Storage technology and systems

As a core element of logistics planning, selecting the right storage technology, also known as storage system technology, sets the stage for logistics success. The optimum solution must be designed from a comprehensive range of system components for storage and conveyor technology. This design is tailored to the specific application.

Storage technology at the heart of logistics

Optimal means taking into account not only economic but also qualitative conditions such as reliability, flexibility and compliance with the FIFO principle. When selecting storage technology, we consider the entire range, from the simplest conventional solutions such as block storage to high-tech automated systems with robots and sorters. A warehouse and material flow simulation is used to underpin investment decisions, especially when procuring automated systems.

The term storage technology, or more precisely storage system technology, encompasses all the equipment used to transport, store, pick or identify goods within a warehouse. If you think of high shelves full of pallets, you are not far off. But pallet racking is only one small aspect of the increasingly diverse range of storage systems available today.

Choice of storage technology and systems

The first question to ask is: how do we find the ideal storage system or combination of systems? To do this, we need to analyse the requirements for the specific task:

• How many items do you need to store?
• What inventory do you need to store?
• What load carriers are required?
• Are there seasonal influences on the logistics requirements?
• Which customers are to be served?
• Are there special requirements for storage temperature, fire protection, etc.?
• What is the right level of automation?

If automated storage systems are also used, special attention must be paid to their extended requirements.

Aspects of the requirement profile in automation projects

In addition to the economic aspects, qualitative aspects such as reliability, flexibility and maintenance requirements have to be considered. The integration of the system into the existing IT landscape must also be considered.

Design of the storage and material flow system

Based on the requirements analysis, the storage and material handling system is designed. The design includes the type and number of conveyors and storage equipment as well as the control technology. The design must take into account the interfaces with upstream and downstream processes.

Implementation of the warehouse and material flow system

Once the design has been approved, the storage and material handling system is implemented. Implementation includes the procurement of components, their installation and commissioning, and their integration into the overall system.

Support and optimisation of the storage and material flow system

Once the storage and material handling system has been commissioned, it is important to ensure that it runs smoothly and to optimise it if necessary. This includes maintenance and repairs as well as modifications and expansions.

Automated systems are only economically viable with high performance and uptime over multiple shifts. The system must be sized so that the performance can be accessed according to the requirements of the volume structure. In particular, it is a challenge to cope with delivery peaks due to seasonal fluctuations. Flexible systems offer modular adaptability that follows sales trends and can also absorb unforeseen sales spikes or dips.

Automation and ergonomics

As the level of automation increases, the use of physical labour is replaced by technology. This allows us to reduce physical strain and create ergonomic workplaces.

Economic efficiency

Ultimately, economy is the deciding factor, because above a certain system size, automated systems can offer a significant reduction in operating costs compared to conventional solutions. If the systems are well designed or sized, the initial high investment can be recouped in a reasonable period of time. The payback or ROI horizon must remain in focus, as must the consideration of risks and one-off costs.

Warehouse technology and automation: comparison of automation systems

The following factors therefore determine the right choice of automated storage technology:

• Can the system handle peak loads and handle the variety of containers?
• How sensitive is the system to declining or increasing sales?
• How will changes in the structure and number of items affect system performance?
• How will labour market trends affect the economics?
• What is the level of reliability and what response times can be expected in the event of faults?
• What are the references or practical use of the chosen system?

All of the above, and more, need to be considered on a case-by-case basis in order to define the requirements for the storage system technology together with the client. A comparison with regulatory requirements, such as the maximum allowable building height, can rule out certain systems in advance.

Once the requirements have been defined, the experience of ORGAPLAN Logistics GmbH staff can be used to pre-select and quantify the various systems that may be considered. For each storage system, the quantities required are determined and calculated on the basis of the system design and the corresponding operating data. This is the basis for the cost calculation.

The expected investment can be determined using index prices or, if necessary, by specific enquiries to potential system suppliers.

It is important that ORGAPLAN Logistics GmbH is completely neutral with regard to products and suppliers. Without this, it is not possible to provide objective advice based solely on the client’s needs.

Combined with qualitative aspects such as

• Reliability
• Ease of use
• Expandability

The customer is provided with the most important decision criteria. After an in-depth discussion between the client and ORGAPLAN’s logistics consultants, a clear recommendation is usually made, and we are happy to assist with its implementation.