IBM faced either the purchase of a

IBM faced either the purchase of a new system or a total upgrade to its existing ASRS, which serves as the primary warehousing system for raw materials used in production of PCs and point-of-sale terminals. About one-fifth of the ASIRS capacity is also used for finished goods. After investigating the alternatives, it was determined that a true systems upgrade would provide substantial savings-about one-tenth the estimated cost of a new system.
Since completing the upgrade, the ASRS' operating costs have been greatly reduced. Productivity has increased, storage density is higher, and better tracking systems have been implemented. The system can now handle 50 percent more throughput at 220 moves an hour, and uptime is now 98 percent.
Today, the ASRS houses more than 28,000 SKUs in its 10 80-foot high, 500-foot long aisles. An S/RM is dedicated to each aisle, handling both receiving and picking functions.
The entire ASRS system is controlled by a series of PCs networked to an RSl6000 computer. The mainframe decides which products are needed for the day's manufacturing and builds a list of materials. An SIRM is instructed to travel to an individual location where parts are stored. Photo eyes direct the S/RM to the exact location of the desired SKU, and an extractor removes the load. The SRM then delivers the part to a pickupldeposit station at the front of the aisle, placing the pallet on a slipsheet. A conveyor delivers the unit to the manufacturing workstation.
Previously, controllers for the conveyor that replenishes the front of the ASIRS and the conveyor that outputs to production worked independently and required separate control rooms. After the upgrade, both operate from the same PLCs, eliminating one control room and the need for operators in two locations. Monitoring and reporting functions have also been greatly improved.
Installing the new ASIRS system was not an easy task. As an essential component of the plant's production process, the ASRS needed to continue to store and retrieve inventory throughout the entire retrofit process. The crew had to meet a tight schedule to perform that day's installation work, do required testing and verification, and then be ready to switch it all back over for full production the next day.
The upgrade on the S/RM was performed aisle by aisle, with the first aisle taking 7 days for its upgrade and 3 days each for the remaining nine aisles.
All 4800 feet of floor rails that guide the SRMs were also replaced with new thermitewelded epoxy-grouted rails designed to prevent deterioration.
The original safety concerns have now vanished. Gone too are obsolete and proprietary parts, as all components are state-of-the-art and Y2K compliant and readily available from a variety of suppliers.

lize lift trucks. However, the basic use of RFDC to instruct movement of lift trucks is expanded in an information-directed application to become a highly integrated materials handling system. Tn the layout and design, the warehouse facility is essentially the same as any mechanized facility. The difference is that all lift truck movements are directed and monitored by some combination of computer mounted on the lift truck, handheld computer, or voice-activated communication. The real time information interchange is designed to achieve flexibility and better utilization.

The main advantage of RF is to improve speed and flexibility of lift truck operations. lnstead of following handwritten instructions or computer listings generated in batches, drivers receive work assignments through either handheld or vehicle-mounted RF terminals. Use of RF technology provides real time communication to central data processing systems. In operation, the WMS in conjunction with the operations control computer plans and initiates all movements, communicates the requirements to the material handlers, and tracks the completion of all tasks. Decision support systems analyze all movement requirements to assign equipment in such a way that direct movement is maximized and deadhead movement is minimized. Less exotic

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IBM menghadapi baik pembelian sistem baru atau total upgrade ke ASRS yang sudah ada, yang berfungsi sebagai sistem pergudangan utama untuk bahan baku yang digunakan dalam produksi PCs dan point-of-sale terminal. Sekitar seperlima dari kapasitas ASIRS juga digunakan untuk barang jadi. Setelah menyelidiki alternatif, bertekad bahwa upgrade sistem sejati yang akan memberikan substansial tabungan-tentang sepersepuluh perkiraan biaya sistem baru.Sejak menyelesaikan upgrade, ASRS' biaya operasi telah sangat berkurang. Produktivitas telah meningkat, Penyimpanan kerapatan lebih tinggi, dan lebih baik sistem pelacakan telah dilaksanakan. Sistem sekarang dapat menangani 50 persen lebih throughput pada 220 bergerak satu jam, dan uptime sekarang 98 persen.Hari ini, ASRS memiliki lebih dari 28.000 SKU di yang 10 80-kaki tinggi, 500 kaki panjang lorong. S/RM didedikasikan untuk setiap gang, penanganan menerima maupun memilih fungsi.Seluruh sistem ASRS dikendalikan oleh serangkaian PCs jaringan komputer RSl6000. Mainframe memutuskan produk apa saja yang diperlukan untuk pembuatan hari itu dan membangun daftar bahan. SIRM diperintahkan untuk melakukan perjalanan ke lokasi tertentu yang menyimpan bagian. Foto mata langsung S/RM ke lokasi yang tepat dari SKU diinginkan dan extractor mengangkat beban. SRM kemudian memberikan bagian ke Stasiun pickupldeposit di bagian depan gang, menempatkan kasur di slipsheet. Ban berjalan memberikan unit ke workstation manufaktur.Sebelumnya, controller untuk conveyor yang depan ASIRS dan conveyor yang output produksi bekerja secara independen dan diperlukan kontrol terpisah kamar. Setelah upgrade, keduanya beroperasi dari PLC sama, menghilangkan satu control ruang dan kebutuhan untuk operator di dua lokasi. Pengawasan dan pelaporan fungsi juga telah sangat ditingkatkan.Instalasi sistem ASIRS baru bukanlah tugas yang mudah. Sebagai komponen penting dari proses produksi tanaman, ASRS diperlukan untuk terus menyimpan dan mengambil persediaan sepanjang seluruh proses retrofit. Kru telah memenuhi jadwal yang ketat untuk melakukan pekerjaan instalasi hari itu, melakukan pengujian dan verifikasi diperlukan, dan kemudian akan siap untuk beralih itu semua kembali untuk produksi penuh hari berikutnya.Upgrade pada S/RM dilakukan lorong oleh gang, dengan gang pertama mengambil 7 hari untuk meng-upgrade dengan dan 3 hari masing-masing untuk sisa sembilan lorong.Semua 4800 kaki rel lantai yang memandu SRMs juga diganti dengan baru thermitewelded rel epoxy-dibentuk yang dirancang untuk mencegah kerusakan.Masalah keamanan asli sekarang telah lenyap. Pergi terlalu usang dan kepemilikan parts, seperti semua komponen adalah negara-of-the-art dan Y2K compliant dan tersedia dari berbagai pemasok.lize lift trucks. However, the basic use of RFDC to instruct movement of lift trucks is expanded in an information-directed application to become a highly integrated materials handling system. Tn the layout and design, the warehouse facility is essentially the same as any mechanized facility. The difference is that all lift truck movements are directed and monitored by some combination of computer mounted on the lift truck, handheld computer, or voice-activated communication. The real time information interchange is designed to achieve flexibility and better utilization.The main advantage of RF is to improve speed and flexibility of lift truck operations. lnstead of following handwritten instructions or computer listings generated in batches, drivers receive work assignments through either handheld or vehicle-mounted RF terminals. Use of RF technology provides real time communication to central data processing systems. In operation, the WMS in conjunction with the operations control computer plans and initiates all movements, communicates the requirements to the material handlers, and tracks the completion of all tasks. Decision support systems analyze all movement requirements to assign equipment in such a way that direct movement is maximized and deadhead movement is minimized. Less exotic