Automated Material Handling and

Storage Systems
How do we define automated material handling
and storage systems?
How do they work?
What is automated guided vehicle systems?
 Automated Material Handling and
Storage Systems
Automated guided vehicle systems == driverless
vehicles
Flexible manufacturing systems requires
Machine/machining flexibility
Storage and retrieval flexibility
 Automated Material Handling and
Storage Systems
Material handling systems:
Handling, storing and controlling of materials
Materials are:
Raw materials
Work in progress
Sub-assemblies
Finished assemblies
The goal in material handling is:
Right amount of material
Delivered safely
To required location
At the right time
At a minimum possible cost
Depends on the business, material handling cost might take up
to 10 to 80% of total cost
 Automated Material Handling and Storage Systems
Principles of material handling
Orientation principle: study and understand the system for further enhancements
Planning principle: Establish a plan to include basic requirements, options etc.
System Principles: Integrate the handling and storage activities
Unit load principle: Handle products as large units as possible
Space utilization: Use the cubical space efficiently
Standardization: Standardize handling and methods and equipments if possible
Ergonomic principles: Do not ignore human factor
Energy principle: Energy consumptions should be justified economically
Ecology principle: Minimize the effects to environment
Flexibility: Use methods and equipment can easily be modified
Simplification: Eliminate, reduce or combine unnecessary movements/equipments
Gravity principles: Take advantage of gravity when you can
Safety: Use safe equipment and methods
 Automated Material Handling and Storage Systems
Principles of material handling
Computerization principles: Consider computerization systems as much as you can
System flow principle: Integrate data flow with the physical material flow in
handling and storage
Layout: Prepare an operational sequence and equipment layout for all viable system
solutions then select the alternative system that best integrates efficiency and
effectiveness
Cost: Justify the system economically
Maintenance: Schedule regular maintenance that has minimal effect to work delays
Obsolescence principles: Develop systematic approaches for replacement of the
equipments
 Automated Material Handling and Storage Systems
Material handling equipments
Industrial Trucks Hand trucks Powered Trucks
Two-wheeled, Four- Forklifts, Tractors, Trailer
wheeled, Hand lift, Forklift trains, Crane trucks, Side
loaders
Conveyers Belt, Chute, Roller, Wheel, slat, chain, bucket, trolley, tow
screw, vibrating, and pneumatic
Monorails Bridge, Gantry, Tower, Stacker
Hoists
Cranes
Automated guided Unit load carriers, towing, pallet trucks, fork trucks and
vehicle systems assembly lines
Automated storage Unit load, mini-load, person-on-board, deep lane, storage
and retrieval systems carousel systems
 Automated Material Handling and
Storage Systems
Automated Guided Vehicle Systems
Battery-powered, driverless vehicle system
Destination, path selection, positioning
capabilities can be programmed
They are used to transport material from various
loading locations to unloading locations
These systems includes intelligent collision
avoidance capabilities
Communication with the vehicle sustained by
Wires installed on the floor
Radio signals
 Automated Material Handling and
Storage Systems
Components of automated guided vehicle
systems (AGVS)
The vehicle: transports the material
The guide path: guide
The control unit: monitors, evaluate the feedback etc
The computer interface: interacts with other
computers/systems
Mainframe
Host computer
Automated storage and retrieval system
Flexible manufacturing systems etc
 Automated Material Handling and
Storage Systems
The type of AGVSs
Towing vehicle
Unit load transporter
Pallet trucks
Forklift trucks
Light-load transporters
Assembly-line vehicles
 Automated Material Handling and
Storage Systems
Unit Load Transporters

Power and Free Overhead

conveyor systems
Towline Conveyor Systems
 Automated Material Handling and
Storage Systems
Forklift and Pallet Trucks

Outrigger Type Pallet AGV Reach Type

Forklift
Forklift AGV
 Automated Material Handling and
Storage Systems

Conveyor Deck Lift Deck type Custom made

type AGV AGV AGVS
 Automated Material Handling and
Storage Systems
Towing vehicles
First kind and it is still popular
It is a automated guided towing tractor
Efficient to use for long distances with high
volumes
Distance is > 1000 ft
Capacity range might be 8000 to 50,000 lb
Speed is 264 ft/min
Turning radius is 7 ft
 Automated Material Handling and
Storage Systems
Unit load transporters
Carries only one individual material (container etc) on the
board
Deck might have powered or non-powered roller, belt etc
Can lift
Might have multiple compartments
Used in warehousing and distribution systems
Guide length path is short
Volumes is high
Travels about 176 ft/min, carries 500 to 1000 lb. Turning
radius is 2 ft
 Automated Material Handling and
Storage Systems
Pallet trucks
Lift, maneuver and transport palletized loads
Pick up and deliver in floor level
1000 to 2000 lb capacity
264 ft/min speed
7 ft turning radius

