How to Optimize Pallet Storage and Picking

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Pallet Storage and Handling Systems

1. 2. 3.

Pallet Storage Systems Pallet Handling Systems Pallet Storage and Handling Systems Selection

Pallet Storage & Handling Systems

In our taxonomy of pallet storage and handling systems we begin the classification by dt hi ve i tdwi nog stuhbe- ss yy ss tt ee mm ss iwn ot or k( 1h)apnadl -l ient -shtaonr adg, et hsey ss tt eo mr asg ea ns dy s(t2e)mp as el lleetc ht iaonndilsi ndgr isvyesnt epmr ism. Ta rhiol yu gb hy t b t u h y r e n t h c o o e v n e c c r o e n o r c f n e t h r f n o e r i f t o i e m r m h p s i r g i o n h v p e h a d a l n l s e d t t l o i s n r t a g o g r p e a r g d o e d e . n u T s c h i t t i e y v c it a h y n o a d ic n e i d s o t f d r t a i h c d t e a e h o te a ff d n s d b in l y in r t g e h q s e y u s i o r t n e e - m d h a c i a s n p d d i r t i i a n v l v e i n e n n v p t e r o s i r m t y m a a e r n n il d t y . We conclude with a description of how the combined decision is optimized (Section 3).

Figure.1 World Class Warehousing Taxonomy of Pallet Storage and Handling Systems

1 Pallet Storage Systems Pallet storage systems fall into three sub-categories based on the nature of the racking tSyyps et e: m( 1s ). EPaaclhl eat l tSetrancaktiinvge -Siyt sstpe rmoss,, c( o2n) sS, taantdi c r eRlaact ekdi ncgo sStyss-t ei smdse, sacnr idb e(d3 )b eDl oy nwa. m i c R a c k i n g

Pallet Storage & Handling Systems

1.1 Pallet Stacking Systems PS taal lcekti ns gt a Sc ky isnt eg ms ys .s tTehmesr eh aa vr ee pt wa lol e tt ys pset as c ok fe dp aol nl e tt ospt aoc fk ionnge saynsot et hmesr , –h ebnl oc cek t hs et a nc ka imn ge , Poaf lt leent referred to as floor storage, and pallet stacking frames. Block Stacking Bs tloorcakg set al acnkei ns g( br el of ec kr ss )t ot yupni ci ta llloya3d st os t1a0c kleoda dosndteoepp o. f Belaocchk os tt ha cekr i na ng di ss pt oarret di c uolna rtlhyeefflfoeoc tri vi ne wi n hl ea nr gtehienrcer ae mr eemn tusl ti .iep. l seepvaelrl ae lt sl opaedrs SoKf Ut h(es tsoacmk ek Se Ke pUi na gr eurnei ct )e iavnedd wa nhde/noirnwv ei tnhtdo rr ay wi sn tautr no ne de tsitma cek. iBnegc aius s ee ansoyr atcok i ni mg pi sl erme qeunitr,e da,ntdh e iitn vaelsl ot mwes n tniena ar - bi nl of icnki tset a fclkeixni gb isl iytsyt e fmo ri s flloowo r, sbpl oaccke configuration.

Figure 2 Block stacking in a Coca-Cola Plant Warehouse. (Charlotte, USA) Note that some loads are stacked one high, two high, two and half high by straddling adjacent stacks and some three high.

Pallet Storage & Handling Systems

Floor storage may be the only reasonable pallet alternative iwnitthhelofiwgucrleeabreilnogws.. Such was the case at the Japanese beverage wholesaler’s multi-story DC

Figure 3 Block stacking in low-bay space. (Tokyo, JAPAN) Block stacking is sometimes is the only viable alternative due to capital restraints. Such is the case in the Latin American CPG finished goods warehouse depicted below.

Figure 4 Block Stacking a Large Latin American CPG Finished Goods Warehouse

Pallet Storage & Handling Systems

Figure 5. Block stacking with case picking front.

Stack Height Constraints Th ehieg hs tt oorfaegaec hd ebnl os ictky. iAn mb lyorci ak ds toaf cfka icnt go rssyms t ae ymcsoins sdt reat ienr ms tiancekdhteoi gah tl as rignec l du edgi nr ege: b y t h e s t a c k • load shape, • load weights, • crushability of the loads, • pallet conditions, • floor loading restrictions, • weather (due to corrugated softening in high humidity), • vehicle lift height capacity, and/or • building clear height.

Pallet Storage & Handling Systems

Figure 6 The height of block stacking in one of our cement manufacturer client’s warehouses is constrained by product weight and shape.

Figure 7 Block stacking in an aluminum can plant. Light weight and uniform permits stacking four high.

Pallet Storage & Handling Systems

Figure 8 Block stacking in a raw material warehouse. (Lima, PERU)

Honeycombing Ha oh no er iyzcoonmt abl i nl agn ies ot hr ev leor st si c oa fl sc tool ruamg en coaf psat co irt ay gde u. eI f tloa nt he edreepqt uhisr eamr ee tnot ot od es teopr, ea as si si nt ghlee cSaKs Ue ii nn tt ho oe sphhoortto, ,t ot hoel af lrogoeras ppaocret i ionn for of tnht eoffl ot ho er sbpaaccke ipsadl leevt so ties dutnodaeirsul et isl .i zI fe tdh. eI fptahl el e lt as naer ed ne po tt hesa sairl ye stackable, too much of the available clear height is lost. Loads in a block are retrieved last-in-first-out (LIFO). Hence, if highly restrictive (femaosirbelestsrtiocrtatgheanmelotthoodr.code date) FIFO requirements are in place, block stacking is not a As loads are removed from a storage lane, a space-loss phenomenon referred to as honeycombing occurs with block stacking. Since only one SKU can be effectively stored in a li as neem, epmt i epdt y. Tpha el lreet f sopr ae c, iens oarrde ecrr et oa tme da iwn thaiicnh hciagnhnuotti lbi zeaut itoi lni zoefdt he ef f ea cvtai vi l ea lbyl eu ns ttoi lraa ng ee pn ot isriet iloannse, the lane depth (number of loads stored from the aisle) must be carefully determined. A lane

Pallet Storage & Handling Systems

dd ee pp tt hh yo ipetl idmi ni zgatthi oe nl oawn ea sl yt sf il so odresvpeal oc ep er edqfuoirr ea mr eecnetnf to rc lei ea nc ht iist epmr eissernetceodmi nm Fe ingduer de t3h. r oT uh ge hl at hn ee analysis.

