Fully automated warehouse system will take control techniques into the millennium

Citation

(1998), "Fully automated warehouse system will take control techniques into the millennium", Assembly Automation, Vol. 18 No. 2. https://doi.org/10.1108/aa.1998.03318baf.011

Fully automated warehouse system will take control techniques into the millennium

Fully automated warehouse system will take control techniques into the millennium

Keywords Automation, Cegelec, Control techniques, Storage, Warehousing

By rationalising the way in which it receives, stores and retrieves components for its manufacturing operation at Newtown, Mid Wales, UK, Control Techniques Drives Limited has not only increased its production capacity, but has built in considerable expansion capabilities for the future. The multi-level computer controlled system, involving programmable controllers, automatic cranes, and other mechanical handling techniques, was designed and engineered by Cegelec AEG Automation Systems Limited (Plate 9). The automatic storage and retrieval system supports increases in production output.

Established in 1973, Control Techniques Drives Limited is the manufacturing division of Control Techniques plc, manufacturer of AC and DC drives, and servos. In 1991, as one of the fastest growing electronics companies in Europe, the company realised that with its existing and planned growth rates, its manufacturing capacity would not be able to keep pace with demand.

A study conducted by Control Techniques in 1992 confirmed that a major investment needed to be made within an automated warehouse infrastructure. The study identified the following objectives:

1. 1.

   (1)The component picking operation was to be relocated from the shopfloor to a new warehouse, and material control handled by material controllers, freeing up floor space for manufacturing capacity.

   (2) To maintain quality levels, a first in, first out (FIFO) storage and retrieval system was necessary.

   (3) Overall warehouse throughputs, i.e. capacity to supply materials and components to the two production facilities had to be dramatically increased.

   (4) The supply process, from goods in to order fulfilment, had to be streamlined.

   (5) A new manufacturing facility would be provided, which centralised and automated activities originally performed at three separate sites.

Plate 9 Components store crane, Cegelec AEG Automation Systems Ltd

The Engineering Division of AEG (UK) Ltd ­ now Cegelec AEG Automation Systems Ltd ­ was asked to examine the problem and suggest a cost-effective solution, which after considerable research resulted in the proposal of a fully automated warehouse system integrating to Control Techniques' PCB and module assembly operations. The system would provide many advantages, including total stock control, accurate picking, fast response, consistent product handling, plus optimised management reports and marketing tools.

The eventual solution was to retain the original modular assembly plant, but augment it with a new integrated automated warehouse/PCB assembly plant constructed on the adjacent site, and connected via a high level bridge over the reception area. The new facility incorporates one bulk store crane servicing 888 pallet storage locations, two component store cranes servicing 4,356 tray storage locations, one 640-location "pick by light" system and around 400 metres of conveyor.

This advanced facility provides a centralised storage and distribution system with rapid access, on demand, to a large number of stored components and assemblies. The materials handling system (MHS) provides this by accessing a central storage area with pallet and component stores, each with fully automatic stacker cranes for storage and retrieval of components, subassemblies and printed circuit assemblies. The warehouse management system is controlled by dual HP computers running specially designed warehouse control software.

In response to orders, which originate from the warehouse management computer system or via direct manual input, the system promptly retrieves those parts required to complete the order and delivers them to the relevant storage and manufacturing area. Specially designed system software covers booking of goods in, replenishment of components and PCB assemblies, flow control of production orders between PCB and module assembly, and kitting of material to the production area. The system is fully interfaced with the host MMX management computer, where all warehouse and production activity is reported and mirrored.

Contact Barbara Grimm or Richard Simpson, Cegelec AEG Automation Systems. Tel: +44 (0)118 9698330.