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12-07-2017
1
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
R. de Koster, Warehousing 4.03
WAREHOUSING 4.0
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Main features
• Decentralized control and decision making
• Autonomous
• Elements are interconnected
WHAT DOES IT MEAN?
R. de Koster, Warehousing 4.05
Source: DHL, 2014
OPPORTUNITIES
But also threats….
R. de Koster, Warehousing 4.06
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
R. de Koster, Warehousing 4.07
Source: K. Furmans • Research opportunities
Properties: Design patterns:
1. What you see is what
you get
2. Plug & Play capability
3. Scalability
• Reconfigurability
4. Robotized
5. Reliability through in-
place replacement
• Inherent safety
6. Self adaptability
• Slack capacity
• Modularity
• Function integration
• (partly) decentralized
control
• Interaction
• Standardized physical and
information interfaces
• Network structure
IMPLICATIONS
R. de Koster, Warehousing 4.08
Source: K. Furmans 7. Research opportunities
WYSIWYG
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• 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
R. de Koster, Warehousing 4.010
2.
FlexConveyor, KIT, Courtesy: Kai Furmans
SCALABLE - RECONFIGURABLE
12.07.201711
Implementation of GridFlow, KIT – courtesy: Kai Furmans
3.
P-N-P; SCALABLE, RECONFIGURABLE
R. de Koster, Warehousing 4.012
Developments
• FlexConveyor
• GridFlow
• GridPick
• GridSorter
Commercial products
• Gebhardt: FlexConveyor
• Valor: QliqFlow
• Alvey: EvoLinkIntralox
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ROBOTIC STORAGE, ROBOTIC SORTING
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GridStore/GridSort – Gue/Furmans
ROBOT SORTING
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Shentong parcel service: 300 robots
ROBOTIZED…
FULLY ROBOTIC WAREHOUSES?
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4
FULLY ROBOTIC WAREHOUSES EXIST
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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
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Autostore, Catch of the Day, Australia
RESEARCH ON AUTOSTORE
Research questions
• Dedicated storage, or shared storage?
• Zoned storage or not?
• …
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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
R. de Koster, Warehousing 4.0
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)
R. de Koster, Warehousing 4.024
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5
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)
R. de Koster, Warehousing 4.025
RESEARCH ON PERFECT PICK
• What is better : AVS/R or PP?
R. de Koster, Warehousing 4.026
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
R. de Koster, Warehousing 4.027
ELA 2017
MODEL (WITHOUT ROBOT BLOCKING)
28
Approximate Mean Value Analysis
R. de Koster, Warehousing 4.0
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.
R. de Koster, Warehousing 4.029
B. MANY VEHICLE (ROBOT)-BASED STORAGE SYSTEMS
ON THE MARKET
AGVs transporting racks
• Kiva (Amazon robotics)
• Grey Orange
• Swisslog/Grenzebach
• Scallog
• Etc.
R. de Koster, Warehousing 4.030
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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
R. de Koster, Warehousing 4.034
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
R. de Koster, Warehousing 4.035
AGV – AUTONOMOUS, INTELLIGENT, SWARM
R. de Koster, Warehousing 4.036
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ROBOTIZED
BUT WHAT ABOUT DRONES?
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RELIABLE
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• Robots take themselves out of operation when maintenance is needed
Symbotic robot, C&S Grocery, Newburgh, NY
5.
SELF-ADAPTABLE
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Electronic display – click and work
6.
Source: Fraunhofer IML
FROM WAREHOUSE TO CUSTOMER!
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Properties: Design patterns:
• What you see is what you
get
• Plug & Play capability
• Scalability
• Reconfigurability
• Reliability through in-place
replacement
• Inherent safety
• Robotization
• Self adaptability
• Slack capacity
• Modularity
• Function integration
• (partly) decentralized
control
• Interaction
• Standardized physical and
information interfaces
• Network structure
FUTURE PRODUCTION, INTRALOGISTICS AND LOGISTICS
R. de Koster, Warehousing 4.041
• 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
R. de Koster, Warehousing 4.042
7.
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8
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?
R. de Koster, Warehousing 4.043
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
R. de Koster, Warehousing 4.044
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
R. de Koster, Warehousing 4.045
Interested in Review Paper?
Mail René de Koster: rkoster@rsm.nl
CONTACT
rkoster@rsm.nl
www.rsm.nl/rdekoster
R. de Koster, Warehousing 4.046
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