Figure 9 Honeycombing in a large beverage distribution center.

Pallet Storage & Handling Systems

Figure 10 Block Stacking Layout

Lane Depth Optimization Wo pet i ums iez el atnhee duet ipl it zha ot ipotni mo fi zf al ot ioorns pt ao chee. lOpumr li at ingea tdeeapnt hd ompitni mi mi zi zaet i ho no nseyys ct eo mm bt ai nkge se fi nf etcot sa cacnodu nt ot xa,lya,ragnedcoznasnudmceormppruotdeuscatsndcoompptiamnayl isstoinraFgigeularne e1d1e. pth for each SKU. An example output for

Pallet Storage & Handling Systems

Figure 11 Lane Depth Optimization

In addition to optimizing lane depths… 1. 2 3 . . RR ee t- wr i eavr ee hf rooums emwohsetndne pe cl eetsesda rl ay n. e f i r s t . 4. AMlilxowlanaeccdeespstfhrsomwibthoitnhasibdaeys.. 6 on one side. 2 on the other. Etc.

Pallet Stacking Frames Pc oanl l teat i nset da csktienegl uf rnai tms ems a adree u epi tohf edr e cf rkasma ensd aptot satcsh. e Sdt atcok i sntga nf rdaamr de s wa or eo dpeonr t apballel eat ns doer n sa ebllfe- tdhi sea susseemr btloedsat na cdkstmoraetderiinala ms eivnei mraul ml oaamd souhni gt ho.f spWa chee. n n ot i n us e , t he f ra mes ca n be Stacking frames are commonly used when loads are not stackable and when other rpaocpkui nl agr awl theernn at ht ievrees i as rae snhootr tj -utsetri mf i a sbpl ei k. eAi nl s oi n, vsei nn ct eo rsyt aa cnkdi nt hg ef rf raammees s caarne bnee el edaesde tdo, it nh cerye aa sr ee storage density in what is normally open floorspace. All of the storage density losses due to honeycombing described earlier for block stacking also apply to stacking frames.

Pallet Storage & Handling Systems

Figure 12 Pallet stacking frames. (NTT Logistics, Tokyo, JAPAN)

Pallet Storage & Handling Systems

Figure 13 Inbound pallet stacking frames. (Ford, Atlanta, USA)

1.2 Static Racking Systems Satnadticcarnatcilkeivnegrsryasctke.ms include single deep pallet rack, double deep pallet rack, drive-in rack, Single-Deep Pallet Rack Sp irnogvlied- idnege pi mpma el l de ti a rt ea c(kpi incgk -ifsa cae )s iamc cpel es s ctoon es tarcuhc tl oi oand os ft omr eedt a(li . eu.pnr oi g hh tosn ea yncdo mc r bo isns g- m) . e Umnbl ei kr es bi ml omc ke ds itaatcekl iyn ag v, awi lhaebnl ea i np aslilne gt l sep- da ec ee pi sr ac rc ek ai nt egd. bAyl s toh, es i rnecme or va ac kl ionfg ai sl osaudp, pao pr tai lnl eg t eovpeer ny i nl oga di s, sStKaUc ks icnagnhbeei gshtta icskne odtilni mt hi teesdabmyet hvee rsttiaccakl acbo il lui tmy na nodf /s ot orrcargues hs pa abci lei t. y o f t h e l o a d s , a n d m u l t i p l e

Pallet Storage & Handling Systems

Figure 14 Single deep pallet rack (American Cancer Society’s National Logistics Center, Atlanta, USA) Loads do not need to be stackable and may be of varying heights and widths. In isnusptpanorctessowr dheecrkeinthge. load depth is highly variable, it may be necessary to provide load A typical single-deep rack position costs between $40 and $50. The major advantage it so faui lsl l ea sc c- etsyspi bi ci al iltl yy t5o0 a%l l tuon6i t0l%o a odfs t. hTe haev ma i laaj bo lredf il soaodr vsapnatcaeg. eAi ss at hree sa uml to, ui nn tc aosf essp wa cheedr ee vt oh teer de ai nr ea tfharcei ne go rp emropreenpd ai clul eltasr ot no -thhaensdt oorf aagneSaKi sUl e, ams at oyrba egepmr eeftehroa bd lteh. a t h o u s e s a t l e a s t t w o p a l l e t s Selective pallet rack might be considered as the "benchmark" storage mode, against ws yhs itcehmos t bheenr esf yi ts tf er omms tmh ae yu sbee ocfo amt pl ea ar es td sfoomr ea ds ve al encttai vg ee sp aa nl l de t driascakd vf oarn tSaKgUe ss . wMh oosset ss tt oo rr aa gg ee requirement is less than three to five pallet loads.

