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 International Journal of Computer Applications (0975 – 8887)
Volume 177 – No. 16, November 2019

The Automatic Storage and Retrieval System: An

Overview
Hanan M. Hameed Kharia A. Al Amry Abdulmuttalib T. Rashid
Electrical Engineering Dept. Electrical Engineering Dept. Electrical Engineering Dept.
University of Basrah University of Basrah University of Basrah
Basrah, Iraq Basrah, Iraq Basrah, Iraq

ABSTRACT improved throughput level (Fig. 1) show basic element of

In this paper an overview on automated storage and retrieval general AS/RS system that consist of one or more storage
system AS/RS is denoted. In industries AS/RS systems are aisles that are serviced by a Storage /Retrieval machine . The
the main task that designed for automated storage and stored material are held by a system of storage racks and
retrieval of things in manufacturing where their application aisles[2]. The S/R machine are used to deliver and retrieval
vary widely from simple storage and retrieval system for materials in and out of inventory. There are one or more
small parts to central systems where production, assembly, input/output stations in each AS/RS aisle for delivering the
and manufacturing operations are concentrically located material into the storage system or moving it out of the
around them. The selection of the storage system depends system. In AS/RS terminology, the input/output stations are
upon the available space, weight of items to be stored, method called Picked and Deposit station [3].
of storage operation and another factors that take the For mobile robot AS/RS system S/R machine will be a mobile
important role in the design of the automated storage and robot that take the roll of S/R machine for storage and
retrieval systems. This paper will have all argument that retrieval material between rack and input/output station so,
needed to construct AS/RS system in a survey form which this research will discussing the development in AS/RS
will gives us a highlight about the factors that consider the system reaching for using the mobile robot for these systems
backbone to build the warehouses. The performance of AS/RS (Fig. 2) where the term Flexible Manufacturing System
will be the result for interaction of many complex and generally means a fully automated system that consist of four
stochastic subsystems. The differences among the surveyed basic elements which are:
approaches are discussed and the results are summarized.
• Robot
General Terms • Workstation
Automated storage and retrieval system.
• Material transport and storage system
Keywords
Multi- robot system, AS/RS, warehouses, workstation. • Computer controlled system [4].

1. INTRODUCTION 2. HISTORY OF AS/RS

The Automatic Storage and Retrieval System (AS/RS) The AS/RS is a major category of material handling
generally it can be known as material handling support equipment. There are primarily two types of AS/RS, unit-load
systems those are in majority used in automated factories, AS/RS and the mini-load AS/RS. AS/RS usually consists of
distribution centers, warehousing and non-manufacturing conveyors, storage racks SR and automated S/R machine that
environment. can travel along narrow aisles between the SR to store and
retrieve loads. The S/R machine can manipulate either pallets
Basically, Warehouses can be classified into three types: (unit-load system) or totes (mini-load system) [5]. Over the
past 50 years, many studies of AS/RS had been performed
• Distribution warehouses
within the material handling research community. The
• Production warehouses intensive development of AS/RS began with the development
of informational and computer science. Hausman et al.
• Contract warehouses. (1976), Graves et al. (1977) presented travel time models for
In distribution warehouses, products from different suppliers AS/RS assuming that the SR was square-in-time, which meant
are received and stored for delivery to several customers. that times to the most distant column tx = L SR / vx and tier
Production warehouses are usually used for storing raw ty = H SR / vy (L&H length and height ) were both equal (tx
materials, semi-finished products and finished products in a =ty).Distance IR sensor.
production facility. In a contract warehouse, warehousing They analyzed different storage strategies, e.g. randomized,
operations are performed on behalf of one or more customers turnover based and class-based storage assignment rules.
[1]. Gudehus (1973) presented principles for calculations of the
Today, quite recently appreciable attention has been going in cycle times for the Single Cycle SC and Dual Cycle DC. In
the direction of automation for storage and retrieval system the case of the SC the S/R machine could perform one storage
(AS/RS) by the industrial companies. AS/RS represent an or retrieval request, only. More advanced is the DC where the
innovation alternative to controlling and managing storage and the retrieval request are done simultaneously by
warehouse. Many benefits can be obtained from the the S/R machine. With regard to other cycle time expressions,
automation of AS/RS systems such as saving in labor costs he considered the impact of the acceleration and deceleration
and floor space ,the ease and the speed of handling items and rate on travel times.

