Mode
Generally, there are two types: fruit-picking and seed-planting.
Picking method: Picking method is to pick for each order (i.e. each customer). Pickers or equipment go around each storage location and take out the required goods, which is similar to picking fruit.
Seeding: Seeding sorting combines multiple orders (the needs of multiple customers) into a batch, first summarizing the quantity of each type of product, and then distributing the products to all customers one by one, which is similar to seeding.
Based on the workflow design, two operating modes can be used simultaneously in the same warehouse.
Ø Applicable
E-commerce, pharmaceuticals, apparel, and other industries. Various logistics and distribution centers with diverse product ranges and small-batch delivery needs.
Planning, design, and implementation
It is important to emphasize that automated equipment is not the same as modern logistics. A modern warehouse requires not only scientific planning and design in the early stages, but also reasonable process implementation in the later stages.
For newly built warehouses, a detailed analysis of the company's specific situation is necessary in the early stages of construction. This includes the company's current logistics status, the warehouse's functional positioning, historical data analysis, and medium- to long-term development plans. Then, a reasonable and feasible plan should be designed, including warehouse layout, operational flow, equipment, budget, and preliminary operational process planning. Companies with the resources can engage a specialized consulting firm to complete this process.
Once the warehouse is built, robust processes are needed to support the initial planning, making the Warehouse Management System (WMS) the "central nervous system" of warehouse operations. Adhering to the planning intent, it designs rational and convenient detailed operational processes, integrates and schedules various automated systems, and achieves efficient and precise warehouse operation.