Pallet Storage & Handling Systems

Figure 15 Single deep pallet rack with pallet staging bays. (London, ENGLAND)

Figure 16 Single deep pallet rack with all-clear aisle lights. (Otto, Munich, GERMANY)

Pallet Storage & Handling Systems

Figure 17 Single deep selective rack. (Caterpillar, Atlanta, USA)

Pallet Storage & Handling Systems Double-Deep Pallet Rack a n D d e o e v u d a b n e le d ta - . d g I e e n e m o p f o p t s a w t l l c o e a - t s d r e e a s e c a p k 5 s r 0 a a % r c e k a m i f s a e l c e e e . Ha notwi cei pv ae tre, wa e7 c0a%n nt oo t7a5s%s u mu tei l it zhaatti oa n5 0o f%t ht er uaevsapi laacbel es aovpienngisnwg si l (l dbue ea ct oh iheov ne de ysci on mc ebwi negc)a. n( 8o0n%l y to 85% utilization is common for single deep racking.) 16 r i e n s l p g y s a s c ( e e p l s e e a c r v t p i i v e n n e g d s r i a i c s c u k a l s c a h r t i h e t a o v t e t a d h r v e e e t a r w s is u o l s e p ) s a in i l s l g e l t t e h p - a d o t e s e i f t e p i w o s n e e s l r e d c a e t i i s e v l p e e . s r a T a c h r k

Figure 18 Double deep pallet rack. (Storemax, London, ENGLAND)

Double deep racks are typically used when the storage requirement for an SKU is five pp aa ll ll ee tt ss . o r ( gArsesai gt enri nagn dS KwUhse nwpi trho dounclty i sa r es icnegi vl ee dp aa nl l de t poi cnk-ehda nf rde qt uo e nd toluy bilne -md euel pt i prl ea sc koi fn gt wios na roen ss teonrsei dc atlws oi ndc ee eopn, ea odfotuhbel et wr eoapc ohsfiot iroknlsi fitni sa rfeaqc ui ni rgeids faourt os tmo raat igcea/l lrye twr iaesvt aeld. . ) S i n c e p a l l e t s

Pallet Storage & Handling Systems

Figure 19 Double deep pallet rack accessed via double deep reach truck.

Drive-In/Thru Rack y a s pp oa lslseitbsl ea tbae chaeui sgeh tt haeb or av cekt hc oa tn soifs tt sh eo fl iuf tptrri ug hc kt . c oTl hu ims nc so nt hs tartuhc at ivoen hpoerri mz oint st aml rual ti li sp lteo l seuvpe lpsoor tf pallet storage, each level being supported independently of the others. l p D if r r t o i v t v r e i u d -i c i n n k g r t a o s c t d o k r r s i a v e g e x e t i l n e a n n t d o e s t t h h fr e e o r m r a e c d 5 k u t s c o e t i v 1 o e 0 n r a lo o l a f p d a a s i l s l d e le e t e p s p p o s a a i c n t e i d o b n 3 e s t g o a u n 5 n d l w o s a t i o d th r s e h d o i o g r u h r b . e l t e D r - r i d e iv e v e e e p - a i n p p r a a a l l l c l e e k t t s . r a a T l c l h o k i w s b i

Pallet Storage & Handling Systems

Figure 20 Drive-In Rack in a Honda Parts DC One drawback of drive-in rack is the reduction of lift truck travel speed needed for shaofnee yncaovmi gba itni ognl ows si tehsi ns i nt hc ee nc oo nmf i onrees tohfa nt hoen reaSc Kk Uc os nh os turludc tbi eo nh. o uAs endo tihne ra ldarnaew. bAasc ka irse stuhlet dA rs i wv ea- si nt hr ae ccka si se bweist thubsleodc kf osrt as cl okwi n gt o, l mo aeddsi us mh o vuel dl obcei t ryeSt Kr i Ue vs ewd i wt hi tt he na oLrI FmOodr ei s pc iapl ll ient se oa nn d- hwa ni tdh. a retrieval discipline to free up each lane as quickly as possible. Drive-thru rack is merely drive-in rack that is accessible from both sides of the rack. Ir te it sr ioe fvt eedn autstehde footrhsetra eg ni ndg. lTohaed ss ai mn ae cf loonws -i dt herrua tfiaosnhsi of onr wd reirvee a- i np ar lal ce kt iasplpo laydteoddarti voen- et hernudr aa cnkd.

Pallet Storage & Handling Systems

Cantilever Rack Cp aa lnl teitlse.v Ietr irsatcykp iiscaclol ymamc coenslsyeudsveida tsoi dheol ouasde el or nt rguocbkj. e c t s s u c h a s b a r st o c k , l u m b e r , a n d

Figure 21 Cantilever rack in a Caterpillar Distribution Center. (Atlanta, USA)

Figure 22 Bar stock in a cantilever rack. (Aurora, Indianapolis, USA)

Pallet Storage & Handling Systems

1.3 Dynamic Racking Systems D(PyBnRa)m, aicnrdamckoinbgilesypsatlelemtsrafocrkp(aMllPeRt )s.torage include pallet flow rack (PFR), push back rack Pallet Flow Rack Irna i pl safl rl eotmf l oown ereanc kd loofaad ss taorrea gc oe nl va enyeetdo (tFhIeF Oo t)hoenr . s kAast ea wl oha edeilscroenmv eoyvoe rd, frrool ml e rt choenfvr eoynot ro, foar stotoprraogveidlaenheigthhethnreoxut glohapduat dpvaallnect esstotroatgheeapnidckrefatrciee.vTalhe main purpose of pallet flow rack is and good space utilization. Hence, it Ti shues me da fj oo rr tdhi os as ed vi taenmt asgwe iot hf phai gl lhe tpfal lol we t irna vc ke ni tsotrhyet ue rxnp oe vnes re ;a $n2d0w0 i tt ho s$e5v0e0r apl epra pl l ae ltlse to ns t- oh raangde. position.

Figure 23 Pallet flow rack (Rear View)

Pallet Storage & Handling Systems

Figure 24 Pallet flow rack. (New Installation)

Figure 25 Pallet flow rack replenishment.

