PowerPoint Presentation · 09-10-2018 1 warehouse robotics: state of the art and research...

09-10-2018

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WAREHOUSE ROBOTICS:

STATE OF THE ART AND

RESEARCH OPPORTUNITIES

RENE DE KOSTER

ERASMUS UNIVERSITY ROTTERDAM

2018 FRANCQUI CHAIR, UNIVERSITY OF HASSELT

LSCM2018, LOGISTICS SUMMIT, 5 OCTOBER 2018, HONG KONG

AUTOMATED STORAGE SYSTEMS

Crane/truck-

based

Shuttle/lift based

Single/double

deep• AS/RS

Multi-deep:• Captive satellite

• Roaming satellite

• Conveyor

• Rotating

conveyor

• Push-back rack

• Flow rack

Static

rack

R. de Koster (c), Warehouse Robotics, LSCM2018, 5 Oct 2018

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AGV based• PS AGVs

• (Mobile) Pick AGVs

Automated storage

systems

moveable

rack• RMFS

Single/multi deep• AVS/RS

• Rackracer

• Perfect pick

• Autostore

• Shuttle/transfer car

Loads on shuttles

• PBS

Pick stations• Manual picking

• Robot picking

‘Classic’ automationRobotic/autonomous systems

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FULLY ROBOTIC WAREHOUSES?


FULLY ROBOTIC WAREHOUSES EXIST


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THE LAST FRONTIER: ROBOTIZED ROLL CAGE STACKING

It is already there!

• Picking robots (still slow, expensive)

• Dispensing systems with roll cage stacking (becoming

common in warehouses of retail chains)

R. de Koster(c), Warehouse Robotics, LSCM2018, 5 Oct 20185


Crane/truck-

based

Shuttle/lift based

Single/double

deep• AS/RS



• Conveyor

• Rotating

conveyor

• Push-back rack

• Flow rack

Static

rack


6



Automated storage

systems

moveable

rack• RMFS


• Rackracer

• Perfect pick

• Autostore


Loads on shuttles

• PBS• Shuttle sorting


• Robot picking

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4


Crane/truck-

based

Shuttle/lift based

Single/double

deep• AS/RS



• Conveyor

• Rotating

conveyor

• Push-back rack

• Flow rack

Static

rack


7



Automated storage

systems

moveable

rack• RMFS


• Rackracer

• Perfect pick

• Autostore


Loads on shuttles



• Robot picking


Crane/truck-

based

Shuttle/lift based

Single/double

deep• AS/RS



• Conveyor

• Rotating

conveyor

• Push-back rack

• Flow rack

Static

rack


8



Automated storage

systems

moveable

rack• RMFS


• Rackracer

• Perfect pick

• Autostore


Loads on shuttles

• PBS

• Shuttle sorting


• Robot picking

09-10-2018

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Crane/truck-

based

Shuttle/lift based

Single/double

deep• AS/RS



• Conveyor

• Rotating

conveyor

• Push-back rack

• Flow rack

Static

rack


9



Automated storage

systems

moveable

rack• RMFS


• Rackracer

• Perfect pick

• Autostore


Loads on shuttles

• PBS

• Shuttle sorting


• Robot picking


Crane/truck-

based

Shuttle/lift based

Single/double

deep• AS/RS



• Conveyor

• Rotating

conveyor

• Push-back rack

• Flow rack

Static

rack


10



Automated storage

systems

moveable

rack• RMFS


• Rackracer

• Perfect pick

• Autostore


Loads on shuttles



• Robot picking

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6


Crane/truck-

based

Shuttle/lift based

Single/double

deep• AS/RS



• Conveyor

• Rotating

conveyor

• Push-back rack

• Flow rack

Static

rack


11



Automated storage

systems

moveable

rack• RMFS


• Rackracer

• Perfect pick

• Autostore


Loads on shuttles



• Robot picking

NEW, ROBOTIZED STORAGE/PICKING SYSTEMS

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A. Shuttle based (AVS/R) systems

– Horizontal (Autostore)

B. Shuttle based, dynamic racks: Movable robots (RMFS:

Kiva)

C. Loads on shuttles

– Puzzle-based storage: PBS

– Shuttle-based sorting

D. Pick stations

E. Picking with AGVs

– PS AGVs

– Mobile pick AGVs

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FULLY ROBOTIC WAREHOUSES EXIST


A. AVS/R SYSTEMS(AUTONOMOUS VEHICLE-BASED STORAGE AND RETRIEVAL)

Horizontal movement only:

– Savoye

– Symbotic

– Knapp

– Vanderlande (Adapto)

– Dematic

– SSI Schafer

– Etc.

Horizontal + vertical movement:

– Autostore (lifting capabilities)

– OPEX: Perfect Pick

– Exotec Skypods

Horizontal + diagonal movement:

– Fraunhofer IML (rack creeper)


A.

-Malmborg, 2002

-Fukanari, Malmborg, 2008

-Roy et al., 2012, 2014, 2015

-Marchet et al., 2012

-…….

