PowerPoint Presentation Session 4_René de...12-07-2017 1 warehousing 4.0 pi enabling technologies...

12-07-2017

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WAREHOUSING 4.0

PI ENABLING TECHNOLOGIES

RENE DE KOSTER

ERASMUS UNIVERSITY ROTTERDAM

IPIC 2017

JULY 4-6, 2017

IPIC 2017, GRAZ, 4-6 JULY

INDUSTRY 4.0

2

Centralized power generation

thermic / mechanical

Decentralized powergeneration

electric

Central / local

controls

Decentralized,

connected controlsDrivers

1.0: mechanization

2.0: electrification

3.0: automation

4.0:

digitization &

autonomy

End of 18th

century

Begin of the

20th century

Begin of the 70’s

20th century

today

Source: K. Furmans

R. de Koster, Warehousing 4.0

WAREHOUSING 4.0


WAREHOUSING 4.0


Main features

• Decentralized control and decision making

• Autonomous

• Elements are interconnected

WHAT DOES IT MEAN?


Source: DHL, 2014

OPPORTUNITIES

But also threats….


Infected M.E.Doc bookkeeping software update infected many

companies and spread rapidly worldwide

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Properties: Design patterns:

• What you see is what you

get

• Plug & Play capability

• Scalability

• Reconfigurability

• Robotized

• Reliability through in-place

replacement

• Inherent safety

• Self adaptability

• Slack capacity

• Modularity

• Function integration

• (partly) decentralized

control

• Interaction

• Standardized physical and

information interfaces

• Network structure

IMPLICATIONS


Source: K. Furmans • Research opportunities


1. What you see is what

you get

2. Plug & Play capability

3. Scalability


4. Robotized

5. Reliability through in-

place replacement

• Inherent safety

6. Self adaptability

• Slack capacity

• Modularity



control

• Interaction




IMPLICATIONS


Source: K. Furmans 7. Research opportunities

WYSIWYG


• From CAD drawing -> VR

• From VR -> Lab

• From Lab -> Floor

C

A

D

↓

V

R

V

R

↓

L

A

B

LAB↓FLOOR

1.

P-N-P


2.

FlexConveyor, KIT, Courtesy: Kai Furmans

SCALABLE - RECONFIGURABLE

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Implementation of GridFlow, KIT – courtesy: Kai Furmans

3.

P-N-P; SCALABLE, RECONFIGURABLE


Developments

• FlexConveyor

• GridFlow

• GridPick

• GridSorter

Commercial products

• Gebhardt: FlexConveyor

• Valor: QliqFlow

• Alvey: EvoLinkIntralox

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ROBOTIC STORAGE, ROBOTIC SORTING


GridStore/GridSort – Gue/Furmans

ROBOT SORTING


Shentong parcel service: 300 robots

ROBOTIZED…

FULLY ROBOTIC WAREHOUSES?


4

FULLY ROBOTIC WAREHOUSES EXIST

R. de Koster , Warehousing 4.016

Source: Azadeh et al., 2017

AUTOMATED STORAGE/PICKING SYSTEMS

Crane/truck-

based

Shuttle/lift based

Single/double

deep• AS/RS

Static

rack

Multi-Deep• Captive

satellite

• Roaming

satellite

• Conveyor

• Rotating

conveyor

• Push-

back rack

• Flow rack R. de Koster , Warehousing 4.017

Carousels• Horizontal

• Vertical

• VLM

Automated storage

systems

moveable

rack• RMFS

Single/double

Deep• AVS/RS

• Rackracer

• Perfect pick

Multi-

Deep• Shuttle/

Transfer car

Compact

Storage• PBS

• Autostore

NEW, ROBOTIZED STORAGE/PICKING SYSTEMS

18

A. AVS/R systems

– Horizontal (Autostore)

– Vertical (Perfect Pick)

B. Movable racks with robots (RMFS: Kiva/Amazon Robotics)

C. AGV-based picking

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A. ROBOTIC WAREHOUSE EXAMPLES


Autostore, Catch of the Day, Australia

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, 2017

Queueing model

Autostore: Dedicated or Shared storage?

21

Dedicated Shared

Yu et al. (2015)

R. de Koster, Warehousing 4.0 22

Zoned Storage Stacks

Autostore: Random or Zoned Storage?

Random Storage Stacks

• Less storage space• More storage space

• Shorter system throughput time ?

• Storage policy—among storage stacks


Autostore—System cost optimization

23

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 = 10,000

MANY VEHICLE (ROBOT)-BASED STORAGE SYSTEMS ON

THE MARKET

Horizontal movement only:

– Savoye

– Symbotic

– Knapp

– Vanderlande (Adapto)

– Dematic

– SSI Schafer

– Etc.