Pallet Storage & Handling Systems

Push-Back Rack ePmu sphl -obyai nc kg raarcaki lp- gr ou vi di de edsclaarsrti-ei nr -f foi rr seta- oc hu tpdael leept ll oa na de . (At ys pai cl oa al ldy itswpol at oc ef di vien pt oa lsl teot sr adgeee, pi t)s swt oeri ag ghet ac rneda tt eh er of oo rmc ef oorf tthhee apdudt iatwi oanya lv leohaidc l. eApsuas hl oeasdt hi seroe tmh oe rv el od af dr os mi n t thhee f lraonnet bo af ca ks ti no rt oa gt eh el alnaen, et ht oe we veeirgyh St Ko fUt/hlea nr eemh aa isnai nl ogal do at dh aatuitsoimmamt iec da li layt ealdyvaacncceesss irbelme aa li on ni nggt lhoea adiss lteo. t Ihne arda dc ki t if oa nc e, .s iHn ec ne cael l, oa tf ttahceh pmuet na tws aays awnads rteht er i ceavsael twa ikt ehs dpol au cbel ea- td teheep rraacckkf. a Ac en, tahdevraeni tsa ng oe no ev ee dr df or ri vsep- ei nc i raal cl ki f ti st rtuhcakt e s r t a g o k n n f 5 K e e w is r i n a l t v l h e e r t r e p t e i o c t s t t h i e o o n n n . p e ay lcl oe mt s boinn-gh. aPnuds. hT- bh ae ccko rs at cokf a o i l p th o 0 U r p s e d g $ 1 t S h e v a o i r - n a m c t i t s y h p e a r p ic e p a i r l s o p n p u o r s i h n a - t e b e e a d fo c t k r o m r d a e r c d i k v i e u is m i n in t t o o th t f h e a

Figure 26 Push-Back Rack in a Honda Parts DC (Honda, Atlanta, USA)

Pallet Storage & Handling Systems

Figure 27 Two-Deep Push Back Rack, American Cancer Society, Up Against a Wall, No FIFO requirement (American Cancer Society, Atlanta, USA)

Mobile Pallet Rack eMnot bi riel er po awl l eotf rr aa cc kk ss at or eme os sveenat wi a lal yy fsri on mg l ea-ddjeaecpe npta rl laectkr ar oc kwsso. nTwh eh euenlds eorrl yt ri na gc kpsr pi necrimp ai tl tiisn gt haant av iasl lueas bal er es po ancl ye . j uAsct ci fei es sd two hae pn atrht ei cyu laarre sbt oe irna gg eu rs oe dw; itsh ea crheisetv eo df tbhye mt i mo vei nt gh e( ymaerceh aonc iccuapl lyyi nogr mt haa nn u1a0l l%y ) ot hf et haed jfal ocoe rnst praocwe ai sn dd ecvroetaetdi ntgoaani saliessl e, ai nn df rsotnotr aogf et hdeednes si ti yr eids rt ho we h. iAg sh ea srt eos fu al tn, lye sosf o i t s h f e s a c n p a y a r l c o l e e f t t a h s n e t d o a r l e a t x e g p r e n e a n a l t s t i i e v v r e e n s , a w a t n i e v d e h s f a o . v r U e s n c l o o fo n w r s t - i u m d n e o a r v t e i e d n l . y g , H S t e K h n e U c s p e a , w m ll i e t o t h b r i o e l n e tr e r i a e t c v o k a t s l h p a r r r e e o e d j p u u s a c t l t l i i f e v i t a i s t b y o l e n is w - h t h h a e e n n d l o . s w p T a e h c s e e t cost of typical mobile rack is in the range of $250 per pallet position.

Pallet Storage & Handling Systems

Figure 28 Mobile pallet rack is most easily justified in situations where occupancy costs are extremely high and throughput requirements are fairly low, as is the case in KAO’s CPG slow mover’s warehouse near Tokyo. (KAO, Tokyo, JAPAN)

Pallet Storage & Handling Systems

Figure 29 Mobile Pallet Rack Installation

Pallet Storage Systems Selection The key to selecting the appropriate pallet storage system configuration is to assign each SKU to a pallet storage system whose storage and productivity characteristics match the activity and inventory profile of the SKU . The figures below assist this matching process. Figure 5.x is a sl ouamd ma ac rc ye sos fi bt ihl iet yk, etyh rf oe ua tguhrpeus t ocf aepaacchi t yp,a il nl evt esnttoorrayg ea nsdy sltoecma t ii on nc l uc do ni nt gr ocl o, sFtI,FsOt omr aagi en tde enna sni ct ye ,, load size variability, and ease of installation.

Pallet Storage & Handling Systems

Figure 30 Pallet storage systems comparison. Figure 31 below illustrates an example pallet storage mode analysis. The example is twa ikdeenl yf raos ma f au npcat ri ot inc uolfatrh ceacsoes ta an nd dc aa vnaniol at bbi lei t gy eonf el ra abloi zr eadn ds i snpc ae cteh. eT ph reeaf enrael ny sc ies ri ne dg ii oc antse sv at hr ye mmoodsteesc. onomically appropriate assignment of popularity-inventory families to pallet storage

Pallet Storage & Handling Systems

Figure 31 Example pallet storage mode optimization for a large grocer.

Pallet Storage & Handling Systems

2 Pallet Handling Systems In rank order from least expensive to most and simplest to most complex, the most popular pallet handling systems are: • Conventional Vehicles • walkie stackers (WS), • counterbalance lift trucks (CBLT), • sit-down counterbalance lift trucks (SDCBLT) • stand-up counterbalance lift trucks (SUCBLT) • driverless counterbalance lift trucks (DLCBLT)

• Narrow Aisle Vehicles • straddle trucks (ST), • Very Narrow Aisle Vehicles • turret trucks (TUT),

• straddle reach trucks (SRT), • sideloader trucks (SLT),

• swing fork turret truck (SFTUT), • swing mast turret truck (SMTUT), • hybrid trucks (HYT), • Automated Vehicles • automated storage and retrieval (ASR) machines, and • automated guided storage/retrieval vehicles (AGSRV).