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A. AVS/R SYSTEMS

Horizontal movement only:

– Savoye

– Symbotic

– Knapp

– Vanderlande (Adapto)

– Dematic

– SSI Schafer

– Etc.

Horizontal + vertical movement:

– Autostore (lifting capabilities)

– OPEX: Perfect Pick

– Exotec Skypods

Horizontal + diagonal movement:

– Fraunhofer IML (rack creeper)


A.

RESEARCH ON AUTOSTORE

Research questions

• Dedicated storage, or shared storage?

• Zoned storage or not?

• …


Storage Stack

Workstation

Robot

Schematic View

Zou, De Koster, Xu, Transportation Science, 2018

Semi-Open Queueing Network model

Aggregation + CTMC analysis

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Autostore: Dedicated or Shared storage?

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Dedicated Shared

Yu et al. (POM, 2015)


Autostore—System cost optimization

Given: throughput, storage capacity, #products

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𝐶𝑅 = € 30,000 amortized in 7 years

𝐶𝐹𝑆 = € 40 amortized in 10 years

𝐶𝑆 = € 500/m2 amortized in 30 years

4 pick stations

λ = 300 picks/hour, 10 sec/pick

𝑁 = 10,000

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Autostore—System cost optimization

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𝐶𝑅 = € 30,000 amortized in 7 years

𝐶𝑆𝑃 = € 40 amortized in 10 years

𝐶𝐹𝑆 = € 500/m2 amortized in 30 years

4 pick stations

λ = 300 picks/hour, 10 sec/pick

𝑁 = 10,0000

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

1

0 0,2 0,4 0,6 0,8 1

s=0,065

B. ROBOTIC MOBILE FULFILMENT SYSTEMS

MOVABLE ROBOTS (AGV)

AGVs transporting racks

• Kiva (Amazon Robotics)

• Grey Orange

• Swisslog/Grenzebach

• Scallog

• Suning

• Etc.


B.

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RECENT RESEARCH ON RMF SYSTEMS

• Lamballais et al. (EJOR, 2017)

Objective: minimizing order throughput time.

• Zou et al. (EJOR, 2017)

Objective: impact of battery charging policies

• Boysen et al.(EJOR, 2017)

Objective: determine slotting strategy for pods

• …


C. LOADS ON SHUTTLES: PUZZLE-BASED STORAGE

C.


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LOADS ON SHUTTLES - SORTING


GridStore/GridSort – Gue/Furmans

PUZZLE-BASED STORAGE/SORTING


Little literature yet

• Gue, Kim, NRL, 2007: optimal movement patterns

• Gue, Furmans, Seibold, Uludag, IEEE T on Automation Science, 2014:

deadlock free gridlock control algorithm

• Zaerpour, Yu, De Koster, Transportation Science, 2017: optimal design

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D. ADVANCED PICK STATIONS


D.


Crane/truck-

based

Shuttle/lift based

Single/double

deep• AS/RS



• Conveyor

• Rotating

conveyor

• Push-back rack

• Flow rack

Static

rack


26



Automated storage

systems

moveable

rack• RMFS


• Rackracer

• Perfect pick

• Autostore


Loads on shuttles

• PBS

• Shuttle sorting


• Robot picking

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E. PICKING WITH AGVS

MANUAL WORKING WITH THE ROBOT/AGV


Fetch Robotics

E.

MODELING PS-AGVS


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ROBOTIZED:

FULLY AUTOMATED PICKING?


TORU - Magazino

RESEARCH OPPORTUNITIES


09-10-2018

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RESEARCH OPPORTUNITIESMost systems shown have hardly been researched

Only (to some extent): RMF, AVS/R systems

Opportunities:

• Manual order picking with AGVs

– Routing, control, assignment

• Integrated systems: AVS/R system with order picking

• Interaction man – robot: Operator 4.0

Research questions:

• How do they compare to other (manual) systems?

• How to divide work in robot and human tasks?

• How do humans perform with such systems?

• How to select systems?

• How to design: layout, #workstations, #robots?

• How to control for performance (throughput, flow times, response)?

• How to flexibly handle peaks?

• How to integrate them in supply chain concepts?


6

RESEARCH OPPORTUNITIESMost systems shown have hardly been researched

Only (to some extent): RMF, AVS/R systems

Opportunities:

• Manual order picking with AGVs

– Routing, control, assignment

• Integrated systems: AVS/R system with order picking

• Interaction man – robot: Operator 4.0

Research questions:

• How do they compare to other (manual) systems?

• How to divide work in robot and human tasks?

• How do humans perform with such systems?

• How to select systems?

• How to design: layout, #workstations, #robots?

• How to control for performance (throughput, flow times, response)?

• How to flexibly handle peaks?

• How to integrate them in supply chain concepts?


6

09-10-2018

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ROBOTIZED WAREHOUSES

It is not yet so far

We still have a long way to go

But we are on the way

Great opportunities for Research!


Interested in Review Paper?

Mail René de Koster: [email protected]

PowerPoint Presentation · 09-10-2018 1 warehouse robotics: state of the art and research...

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