They can be loaded/unloaded

Automatically
Manually
 Automated Material Handling and
Storage Systems
Forklift trucks
Relatively new AGVS
Pick up/ drop off palletized materials
Both at the floor level or
Higher levels within the forklifts reach
One of the most expansive AGVS types
Mostly used in fully automated systems
Can handle 1000 to 2000 ld load
264 ft/min speed with 7 ft turning radius
 Automated Material Handling and
Storage Systems
Assembly-line vehicles
Main part is carried on the trucks among the different
work stations
Most of the machining and assembly operations being
done while the material is still on the board
When the assembly is completed in one station, operator
releases the vehicle, so it can go to the next assembly
station
Such systems is efficient in measuring the efficiency of
assembly job
Speed range is 100 to 2000 ft/min
Load capacity is between 500 to 2000 lb
2 to 7 ft turning radius
 Automated Material Handling and Storage Systems
AGVS guidance systems
The goal is to keep the vehicle in pre-designed path
The main advantage comparison to fixed systems is the path can be
changed easily
Guidance systems are:
Wire-guided systems: energized wire is located in the floor. The antennas of
receives the information from embedded wires.
Optical guidance systems: colorless florescent particles are painted on the
path. Vehicle finds its path sensing these signs on the floor
Inertial guidance systems: vehicle follows a preprogrammed path. A sonar
system is used to detect obstacles around the vehicle
Infrared guidance system: infrared light reflectors located on the roof of the
building is traced by the vehicle and used to calculate position and
directions.
Laser guidance systems: laser beams are used to compute location and
direction
Teaching type guidance systems: neural networks concepts is used.
 Automated Material Handling and Storage
Systems
AGVS control systems
Computer control systems
Most efficient but most expensive and complex controller
Remote dispatch control system
Human interactions takes place using remote controls
Human factor is not directly involved in performing the task
Only destination and material information are sent
Manual control systems
Operator loads the vehicles
Inputs the location and path information on the board
Vehicle is routed by itself
Unloading is being done by humans as well
 Automated Material Handling and Storage
Systems
Advantages of AGVS over other material handling
systems
Flexibility
Higher reliability
Higher operating savings and lower investment
Unobstructed movements
Easy interfacing with other systems
 Automated Material Handling and Storage
Systems
The Intelligent Assembly System (IAS) vehicles are either passive-inductive or
optically guided . The AGV typically moves from one workstation to another and
production / assembly operations are undertaken upon its build platform. The kit
of parts required during assembly can also be carried by the IAS.

Intelligent Assembly Intelligent Assembly

System with fixed System with
height build platform. adjustable lift table
 Automated Storage and Retrieval Systems

Imagine your plant without cluttered aisles, excess inventory,

lost or damaged products, inaccurate records, endless
searching, climbing, bending and frustration. Imagine a highly
profitable operation that adds value and decreases expense.
 Automated Storage and Retrieval Systems
AS/RS
Functions of storage systems
For:
Raw materials, purchased parts, work in progress,
Finished products,pallets, fixtures, tools, spare parts,
Rework and scraps, office supplies
AS/RS performs following functionalities
Receiving, identifying and sorting
Dispatching to storage, placing in storage and storage
Retrieving from storage
Order accumulation, packing, shipping and record keeping
 Automated Storage and Retrieval Systems
AS/RS

AS/RS is a combination of equipment and controls

Handles, stores and retrieves materials
With precision, accuracy and speed
Under a defined degree of automation
 Automated Storage and Retrieval Systems
AS/RS
AS/RS components
A series of storage aisles having storage racks
Storage and retrieval machines-normally one machine
per aisle
One or more pick up and delivery stations
An optimal AS/RS uses all 3 dimensions available
 Automated Storage and Retrieval Systems
AS/RS
AS/RS Examples

HIGH-SPEED, HIGH-
General AS/RS systems DENSITY STORAGE FOR
BOXES AND TOTES
 Automated Storage and Retrieval Systems
AS/RS
Why companies need AS/RS
Space efficient (Cubical space usage)
Increase storage capacity, can reach far corners
Improve inventory control system
Fast response time to locate, store and retrieve
Better inventory management therefore less shortages and excess
inventory
Reduce labor cost
Improve security
Flexible and can be used with other computerized systems (AGVS
and FMS)
An important factor in JIT concept
 Automated Storage and Retrieval Systems
AS/RS
Types of AS/RS:
Unit load systems: Controls parts in pallets or containers
over 500 lb
Mini-load systems: Designed to handle small loads
Person-on-board: A person rides with the
Storage/Retrieval machine
Deep-lane: Items are stored in multi-deep storage with up
to 10 items per row
Automated item retrieval system: Items stored individual
and can be automatically released