Pallet Storage & Handling Systems

Figure 32 Pallet Handling Systems The applications, pros, cons, and related costs of each system are described below. 2.1 Conventional Vehicles Whaanldkliiensgtasycksteerms as.nd counterbalance lift trucks make up the class of conventional pallet Walkie Stacker Ao pwe raal kt oi er ss tt ea ec rkse rf r aolml o wa ws aa l pk ianl lge tp ot os i bt ieo nl i fbt ee hd i, nsdt atchkee vde, ha incdl e .t rIann as psoi trut ae tdi osnh owr ht edries ttahnecreesi. s Tl ohwe tdhersoi ruegdh, pt uh te, swhaolrkti et r satvaeclkdeirs tma na cye bs ,ea anpdpl roowp rvi eart tei. c aAl st tyopriacga el wh eai lgkhi et , satnadc kaelro wc a nc osstta scokl ul ot iaodns i as mh aanxdi mo fuf mr e qouf itrherde)e ol fo pa da lsl ehti gr eht, rci oe svtasl /i np ut thaewraa yn gaen do ft r$u1c0k, 0l o0 a0d, ai nngd/ ou fnf leorasdtihneg .d u a l p u r p o s e ( n o

Pallet Storage & Handling Systems

Figure 33 Walkie stacker in receiving operations for a large biotech. (Carlsbad, USA)

Counterbalanced Lift Truck At rsu ct hk et on as tma eb i il mi z ep llioeasd, cs ocuanr rt ei erdb aalnadn cl ief tlei fdt ot rnuac kms aesmt ipnl ot hy ea f rc oo nu tn toef rtbhael at rnucceki.n Ctohue nbt ae cr bk aol af nt hc ee ll ii ff tt turnuicqkuse ml oaayd bceo gnaf isg ou rr abt ai ot tnesr yo np oa wv ee rr et idc .a lBme saisdte. s Tf ho er khse, iogthhte lri ma tittaact hi omn eins tgs emn earya bl l ey ua sr eo du nt od 2t r5u cf ke es ta. r eA acvoaui lnatbelrebwa liat nh coepde trraut icnkg mc aapya nc iot it ebs eu pu steod1 t0o0 ,s0t 0o 0r epdo ouunbdlse adnede pc o. s tC ionu tnht ee rrbaanl ga en coef $30,000.

Pallet Storage & Handling Systems

Figure 34 Sit-Down Counterbalance Lift Truck

Since the operator rides (seated or standing in the case of stand-up counterbalance tsrt ua cc kk es )r so. nC tohuen tveerhbiacllaen, cceo ut rnut ec kr bs aal al snoc eo f tf reur ctkhse cf al enx ibbei l iut ys etdo froert rlioe nv eg /e pr umt aowv ea sy tah pa na l lwe ta al kni de ll oo awd /cuo ns tl o, amdaak et r tuhcek ci no ut nh et esrabma lea nmc eo vlei f. t Tt rhui sc kf l et xhieb ibl iet ny ,c chomuaprl ke df owr i tahl l t hoet hveerh pi cal lel’est r reel at rt ii ve ve layl voef hliifctltersu. cMk oupltei-rlaotaiodncso.unterbalance trucks can be used to increase the overall productivity

Pallet Storage & Handling Systems

Figure 35 Stand Up Counterbalance Lift Truck (Caterpillar, Atlanta, GA)

Pallet Storage & Handling Systems

Figure 36 Multi-load Counterbalance Truck (Suntory, Tokyo, JAPAN) The major drawback of the counterbalance lift truck is the wide turning radius rr ee qq uu ii rr ee dd . t oTthui rs na ti hs lee vwe hi di ct hl e ri enqauni raeims l ee n. tA iss at hr ees juul st ,t iaf i1c 1a t’ itoon1f2o’ csut so roafgtehaei sallet ewr ni datthi vies tvyephiiccal el lsy. Astsorwageeparioscleesed(htehnrcoeutghhe rthefeerreenmcaeitnoing list, the vehicles will offer progressively narrower narrow aisle vehicles ) and progressively taller reaching hr eeti rgihe tvsa. l /Apt ut thaewsaaym- leo at idm/ eu ,ntlhoea dv ef hl ei cx li ebsl i at yr et hpar to gt hr ees sc iovuenl yt emr boar lea ne xc pe etnr us icvke oa fnf ed rns .o nHe eonf cf eer, tt hh ee ianncdrelomsesnotfahl asnpdacliensgafvleinxigbsilaintyd. cost must be sufficient to pay for the incremental vehicle cost As selective pallet rack is the benchmark pallet storage mode, the counterbalanced tursuec tkh me saaymbee vceohniscilde efroerdl ot ha ed ibnegnacnhdmua nr kl o satdoi rnagg ter/urcekt rs i ea vnadl svteohr ii cnlge . a nWd hreent r ii te vi si ndge lsoi raadbs l, et ht oe rc ao cukn taenr bd a pl aanl lceetd sttraucckki ni sg t hf rea lmo ge isc, atl hceh ooi pc ee .r aFtoi nr gu saei si lne sb l on cokr ms taalcl ky i npgr ,odvri di veed- i na raen ds udi rt ai vbel -et hf rour counterbalanced trucks.

