Application of Automated Warehouse in Aluminum Profile Industry

[China Aluminum Industry Network] 1. Current Situation of the Aluminum Profile Industry China's “Twelfth Five-Year Plan” requires a 16% reduction in energy consumption per unit of GDP, a 17% reduction in carbon dioxide emissions, and a target of 11.4% for non-fossil energy in primary energy consumption.

China's consumption of aluminum profiles in the industrial sector accounts for only 30% of the world. With the economic development and improvement of industrial technology, aluminum profiles have great potential for consumption in the industrial sector. By the end of 2013, there were more than 900 aluminium profile companies in China, with an equipment capacity of more than 13 million tons and an actual output of more than 1,050 tons of extruded steel. From the perspective of product structure, there are 1.9 million tons of aluminum alloy pipe rods and 8.6 million tons of aluminum profiles. Among the aluminum profiles, there are more than 6 million tons of building profiles (about 70%), and about 2.6 million tons of industrial profiles (about 30%). The output is mainly distributed in the Pearl River Delta, the Yangtze River Delta, and the industrially-developed regions of the Bohai Bay.

In the next 10 to 15 years, China will still be in the stage of rapid urbanization and industrialization. It is expected that by 2015, China’s urbanization level will exceed 50%, and that from now until 2020, China’s old buildings will be renewed and transformed into buildings. The demand for aluminum profiles has entered a period of rapid growth. China's production of aluminum profiles is expected to reach 11 million tons, aluminum alloy building profile production is expected to reach 8 million tons/year, and industrial aluminum profiles will reach about 300 tons.

2. Current status of aluminum material storage and access At present, domestic enterprises generally adopt flat libraries, single-layer or double-layer libraries, occupy a large area, have low warehouse space, and have low space utilization; they are bridge cranes, forklifts or manual transport. The way; out of storage frequency is low, digital management is not achieved.

In recent years, although a few domestic manufacturers in the same industry have adopted cantilevered shelf storage and forklift handling and access modes for learning foreign technology development, due to the limitation of design capacity, there is still a large occupied area and low utilization of warehouse space. Digital management is not implemented, and the frequency of inbound and outbound transactions is low.

3. Old storage, access methods and problems 1) Old storage and access methods:

Ground stacking, partial storage of materials, manual picking, forklift or crane access handling.

2) There is a problem:

(1) Large area, low land utilization, and low space utilization;

(2) Large amount of transportation work, use of personnel, time-consuming work, low efficiency, high labor costs;

(3) There are hidden dangers in personal and product safety, manual handling, which can easily cause personnel, cargo defects, collisions, abrasions;

(4) A large number of goods are piled together, relying on manual management, it is easy to send the wrong goods or find the goods, and the warehouse management is difficult;

(5) Repeated labor is often required, often need to reverse the goods, down the library;

(6) manual accounting, inefficiency, and easy error of accounts;

(7) Modern management cannot be implemented. Accounts cannot be seamlessly linked to the company's ERP system. Information from the warehouse cannot be fed back to the sales, finance, and information hubs.

Taking an aluminum plant as an example, its equipment production capacity has reached more than 130,000 tons, its output has reached 105,000 tons/year, and its products have more than 3,000 varieties. Production and sales are booming. However, as the land becomes increasingly tense and personnel recruitment is increasingly difficult to recruit labor costs, the production scale of the plant has been continuously growing, and the finished product warehouse for storing aluminum products (2 floors) is being stored. The volume is also more than 2,500 tons. And the average storage period is 3-4 months or even longer. In addition, the existing finished product warehouses have a large area, many employees, low efficiency of entering and leaving warehousing, errors in manual management accounts, and high production costs in warehousing. This has become a bottleneck for the further development of the company. Daily product classification, packaging, transportation, storage, storage, etc. are very busy, and the amount of material flow is particularly large. The old storage and access technology and equipment can no longer meet the needs of continuous development of production and sales, and the operating rhythm and operational efficiency are in urgent need. As a result, it is necessary to develop automated stereoscopic warehouses with long-standing rods with independent intellectual property rights.


4. Research and Development Goals 1. When the aluminum profile storage and storage automation automated warehouse is running, all the storage and delivery operations are automatically completed by the equipment as long as the storage or delivery instructions are issued.