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Fig. 1 General form of Basic Automatic Storage and Retrieval System.

Fig. 2 .Layout of the Robotic AS/RS System.

Bozer and White (1984) presented an analytical travel time presented a comprehensive review of research on warehouse
model for calculating the SC and DC for non-SIT (Square-In- operation. De Koster at al. (2008) have presented an optimal
Time) racks. Their models were based on randomized storage storage rack design for the 3D compact AS/RS. They have
and retrieval with different I/O configurations of the input introduced the combination of the S/R machine for TUL
queue. Their analytical travel time model was based on the movement in the horizontal and vertical directions and the
assumption that the S/R machine travels all the time at system of inbound and outbound conveyors (powered or non-
constant velocity. Hwang and Lee (1990) presented travel powered) for the depth movement. Roodbergen and Vis
time models by considering the operating characteristics of (2009) presented a comprehensive explanation of the current
the S/R machines for AS/RS and non-SIT racks. Sari et al. state-of-the-art in AS/RS. Rouwenhorst et al. (2000) presented
(2005) have presented the travel-time models for the 3D flow- a comprehensive review of warehouse design and control.
rack AS/RS. They have introduced the flow-rack, where Lerher et al. (2011) presented simulation analysis of a mini-
Transport Unit Load (TUL) loaded by the S/R machine by one load multi-shuttle AS/RS. Recently Bortolini et al. (2015a)
end of the rack, travels to another end of the rack to be proposed an extension for analytical models when computing
retrieved. For the storage operation, the S/R machine operates the expected travel time for the SCs and DCs of AS/RS in
in the same way as the S/R machine in the unit-load AS/RS. three-class-based storage systems. Later, Bortolini et al.
However, the retrieval operation for a particular TUL requires (2015b) proposed non-conventional easy-applicable
that the S/R machine removes all TUL stored in front of the configuration for unit load warehouses with diagonal cross-
requested TUL. The acceleration/deceleration effect on the aisles. Accorsi et al. (2015) presented time and energy based
travel time was not considered by the authors. Lerher et al. assignment strategy for unit-load AS/RS warehouses.
(2006) developed analytical travel time models for multi-aisle Janilionis et al. (2016) presented a comparison between
AS/ RS by considering the operating characteristics of the S/R routing algorithms for storage and retrieval mechanisms in
machine. Using the proposed analytical travel time models, cylindrical AS/RS [6]. E. Vijayaragavan, Sanketh Bhat,
average travel time can be evaluated. Gu et al. (2007) Abhishek Patel and Divyang Rana at 2018a perform study to

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Volume 177 – No. 16, November 2019

design and analyze of a mobile robot for storage and retrieval AS/RS system that can be defined as a combination of
System wherein a load of 550N was applied on the robot, to equipment’s and controls which automatically handle, store
simulate the weight of the storage rack. The results of the and retrieve materials with great speed and accuracy, without
analysis are discussed and their implications on the direct handling by a human worker[15].In general automated
performance of the robot are studied, which help in assessing storage and retrieval system is a set of structured parts that at
the performance and efficiency of the robot with respect to its the end gives us AS/RS systems such as single or more than
aim [7]. Imen Kouloughli, Pierre Castagna and Zaki Sari at this of aisles which consist of multi-tiered racks; stacker
2018b presented a completely new model named SRMAS crane ( S/R machine); input/output (I/O) stations ;
(Storage and Retrieval for Multi-Agent System) that accumulating conveyors and a central supervisory computer
developed a novel and original because it merges two and communication system. AS/RSs require serious analysis
techniques carefully chosen and adapted to AS/RS during the initial design phase because at this stage the
gravitational conveyors which led to a tidy rack [8]. Also, A. designers determine the capacity and throughput system. For
T. Rashid, F. R. Ali and O. T. Rashid presented several example, during the design phase, managers make decisions
algorithms that deal with the enhancement the length of the on the rack configuration and capacity (single or double
paths and the time of arrival in the static and dynamic object depth), the number of aisles and storage/retrieval machines
store system using the line follower robot and representing the (S/R machine) as well as the location of the Input/output
trajectories by the Bezier curve and the digital differential station (I/O station). Once the AS/RSs are implemented, a
analyzer algorithms [9-13]. number of control decisions must be made to obtain the
performance .These control decisions include decisions on
3. THE STORY OF AS/RS SYSTEMS storage policies, the location point of the S/R machine and
In typically configuration, the S/R machine carries at most scheduling, etc. [16].
one pallet. Pallets for storage arrive at the input station and
wait at an accumulator conveyor until the S/R machine In order to give a comprehensive study about AS/RS must be
transports these to their storage locations. This makes it we look forward for the steps that required to structure these
necessary to always select the first pallet from the input systems [15]. The main stages for design any AS/RS is
queue, i.e. First Come First Served (FCFS). The S/R machine physical design stage and decision design stage. So for
deposits retrieval loads at the output station. The S/R machine physical design stage several types of AS/RS are generally
has three independent drivers for horizontal, vertical and fork classified according to their physical configuration, namely.
movement. Hence the travel time of the S/R machine is ● The number of S/R machines and their capacity,
measured by the maximum of the isolated horizontal and
vertical travel times. Figure (3) gives an overview of AS/RS ● The disposition of racks and aisles in the system.
systems, based on the type of crane, type of the loads and the ● The positions of the input/output station,
types of racks that may be used. The overview also includes
carousals and mobile racks, which are usually not considered ● The depth of the racks i.e. maximum number of
as part of the classical AS/RS systems [14]. products that could be stored in the same cell.

