WAREHOUSE REPORT | STORAGE
However, McVicar warns that buy-in cost can be prohibitive for smaller operators. “Initial investment is considerable, and
break-even return on this investment is likely to be in the region of many years. In addition, specialist ASRS storage systems when installed are not easily reversed to regular warehouse layout. Optimisation before automation is key to providing flexibility within the warehouse while still achieving maximum return on investment,” says McVicar. LaBruna argues that with a thorough and holistic assessment of potential
investment in automation the efficiencies will speak for themselves, but he also agrees as to the value of optimising existing resources and suggests that phased improvements can work well for hesitant investors. “Modular racks are a versatile storage solution that allows small businesses to start with a basic set-up and then expand gradually as their needs grow… Existing manual cranes could be upgraded in phases to become semi-automatic or fully automatic systems… This approach is cost-effective and scalable, making it
well-suited for businesses with limited resources that want to accommodate future growth without investing heavily upfront,” says LaBruna. So there seems little doubt that maximising storage through higher and denser options is a smart way to unlock the potential of your warehouse. There are a range of materials handling options and configurations that will suit different operations, and although a considered approach will be required, squeezing denser storage in could release huge value.
AUTOMATED STORAGE SPEEDS THROUGHPUT
Terberg Benschop is a Dutch manufacturer of vehicles and tractors that are used in shipyards, airports and construction, for example. It is a family-run company with an annual revenue of €825m. Terberg took on Knapp for a new centralised production warehouse including an automated small parts storage facility. The system included an OSR Shuttle with two rack line systems, 25 levels and 50 shuttles for containers of up to 50kg. The new system also has four decanting workstations, two Pick-it-Easy Flex picking stations, two dispatch stations, and Knapp’s KiSoft One IT system with Webservices interfacing to the incumbent Dynamics AX. “The choice for an automated solution was a big step for Terberg.
We felt the need to work together with a supplier that has already for local support and maintenance,” says Alexander Kühne, supply manager at Terberg.
The OSR-Shuttle’s dynamic quadruple-deep storage provides 14,250 load unit locations for containers measuring 600x400mm or 28,500 load unit locations for containers measuring 400x300mm. The system contains a shuttle for every level and rack line system, which handles all storage and retrieval movements. “Of course, the goods-to-person system has a higher capacity by eliminating the time a person would need to navigate through the warehouse,” says Kühne. “Other advantages are that the pick-to-light system supports the
picker and helps avoid mistakes in item and/or quantity picked and fact that every new goods receipt is stored in a new empty container,” Kühne adds. The new system has put Terberg on course to achieve throughput of 500 containers/hour by 2027.
xxvi | November 2023 | Overhead Crane Material Handling Industry Supplement
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