2. The three-dimensional form of storage requires that it is possible to improve the space utilization rate of the warehouse. The height requirement for the storage layer is 10 layers. The number of columns near the roof of the plant requires that the number of layers be increased as much as possible. In order to increase the volume ratio of the warehouse and save land resources.

3. Profile handling Unmanned Traditional material handling is usually carried by cranes, manually hooked, manually transported, or forklift trucks lifted. In the course of operations, there are inevitably problems with the safety of people and equipment, the consumption of energy, the pollution of the environment, and occupational health problems that cannot be counted.

The research and development of three-dimensional warehouse to solve the above problems, realize the profile out of storage, the library unmanned automatic handling.

4. Warehouse management intelligent plane warehouse management is manually booked. The large amount of information such as the quantity of inbound warehousing, batch number, customer information, product type, quantity, color, type, weight, and total weight all require manual statistical records, which are prone to errors.

The research and development of the three-dimensional warehouse to achieve intelligent storage management to avoid inventory data, shipping data errors and the wrong goods.

5. Information transmission Networking profiles The finished product warehousing work is in close contact with various departments within the factory. This research and development effort requires the realization of information transmission networking, which enables information sharing and sharing between departments, and reduces or eliminates the exchange of paper document information.

We have built a storage warehouse with about 5,000 storage spaces, with a storage capacity of 3,000-3,500 tons, and an automated warehouse with ≥300 tons of aluminum profiles exported and stored every day.

6. The key technology to be solved To complete the above process, to meet the frequency of inbound and outbound delivery, to ensure equipment reliability, stability, and quality of stored materials, the key technologies to be solved are:

1) Calculation of the carrying capacity of the shelf, testing, and setting of the shelf.

Storage shelves are the infrastructure for storing goods in automated three-dimensional warehouses and require good load-bearing capacity, seismic resistance, and structural stability.

2) Research on long straight rod stacker cranes.

The stacker crane is a lifting and transporting device that is responsible for automatically accessing goods in an automated warehouse. The double-pillar stacker used in this project is 4-5 times the size of an ordinary stacker in the direction of operation. The increase in size imposes higher requirements on the rigidity, stability, and synchronization of the stacker; it requires the development of a new cargo carrier and fork mechanism and lifting mechanism.

7. Analysis of social effects of automated warehouses and analysis of corporate economic effects.

1) Analysis of Economic Benefits of Enterprises (1) Automated warehouses occupy a small area and use less space for investment in a larger space, which increases the space utilization rate and the storage capacity per unit space. Compared with the flat warehouse (including the second floor storage), the floor area is greatly reduced. According to the 10-story conventional warehouse estimation, taking into account the stock density and the same inventory, it is possible to save about 3-4 warehouses with a length of 248m and a width of 28m (6944m2), which will reduce the occupied area by about 20,000-30000m2. Calculated according to the site's lower land price of 800,000 yuan per mu, then: can reduce the cost of land purchase = (20000-30000m2)/666.67x80 = 2400-36 million yuan;

Civil engineering investment is calculated at 1,400 yuan per square meter, then: to reduce the investment in finished product warehouse construction = (20000-30000m2) x 1400 yuan/m2 = 2800-42 million yuan; so the total storage space and total civil construction costs = (2400-3600) + ( 2800-4200) = 5200-7800 yuan.

(2) Use fewer people and reduce labor costs According to the current production capacity, if the original way of entry and exit is used, 28 shifters will be required for each shift, 48 for the warehouse, and 48 for the library. 124 people are needed.

After adopting an automated three-dimensional warehouse, 9 inbound and outbound information officers, 16 warehousing workers, 36 warehousing and maintenance workers, and a total of 62 persons were needed to reduce the total number of personnel. then:

Annual savings in labor costs = 62 persons x (4000-5000) yuan / month. Person x12 = 276-372 million yuan / year.