4. DEFINTION OF THE AS/RS

Fig. 3 Various System Concepts for AS/RSs.

Several AS/RS configurations are used in manufacturing maximize the performance of the AS/RS system. The
systems and distribution centers, such as: unit-load, mini- performance measures may differ according to what the
load, man-on-board, deep-lane and flow-rack [17]. While the company want such as travel time per request, number of
application of control policies must manage the system in requests handled per time period, total time required to handle
order to obtain the maximum profitability. Sequencing the a certain number of requests, waiting times of the cranes,
storage and retrieval requests is one of the important policies. waiting time of requests to be stored/retrieved [18,19].
The company has to determine the sequence in which the
storage and retrieval requests are conducted in order to

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5. TYPES OF AS/RS quantities of stock. The items are stored in multi

AS/RS can arrange warehouse management for material deep storage with up to 10 items in a single rack,
handling system where without automation, filling higher one load behind the next. Each rack is designed for
quantities of smaller orders means more pickers traveling flow-through, with input and output on the opposite
through a distribution center. Eventually, at about 3,000 side. Picker located at the end of aisle can pick
orders per hour, operations hit a tipping point in which foot required few items from unit load and S/R crane
traffic clogs thoroughfares and operations hit a productivity restore the unit load to the rack.
plateau. Rather than just refining manual processes, highly
automated systems and fulfillment workflow modifications
6. AS/RS DESIGN DECISIONS
work together to deliver necessary increases in speed and Design decision consist of physical design and control policy ,
accuracy. AS/RS enables different, more effective so Tab. (1) shows an over view for design decision for general
methodologies to solve the challenge of high-throughput e- AS/RS system. AS/RS design decision consisted of two stage
commerce fulfillment [20]. Figure(4) shows general form of the first stage called physical design while the second stage is
AS/RS system with main unit that required for any AS/RS called control design. The physical design stage consists of
system .So for this , can be divide the AS/RS system two rules that specifies physical base for the system. The
according to the method of handling a load to four type : choice of the AS/RS type and the selected of the system that
must be configured. Then these parameters include: Number
of aisles, the rack structure, as shown in Fig.(5) Number of
aisles, Product characteristics, required throughput, required
storage space available land space and etc.
Table (1) An over view of Design Decision for AS/RS
Class of Decision to be made
problems
System● Number of aisles
configuration
● Height of the storage racks
● Length of the aisles
● Equally sized or modular storage
locations
● Number and location of the I/O points
● Number of crane per aisle
Fig. 4 General form for AS/RS System ● Number of order pickers per aisle (if
any)
1. Unit load AS/RS: is used to store and retrieve loads
that are palletized or stored in standard-sized
containers .Entire unit load is carried by forklift
trucks, conveyors, etc.. Unit load stored and Storage● Storage assignment method
retrieved from AS/RS system in a certain interval assignment
● Number of storage classes
of time[21].
● Positioning of storage classes
2. Mini load System:. This system is designed to
handle small loads such as individual parts, tools, Batching● Type of batching (static or dynamic)
and supplies that are contained in bins or drawers in
● Batch size (capacity or time based)
the storage system. Total storage volume is less than
unit load system .Such a system is applicable where ● Selection rule for assignments of orders
the availability of space is limited to batches
3. Man-on-board: This system allows storage of items ●
Sequencing Sequencing restriction (e.g., due dates)
in less than unit-load quantities. Human operator ● Type of operation (single or dual
rides on the carriage of the SR machine to pick up command )
individual items from a bin or drawer where instead ● Scheduling approach (block or
of retrieving entire load automatically man will be dynamic)
ride over S/R machine and pick only one item from ● Sequencing method
unit load. ●
Dwell- point Type of positioning (static or dynamic)
4. Deep –lane AS/RS : This is a high-density unit load ● Location where idle cranes will be
storage system that is appropriate for storing large placed

