This high-capacity system processes over 60 pallets/hour and occupies 165,000 square feet of floor space. The equivalent number of pallets in a traditional warehouse would take up 750,000 square feet.

12 aisle double deep unit load AS/RS maximizes storage 4 Sorting Transfer Vehicles bring product to/from system AS/RS supports a 24/7 operation with 5 employees System enhances speed and efficiency and controls costs DC floor space is maximized

America’s largest cookware company and the world’s second largest cookware manufacturing operation wanted to enhance the speed and efficiency of shipping a growing range of product to retail customers in the U.S., while maintaining control of operational costs. The company hired Daifuku America Corporation to tackle the challenges.

Daifuku provided a 12 aisle rack-supported unit load Automated Storage & Retrieval System (AS/RS) capable of handling pallets up to 1,200 pounds. In a racksupported system, the rack is incorporated into the actual building and serves as its basic structure while seamlessly integrating with the material handling system.

Benefits include allowing for the maximum storage density and creating a lights out and possibly non-climate controlled area. In this configuration the AS/RS is sheltered from other operations within the facility but integrates with them via 1 of 4 Sorting Transfer Vehicles (STVs). Loads are delivered to the storage system round robin so that like products are distributed to all aisles. Positions are selected by the warehouse control system (WCS) software, which directs the AS/RS cranes to pick and put away in the most efficient order possible. Two work stations and a jackpot conveyor lane are positioned off the STV loop and used for adjusting pallets, cycle counting, inventory audits, and configuring product for special orders.

The AS/RS has locations for 66,000 pallets stored double deep to further maximize storage. The company is considering adding additional unit load cranes, which would take up 135,000 square feet of floor space but would allow the company to further consolidate satellite storage facilities.

is a Proud Member of the AS/RS Product Section of Material Handling Industry of America

5202 Douglas Corrigan Way
Salt Lake City, UT 84116
(801) 359-9900
info@DaifukuAmerica.com
www.DaifukuAmerica.com