(3) Improved precision and efficiency of entry and exit When using manual libraries, the average daily inbound and outbound volume is 460 tons in total, 24 hours for storage, 14 hours for outbound delivery, and 40 hours for outbound and outbound operations. Then: Average outbound and outbound warehouse weight =460/(24+14)=12.1t/h;

After the use of automated three-dimensional warehouses, aluminum profiles are transferred to and from the warehouse. The mechanized and automated operations are realized. The average daily inbound and outbound volume amounts to 600 tons per day, the storage time is 24 hours, the delivery time is 9 hours, and the total storage time is 33 hours. Then: the average storage and storage weight = 600 / (24 + 9) = 18.18t / h;

Automated warehouses increase the efficiency of inbound and outbound warehouses compared to manual warehouses = (18.18-12.1)/18.18x100 = 33%. According to the larger average output of 300t/d, that is, the number of automatic warehouses is more than that of artificial warehouses = 300 (1-1/1.33) = 74.4t/d.

According to the annual working time of 330 days, and the average cost of manual outbound and outbound storage of 64.3y/t, the annual labor cost of entering and leaving the warehouse can be reduced by 74.4 (t/d) x 330 (d) x 64.3y/t = 1.587 million yuan.

It also solved the problems that existed in the library that existed in the past for a long time. When the library was out of stock, it could not find any problems such as dead stock or wrong delivery and restitution. The average annual number of scrapped profiles is 100-120 tons. Calculated at an average of 2,500 yuan per ton of profile processing cost, the economic loss per year is (100-120t)x2500 yuan/t=25-30 million yuan (4) The use of automated three-dimensional warehouses for employees with low labor intensity resulted in mechanized and automated operations for the export and storage of aluminum profiles and storage in the warehouse. Employees were freed from heavy physical labor through man-machine interface operations. And the loading time of every car profile is shortened from the original 14h to 10h, reducing the loading time 4 (h), which means that employees can take a rest from work 4h in advance without reducing the income.

Through the above analysis, we can see that after the use of automated warehouse, the storage link can increase economic efficiency = (5200+276+157.87+25)~(7800+372+157.87+30)=5658.87~8359.87 million yuan.

2) Analysis of Social Benefits (1) Automated warehouse has a small footprint and high space utilization Currently, there are more than 900 aluminium profile companies in China. If there is about one-tenth of the manufacturers use such a warehouse, only the land is occupied. Can reduce the cost = (20000-30000) x 100 = 200-300 million m2, reduce the investment in warehouse construction = (20000-30000m2) x1400 yuan / m2x100 = 284-4.2 billion yuan.

(2) Significant energy saving and emission reduction effects. Roadway stacker crane motor power ≤ 10kw, only a quarter of the same type of motor power, saving power 30Kw. There are 7 stackers in this warehouse. For example, if each stacker is working 12 hours a day, and the CO2 emission per unit of electricity is reduced by 0.997kg, then: reduce CO2 emissions = 7 (stations) x 30 (kw) x 12 ( h) x365(d) x 0.997 (kgC02/kw.h) = 917 t/year.

This shows that the automated three-dimensional warehouse not only saves us cost but also improves work efficiency.

The successful research and development and application of automatic warehouses for aluminum profiles with long straight bars has for the first time achieved a real sense of automation in the import and export of aluminum profiles, storage in three dimensions, unmanned profile handling, intelligent inventory management, and inventory information sharing networks. Change.

Because of the long straight bar type aluminum profile automated warehouse, it is a smart logistics access system integrated with modern technology such as computer, automatic control, network, information, communication, laser, infrared, etc. The system has features such as high land use efficiency, high efficiency of storage and warehousing, three-dimensional high-level warehousing, unmanned profile handling, intelligent inventory management, inventory-sharing information sharing, energy saving, low labor cost, low labor cost, etc. Technology, economic benefits and social benefits. It fills the gap in the domestic aluminum industry and has internationally advanced level. It has accumulated rich project experience and technology reserves in this field. It has a large number of professionals and can provide one-stop solutions according to customer needs and provide customers with "turnkey". "Engineering" is a trusted integrator of automated warehouses and material handling systems.

Sheping can provide "one-stop" solutions based on the needs of customers, apply advanced logistics equipment and control systems, and integrate a series of subsystems (such as three-dimensional warehouse, conveyor system, sorting system, AGV system, RFID system, DPS system And so on, to provide customers with "turnkey projects."

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