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Fig. 5 Design of an AS/RS and Related Decisions.

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Volume 177 – No. 16, November 2019

6.1 Physical design 6. Dynamically position the S/R machine at the last
Typically when we designing an AS/RS system where the location it visited following the completion of either
first step is Physical system design which can be defined as a a single command or a dual command cycle [21].
configuration and dimensions of the system. System can be 6.2.2 Input / Output Position policy
configured based upon previous available data, space
Input-output locations. There is one input and one output zone
availability and requirement, available budget and required
(I/O). The input zone is used to introduce full boxes from
throughput from system. System can be configured as:-
outside the system and has limited capacity. The output zone
● Load size to be handled. is used to remove empty, faulty or out- dated boxes. When a
box arrives at the output zone, it automatically leaves the
● Size parameters such as number of rows, number of system. The functionality of the output differs from the
bays in each row, individual storage space standard AS/RS problem, where it is used to satisfy the
dimensions, number of storage spaces required. customers' requests. This function is made by the picking
● Number of aisles, Rack height and Length of Rack, zones [26].
Number of S/R machine required. The position of the I/O station(s) is also a factor that affects
● Selection of storage spaces such as Equal sized or the AS/RS operation. Bozer and White (1984) analyzed and
modular to face variable dimensions. derived the expected travel time of the following alternative
configurations for the I/O station:
● Location of input-output station [22].
1. Input and Output at opposite ends of the aisle.
Rack structured :-The rack structured consider the important
step in the physical design for AS/RS system where there are 2. Input and Output at the same end of the aisle, but at
two type of rack system either dynamic or static , this different elevations.
classification depends on the behavior of the rack system. In a 3. Input and Output at the same elevation, but at a
dynamic rack system, the rack moves itself to bring the midpoint in the aisle.
required a Stock Keeping Unit (SKU) to the pickup point
while a static rack system is a rack system, where there is no 4. Input and Output elevated at the end of the aisle.
ability for the rack to change the storage locations of SKUs
within it through its own movements, as in the shelf rack 6.2.3 Routing and Sequencing Type of operation
system. An integrated rack system another form of rack policy
where there are some automated mechanisms are integrated Cycle time term refers to the time an order takes from its
with the rack system. There are two types of integrated entrance to the system until it reaches the shipping area. The
system. Movable racks, such as those of the Kiva system, use cycle time has a close relationship with the customer service
a driverless vehicle or robot that used to bring the rack to the level and thus with customer satisfaction. This is due to the
pick-station and the other type is static rack includes a robot fact that customers usually expect timely delivery. The
or automated mechanism built within the rack system operation time is not the only factor that effects the cycle
(integrated in), as in auto store[23]. time, however, there are many other factors such as
palletizing time, transportation time within the whole process
6.2 Control design and also the packaging time. Storage and picking strategies
6.2.1 Dwell-Point Policy have a substantial effect on the cycle time. [27]
A dwell point is an idling location of a Storage/Retrieval
The Type of operation time defines which command cycle is
(S/R) machine when it becomes idle.[24] We determine a
applied to operate an AS/RS. In a single command cycle (SC),
dwell point position which minimizes the expected travel
either a single storage or a single retrieval operation is
time to the position of the first operation after the idle period.
performed. A storage cycle consists of picking up the load at
An effective dwell point policy may reduce the response times
the I/O point, traveling of the S/R machine to the storage
of the AS/RS, since the S/R machine typically performs a
position, placing the load into the rack and returning back to
sequence of operations following an idle period. Hence, if the
the I/O point. A retrieval cycle is performed similarly.
first operation is advanced, then all operations within the
Consequently, during a storage cycle the return travel is an
sequence are completed earlier [25].
empty run of the S/R machine, while for a retrieval cycle, the
Typical dwell point rules include:- travel to the storage position is an empty run.
1. Dynamically position the S/R machine at a location 6.2.4 Storage location assignment policy
that minimizes the expected S/R machine travel or Storage location assignment is a set of rules that determines
response time from dwell point to the points of where incoming storage totes will be located in the storage
need. rack [28] or A storage assignment method is a set of rules
which are used to assign items to storage locations [29] or the
2. Dynamically position the S/R machine at a location
selection of open locations for incoming unit loads. There are
that minimizes the maximum S/R machine travel
three storage assignment policies random storage, full
or response time from dwell point to the points of
turnover storage and class-based storage.
need.
1. Random a storage assignment policy
3. Always position the S/R machine at the input station
Random storage is a completely shared storage policy where
whenever idle.
all incoming storage totes can be stored in any aisle and any
4. Always position the S/R machine at the output open location in the rack. Also it allows products to be stored
station whenever idle anywhere in the storage area. Within a storage class, items are
randomly stored .The name, the open locations in random
5. Always position the S/R machine at the mid-point storage are chosen because of an open location selection rule
location in the rack whenever idle.