Pallet Storage & Handling Systems

2.2 Narrow Aisle Vehicles Nr eaarcrho wt r uaci ks lse, avne dh iscilde se loopa de reartter ui nc kasi sal rees cbleatsws ief ieend xa sa nn da ryr of we e ta iws liedvee. hS ti cr laedsd. l e t r u c k s , s t r a d d l e Straddle Trucks Al o asdt r, ai nd sdtl eea tdr uocf kc opurnotvei rdbeas l al onacde da nwde ivgehht .i c Al es sat arbe islui tlyt tuhsei nagi s ol eu wt r ii gd gt he rrse qt ou isrterma dednlte i st h8e’ tpoa l1l e0t’ ao su torpi gpgoesresd at roe1 d1 r’ it voe1n2 i’ nr teoq ut ihree dr awc ikt haal l oc owui nn tge rt hb ea l amnac set t rt ou ccko. mT eo af lcucsehs swl oi tahd st hi ne spt ao lrlaegt ef, at chee. Hcoesntcsei,nitthisenraencegsesoafry$3to5,s0u0p0p. ort the floor level load on rack beams. A typical straddle truck

Pallet Storage & Handling Systems

Figure 37 Straddle truck in unit load putaway. (Caterpillar, Atlanta, USA)

Straddle Reach Trucks So turtardi gdgl ee rrse ao cnh tthreu cskt sr awd de rl ee dt reuvcekl oapnedd fprroomv i dc oi nngv ean t" iroenaac lh s" t rcaadpda lbei lti rt yu cwk si t bh y as hs coirstseonri nrge at hc he mechanism. In so doing, the outriggers do not have to be driven under the floor level load to

Pallet Storage & Handling Systems

acollnosweravcincegsrsactok cthoset satnodravgeertpicoaslitsitoonras.geHreeqnuceir, enmoernatcsk. beams required at the floor level,

Figure 38 Straddle Reach Truck

Pallet Storage & Handling Systems

Figure 39 Straddle Reach Truck, Sears Returns, GENCO Two basic straddle reach truck designs are available: mast and fork reach trucks. The mf o ar ks tr-er eaac hc hddees isgi gnnc oc onns issi tsst soof faapsaentt oo fg rt raapchk os ra sl ocni sgs ot hr se mo uotur ni gtgeedr os nt htahtesmu paps to. r t t h e m a s t . T h e The double-deep reach truck, a variation of the fork reach design, allows the forks to be extended to a depth that permits loads to be stored two deep. A typical straddle reach truck operates in a 8’ to 10’ aisle and costs in the range of $35,000. Driverless straddle reach trucks cost in the range of $80,000. Sideloading Trucks aAi sslied et ol o aa cdci ne sgst rsut oc rkalgoea dpso saint ido un ns .l oTa hdes rfer oamr e otnweos ibdaes, i tchsui sd eell oi ma di ne ar tdi negs itghnes n. eEeidt hteor t tuhren ei nn ttihr ee mmaasstt monoavepsaonntoagsreatpohf. tracks transversely across the vehicle, or the forks project from a fixed

Pallet Storage & Handling Systems

Figure 40 Sideloader Truck Aisle width requirements are less than for straddle trucks and reach trucks. A typical atois4le0wfeoeutlhdibghe 6an1d/2cofsetetinwtihdeer, raanigl eorofw$i6re5,g0u0i0d.ed. Sideloaders can generally access loads up The major drawback of the sideloader truck is the need to enter the correct end of the ar oi sul tei nt og .a Tc cuersrse ta tpr au rctki sc ualraer dl oe cs ai gt ni oend, tt oh ua sd da dr edsi sn gt htios tshheo rt ti mc oemainn dg wc ohmi l pe l oe fxfiet ryi ni ngvaol ll voef dt hi ne ot rt uh cekr benefits of sideloader trucks. A variety of load types can be handled using a sideloader. The vehicle's configuration particularly lends itself to storing long loads in cantilever rack.

Pallet Storage & Handling Systems

2.3 Very Narrow Aisle Vehicles Vs teorrya gnea rr reot rwi e av iasll ev evheihc liec lseasroe pcel ar sast ief iiend aaiss lveesr y6 nt oa r7r ofwe eat iisnl ewv iedhtihc .l eTsu. r r e t t r u c k s a n d h y b r i d Turret Trucks Twui trhr ei nt tt rhuecakiss l(es wt oi nsgt omr ea sotrarnedt rsi we vi en ga fpoar lkl emt . o Rd ealtsh)edr ,ot nh oe tl or eaqduiisr el i fttheed veei ht hi celre bt oy mf oar kk se wa thui cr nh swing on the mast, a mast which swings from the vehicle, or a shuttle fork mechanism.

Figure 41 Turret Truck

Pallet Storage & Handling Systems

Figure 42 Mast Turret Truck at Honda Motor Parts Turret trucks provide access to load positions at heights up to 50 feet, which provides ti nh ea iospl epso5r tourn6i t yf eteot iwnicdree,afsuer tsht oerr aignec rdeeans si ni tgy swt ohreargee fdl oeonrs istpy a. c e i s l i m i t e d . T h e y c a n a l s o r u n Turret trucks generally have good maneuverability outside the aisle, and some of the dg ue isdi gendsowr itthhet ea li es lsecso mp i anyg bmearsat si l mg uaiyd be de ,darlilvoewni ni ngt of oar sghr iepapt ei nr gs pt reaei dl e ar .nTdhseavf ee thyi ci lne tmh ea ya ibsel ewainr de

Pallet Storage & Handling Systems

rreadnugecionfg$t8h0e,0ch0a0n. ces of damage to the vehicle and/or rack. A typical turret truck costs in the

Figure 43 Swing fork turret truck. (Verizon, Atlanta, USA)