Horizontal + vertical movement:

– Autostore (lifting capabilities)

– OPEX: Perfect Pick

Horizontal + diagonal movement:

– Fraunhofer IML (rack creeper)


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MANY VEHICLE (ROBOT)-BASED STORAGE SYSTEMS ON

THE MARKET

Horizontal movement only:

– Savoye

– Symbotic

– Knapp

– Vanderlande (Adapto)

– Dematic

– SSI Schäfer

– Etc.

Horizontal + vertical movement:

– Autostore (lifting capabilities)

– OPEX: Perfect Pick

Horizontal + diagonal movement:

– Fraunhofer IML (rack creeper)


RESEARCH ON PERFECT PICK

• What is better : AVS/R or PP?


Azadeh, Roy, De Koster (2017)

ASSUMPTIONS:

Compare Perfect Pick™ vs. AVS/R (discrete or continuous lift)

• One aisle

• One L/U point

• All dual command cycles

• No robot blocking

For each system, for each storage capacity:

optimize shape of system for given throughput capacity

Then: compare for annual costs


ELA 2017

MODEL (WITHOUT ROBOT BLOCKING)

28

Approximate Mean Value Analysis


LU point

COST-PERFORMANCE COMPARISON

#Storage

Locations

System Throughput (dual command cycles per hour)

Assumptions: shuttle=€15000; discrete lift= €50000; continuous lift= €60000; iBot= €15000;

amortized in 7 years; interest rate=10%

Floor space= €70/m2/year; picker cost= €35000/year.


B. MANY VEHICLE (ROBOT)-BASED STORAGE SYSTEMS

ON THE MARKET

AGVs transporting racks

• Kiva (Amazon robotics)

• Grey Orange

• Swisslog/Grenzebach

• Scallog

• Etc.


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B. ROBOTIC MOBILE ORDER FULFILLMENT SYSTEM

31

RECENT RESEARCH ON RMF SYSTEMS

• Lamballais et al. (EJOR, 2017)

Objective: minimizing order throughput time.

• Zou et al. (working paper, 2017)

Objective: impact of battery charging policies

• Boysen et al.(EJOR, 2017)

Objective: determine slotting strategy for pods

• Etc.

R. de Koster, POMS2017, Warehouse Robotics32

PROBLEM WITH VEHICLE SYSTEMS: HIGH COST

R. de Koster, Wareholusing 4.033

Optical guidance

Installation time: weeks

Cost: €2000/vehicle

C. ROBOTIZED

MANUAL WORKING WITH THE ROBOT


Fetch robotics, human-robot interactionTORU – Magazino: fully automated

MANUAL PICKING WITH ROBOTS

AGV follows person:

• Fetch robotics

• Pick-by-glove (Crown QuickPick Remote)

• Still iGo neo

• Toyota

AGV guides person:

• Locus Robotics


AGV – AUTONOMOUS, INTELLIGENT, SWARM


Warehouse Robots at Work.mp4

Warehouse Robots at Work.mp4

12-07-2017

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ROBOTIZED

BUT WHAT ABOUT DRONES?


RELIABLE


• Robots take themselves out of operation when maintenance is needed

Symbotic robot, C&S Grocery, Newburgh, NY

5.

SELF-ADAPTABLE


Electronic display – click and work

6.

Source: Fraunhofer IML

FROM WAREHOUSE TO CUSTOMER!



• What you see is what you

get

• Plug & Play capability

• Scalability


• Reliability through in-place

replacement

• Inherent safety

• Robotization

• Self adaptability

• Slack capacity

• Modularity



control

• Interaction




FUTURE PRODUCTION, INTRALOGISTICS AND LOGISTICS


• Research opportunities

RESEARCH OPPORTUNITIES

• All systems shown have hardly been researched

– RMFS, AVS/R systems

• Manual order picking with AGVs

– Routing, control, assignment

• Interaction man – robot

– Operator 4.0


7.

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RESEARCH OPPORTUNITIES

• All systems shown have hardly been researched

– RMFS, AVS/R systems

• Manual order picking with AGVs

– Routing, control, assignment

• Interaction man – robot

– Operator 4.0

• How do they compare to manual systems?

• How to divide work in robot and human tasks?

• 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?


7.

WAREHOUSING 4.0

Enabler for the PI

It is not yet so far

We still have a long way to go

But we are on the way


WAREHOUSING 4.0

Enabler for the PI

It is not yet so far

We still have a long way to go

But we are on the way


Interested in Review Paper?

Mail René de Koster: [email protected]

CONTACT

[email protected]

www.rsm.nl/rdekoster


mailto:[email protected]

http://www.rsm.nl/rdekoster

PowerPoint Presentation Session 4_René de...12-07-2017 1 warehousing 4.0 pi enabling technologies...

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