Integrated Order Selection System including Multiple Level Horizontal Carousels, Mid-rise Storage and Retrieval System (MSRS), and Tote Handling Conveyor system  for an aircraft manufacturer.  

Integrated "design for reliability" project integrating a MSRS (Mechanized Storage and Retrieval System), Horizontal Carousal, Pallet and Tote Handing Conveyor System.  The system was to operate 24/7.  

The original system layout utilized MSRS 60’ tall Hybrid Vehicles operating in 28 aisles 330’ long, Horizontal Carousals, and conveyors. 

Carousals were double decked designed for a third level future expansion. 

The design specification called for an operating noise level limit of 70db A scale. 

The 12,500’ conveyor system concept utilized a “live” storage area (A) that was designed to accumulate orders until complete and flush the selected lanes.  Totes unwanted totes were recirculated and re-indicted into the live storage area. 

Expedited emergency orders were to take no longer than 20 minutes to reach their next destination. 

System acceptance was based upon a 40-hour test of the system operating at the design year rates.  The test script included peak rate induction for a maximum of 20 minutes at specific areas with in the system.  Failures would result in a retest for the 40-hour period.   

The conveyor system as shown above exceeded the project budget by nearly $4,000,000.00.  

Alternative Layout 

Improved logistical material flow

This layout alternative reduced the costs by $4,500,000.00.  

The conveyor system was redesigned to eliminate the “live storage “ concept.  Horizontal carousals were utilized to accommodate the necessity to merge orders coming from different parts of the facility.   

The flow of the main distribution loop (B) was reversed to help reduce the line speed to 150 FPM and in order to reduce noise levels.   

Totes were custom designed to reduce noise levels.   

The system did not exceed the 70 db A scale, slow response, noise target limit.   

The conveyor system length was reduced to 11,000 feet.   

The above changes permitted the conveyor system to come in under budget.   

The test acceptance test passed on the first attempt.   

The entire material handling and storage project was completed ahead of schedule and under budget with no loss of performance nor reliability.