Hybrid Storage/Retrieval Vehicles At h eh yl ob ar idd. ST/hRe vheyhbi rc il de vi se shiimc l iel aerv tool vae dt ufrrroemt t trhuec kd, eesxi gc enpot f t ahna ta tuht eo mo paet er adt os tro' sr ac ga eb ai sn dl i frt ee tdr iwe vi tahl mt r ua cc kh i insenuost ecda pi nt i va eu ttoomaant eadi s sl et o, br augt em/ raeyt rl ieeavvael os ynset eami s sl e. aUnndl i ekne t tehr ea an so/t rhse rm. aPcrhei sneen, ta mh yo bd reilds athvraoiluagbhlepuatrreatseo.mewhat clumsy outside the aisle, but operate within the aisle at a high

Pallet Storage & Handling Systems

Figure 44 Hybrid Truck (U.S. Defense Logistics Agency, New Cumberland, PA) Hybrid vehicles operate in aisle widths ranging from 5 to 7 foot, allow rack storage uwphitcoh6m0afyeebtehhigehatiendaarnadc/kosruapirpcoortnedditbiounileddin. g, and may include an enclosed operator's cab Sophisticated hybrid vehicles are able to travel horizontally and vertically shiimg hu dl tiamn ee no us isol yn atlot oa l el or aa dn cpeoisni ttihoen .r aTc kh ea rl ae ctkh eo fd if sl eaxdivbai lni ttya,gtehseohf ihgyhb cr iadp ivteahl iccol ems .m i t m e n t a n d A typical hybrid storage/retrieval vehicles costs in the range of $100,000.

Pallet Storage & Handling Systems

2.4 Automated Systems Aauuttoommaatteedd gpuaidlleedt hstaonrdalginegansdysrteetmrisevinalclvuedheicaleust.omated storage and retrieval systems and Automated Storage/Retrieval Systems A s A t S n o / r a R a u g S t e . o s m I y t a s i t t s e e d m d e s f t t i h o n a r e t a d u g e s b e / y s r e t f h t ix r e i e e A d v - S a p / l a R s t S y h s p s t t e r o o m r d a u f g o c e r t a p s n e a d c ll t r e io e ts t n r i i o s e f v c a t o h l m e (S m M / o R a n ) t l e m y r i a r a c e l h f H e in r a r e n e s d d r l i u t n o n g n a I i s n n s g a t i o u t n u n t i o e t n l a e o s a o d a r more rails between fixed arrays of storage racks.

Figure 45 Automated Storage and Retrieval System (ASRS)

Pallet Storage & Handling Systems

Figure 46 ASRS input/output front end. (Netto, Copenhagan, DENMARK)

Figure 47 Rack Supported ASRS Building. (Rittal, Dayton, USA)

Pallet Storage & Handling Systems

Figure 48 High Bay ASRS

Pallet Storage & Handling Systems

Figure 49 Interior of a large high-bay ASRS.

A unit load AS/RS usually handles loads in excess of 1,000 pounds and is used for raw mS t aa tt ee rs i iasl ,i wn ot hr ek -hi nu -npdrroecdess,sa, na nd di nf isnt ai sl hl aetdi ognosoadrse. cTohme mn uomn pblearc eo fi ns yasltl emmasj oi nr sitnadl luesdt ri ni etsh. e U n i t e d A typical AS/RS operation involves the S/R machine picking up a load at the front of tl ohcea st iyosnt ,eamn, dt rraent usrpnoirntgi negmtph tey ltooa dt h teoi napnu te/mo pu tt yp ul to c( aI /t Oi o)np, odienpt o. sSi ut icnhg atnh eo pl oe ar adt iionn tihsec aelml epdt ya sbient gwl ee ec no ms umc caensds i(vSeCv) i os ipt es rt aot ti oh ne .I /SOi npgol ei ncto. mA mmaonr de se fafci cc ioemn tpol ips ehreaittihoenr i sa as tdour aa lgceoomr ma ar en tdr i(eDvCa)l ot rpaevreal ti ni ognl. o aAd eddu at ol caonmemmapnt yd lioncvaot li vo ens ( tt yh pe i cSa/lRl y mt haec hc li on see ps ti cekmi npgt yu pl o caa ltoi oand taot tthhee I I//OO ppooi ni nt )t ,, dl oeapdo, st irtai nv ge l itnh ge llooaadde, dt rtaov tehl ien Ig/ Oe mppo ti yn tt, oa nt hd ed leopcoa st ii toi nn go tf ht eh el oda ed s. i rTehde rkeetyr iiedveaal , i sp itchkai tn ign uapd tuhael

