Planning basis
Selecting and sizing storage technology starts with a reconciled planning basis. Item master data, inventory history, receipts, order lines, load carriers, replenishment and peak profiles are reconciled for the planning horizon. ABC and variability classes support the analysis but do not replace process and service requirements.
Technology comparison
Selective and high-bay racking, narrow aisles, mobile racking, flow racks, automated small-parts stores, shuttle systems and goods-to-person solutions are compared with the manual baseline. Capacity, performance, footprint, labour, investment, flexibility, availability and expansion are evaluated consistently.
Sizing and system throughput
Storage locations, aisles, devices, buffers and workstations are sized together. Machine cycle time is not treated as system throughput: front zones, conveyors, controls, identification, load transfer and downstream picking can become the limiting resource.
Results and deliverables
- Validated item, inventory and order analysis
- Planning volumes and peak profiles
- Technology options and weighted comparison
- Capacity and throughput calculation
- Integrated layout and expansion stages
- Investment estimate and requirement specification
Technical basis and limitations
The cycle time of a storage and retrieval machine or shuttle describes only part of system performance. Front zones, conveyors, buffers, identification, controls, load transfer, picking stations and downstream processes can constrain throughput. Capacity, put-away and retrieval performance, peak profile and performance availability are therefore verified separately.
System selection follows the base data, metrics, constraints and objectives of the storage and picking task. Historic standards remain useful methodological foundations; current safety, ergonomics, building and fire-protection requirements are added from valid primary sources for each project. Further reading: planning an order-picking system.