Modelling and design for a shuttle-based storage and retrieval system

The shuttle-based storage and retrieval system (SBS/RS) is a relatively new part-to-picker order picking system. We have developed a performance estimation and design algorithm for the SBS/RS. The performance estimation is based on a queuing model. The design algorithm aims to find the minimum cost configurations in terms of number of tiers, aisles, lifts and workstations with given throughput, tote capacity and order cycle time requirements. We used simulation driven by parameters abstracted from an actual SBS/RS to verify the performance estimation, and applied the design algorithm in the case study. The results indicate that: (1) compared to simulation results, the throughput of the performance estimation is nearly identical when the arrival rate is below the maximum capacity; (2) the design algorithm yields a configuration with 28.1% cost reduction in the current system. In addition, we also compared the shuttle system with the competing robotic order fulfilment system (robotic system in short) in terms of facility cost, building cost and order cycle time. We found that the shuttle system is a better choice if large storage capacity and high throughput are required whereas the robotic order fulfilment system performs better if small storage capacity and low throughput are required.