Pallet Storage & Handling Systems

cvoismitms taontdh,etwI/oOoppoeinrat.tions, a storage and a retrieval, are accomplished between successive A unique feature of the S/R machine travel is that vertical and horizontal travel occur smi ma xui lmt aunme oouf stl hy .e hCoor ni zsoenqtuael natnl yd, vtehret i ct ai ml ter atvoe lt rt iamv eels troe qauni rye dd et sot irneaa tciho nt h ien d tehset i nr aa tci ko ni sf r tohme tpheeromriingiunt.e.Horizontal travel speeds are on the order of 600 feet per minute; vertical, 150 feet The typical unit load AS/RS configuration, if there is such a thing, would include unit lmo aa dc hs i snteo. r eTdh eo no ne ed Ie/eOp p( io. ei n. , ts wi nogul el dd be ee pl o) ,c iant el do nagt tnhaer rl oo ww easits ll ee vs ,eel aocf hs toofr wa ghei cahn dc oant t oa ni nes ean dS /oRf this systMemor.e often than not, however, one of the parameters defining the system is atypical. Ta nh ea ipsol es,sai bnlde vt haer i na tui mo nbseirnac nl udd leo tchaet i do ne pot fh Io/ fOs tpooriangt es ., tTh he ensuemv ab reira ot ifoSn/sRa mr ea dc he si nc er isbaesds iignnme do rt oe detail below. When the variety of loads stored in the system is relatively low, throughput rbeeqnueifri ce ima letnot ss taorree ml ooa dd es rma toer et ot hhai gnho, na en dd et eh pe innu tmh eb er ra cokf . l oAal tdesr nt oa tbi ve es ct oornef di g iusr ah ti igohn, si ti ni sc loufdt een: • Dk eoeupbi lnegduene ipt (s St oKrUa )g ea rwe ittyhpsi icnagl llye -sl tooarde dw ii nd tthh ea issal ems e. Ll oocaadt si oonf . t Ah ems oa md i ef i es dt oSc /kR- machine is capable of reaching into the rack for the second load. • lDooaudbs l ae t daetei pm es taonr da gi en swe ri tths tdhoeumb lsei-ml oualdt a- wn ei do tuhs layi si nl et so. t hTeh de oSu/bRl emdaecehpi nc eu bciacrl er i. e s t w o • Ds teoerpi n gl a wn ei l l sst toorraeg em awt ietrhi asl i inngt loe -t lhoea dl a- nwei sd tohn aeiist lheesr. s iAdne oS f/ Rt h emaai cs hl ei n. eT hdee dl ai cnaetse dm at oy hr eoml do vuep mt oa 1t e0r ilaola df rso me a cthh.e Or anc kt hs .e oTuhtep ur ta cski ds em, aa yd ebdei cda yt enda mr ei ct r, i he va avli nmg agcrhai vn iet ywoi lrl powered conveyor lanes.

Pallet Storage & Handling Systems

• Rp laacckese/nrtercyemi voeds ul ol ead( Rs EoMn t)o/s yf rsot emmsspienciwalhriachi lsai nR Et hMe mraocvke. s i n t o t he ra ck s ys t em a n d Another variation of the typical configuration is the use of transfer cars to transport Sr e/ lRa tmi v ae cthoi nt he es tbhertowuegehnp ua it srl ee qs . u iTr reamn es nf et r. Icna rssu ac hr ea ucsaesde , wt hhee nt htrhoeu gs thoprua tg reerqeuqi ur ei rme me netndt oi se shni goht jbues tsiuf yf f itchiee nptutroc haacsceo mo fma no dSa/tRe mt haecshtionreafgoer reeaqcuhi raei sml ee,nyte. t t h e n u m b e r o f a i s l e s o f s t o r a g e m u s t A third system variation is the number and location of I/O points. Throughput roet hq euri r tehmaenn tt hs eo rl ofwa ceirl i tl eyf td ehsaingdn ccoornnset rra oi nf t st hme arya cmk .a nMd ua tl tei pml eu lIt/i Op l ep oI /i nOt sp mo i ni gths tabt el oucsaet di o nt os sAel tpearrnaat tei vi en bI /oOu nl od c aa nt ido nosuitnbcol uu dn ed tlhoea dt ys paenodf/ tohre tsoy sptreomv i ad te t ahde deint ido noaf l t ht he rroaucgkh(psuotmcea pAaSc/iRt yS. are built underground) and the middle of the rack. A typical as/rs machine costs in the range of $500,000. Automated Guided Storage/Retrieval Vehicles Av euht oi cml east reedc egiuvied ec do msmt our angi cea/trieotnr itehvraol uvgehhai cnl de sr ua nr eo dn rai vgerrilde sos f cwoiurne tsebr bu ar il ea dn cae f rt rauc ct ikosn. oAf Sa Rn iwn ac hg eb reanteeast ha rteh eh isguhr;f awc he eonf wl aabroerh iosussceafrl eoso; r a. nAdS Rw vheehn i cml eosvaer reartaerseabr ue t hciagnh ,bset aj ubsl tei, f iaenddwohveenr predictable paths. ASR vehicles cost in excess of $100,000.

Pallet Storage & Handling Systems

Figure 50 Automated Storage/Retrieval Vehicle

Figure 51 Driverless counterbalance lift truck. (Kirin, Nagayo, JAPAN)

Pallet Storage & Handling Systems

Pallet Handling Systems Comparison and Selection The figure presents a summary comparison of the key features of pallet handling systems.

Figure 52 Pallet Handling Systems Comparison

3 Pallet Storage and Handling Systems Selection Pp ar ol lveitdset oh ri gahg es taonr ad greedt reine vs iat ly saynsdt ehmi gsh ssht oo ur al dg eb/er esterlieecvtaeldt hi nr ocuognhj pu nu tc tciaopna wc i ti tyh. Soinnec ea enaoct hh ei tre tmo hp ar os v ui dnei sq ude i fdf eerme natn ds taonr adg ed/i mh aenndsliionnga l c appr aobf iillei tsi easn dt h es i nkceey e ai sc ht os t odreatgeer m/ rienter i etvhael spyrsotpeemr sdteotreargmei/nraettiroi ne vwa le dc oemv ebl oi npaetdi otnh ef oPra l leeat cShl o ti tt ienmg . O p tTi om i zaes rs i ws t h iocuhr c ocml i epnuttse s i nt h eml oa wk i ensgt ct ohsi st sc toosrt aog fe /srpeat cr ei e, vlaalbaolrt,e rr na ac kt iivneg ,f oarn de a ec hq ui itpe mm einnt .t h eA nw ae rxeahmopulsee at na ka il ny sgi si nftroo mc o nas irdeecreantti ocnl i tehnet engagement is provided in Figure 30.

Pallet Storage & Handling Systems

Figure 53 Example RightChain™ Pallets Storage Mode Optimization

Figure 54 Example RightChain™ Pallets Optimization for a Large Consumer Products Company

Pallet Storage & Handling Systems

KEY CONCEPTS BEST PRACTICES

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