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instead of a random choice. One basic rule important here is Customer order can be combined (batched) into to picking
closest open location (COL). This means that an incoming orders (batches) until the capacity of the device is exhausted.
tote is stored to the closest unoccupied location from the I/O Capacity can be expressed in the number of customer order.
point, with respect to travel time. [30]. Splitting of customer order, i.e. , the inclusion of items from
the same customer order in several picking order[32].
Closest-open-location storage assignment Usually, an order is selected, to be included in a batch, based
In practice, incoming items (e.g. on a pallet) are often on a measure of the ‘distance’ from the order to the seed order
allocated to the closest empty location. ‘Closeness’ here is of the batch.
defined by the travel distance from the input/output (I/O)
8. CONCLUSION
Point (or depot) to the storage location This paper summarizes the various components in an
2. Dedicated storage assignment policy automated storage and retrieval system, lists also the benefits
Materials are assigned to predetermined locations based on of automating a company’s storage operation. Details of the
throughput and storage requirements or each item has its own various control strategies are included and a summary of the
storage location. To minimize the travel distance, the closest performance measures applied to such systems. The findings
to-depot storage locations are commonly reserved for items from this overview are that there is currently a large amount
with a high turnover and little storage space occupation. An of research on-going with particular emphasis on improving
early type of this storage assignment method is the COI-based throughput by analyzing storage, retrieval and dwell point
storage assignment, where the COI of an item is defined as the strategies. The best recorded performance was content a
ratio of the required storage space to the order frequency of current dwell point, simultaneous travel, dual control, free
the item The COI-based method sort’s items by increasing nearest storage and nearest retrieval strategies selected in
COI ratio and locations on increasing distance from the I/O combination. In general, dual control improved performance
point. Next, items are assigned one by one to locations in this (in terms of throughput), simultaneous travel was found to be
sequence (items with the next lowest COI ratio to next better than rectilinear travel, dwell point at origin gave very
quickest-to-access locations). poor results, and a dwell point at current, pick point or deposit
point appears best considers the popularity of items, not their
3. Class based storage policy space occupation. COI-based storage is that the volume-based
Figure( 6 ) shows the class based assignment that It partitions assignment only considers the popularity of items, not their
all products into a number of classes and reserves a physical space occupation. The pick volume of an item can be
portion within racks for each class. This storage policy is expressed in number of units or pick lines during a certain
generally managed according to the dispatching rule based on time horizon. The difference between this method and COI-
the cube per order index (COI) introduced by [31]. It is based storage is that the volume-based assignment only
defined as the ratio of the number of storage addresses considers the popularity of items, not their space occupation.
allocated to an item and the number of transactions per period.
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