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On selecting and configuring automated material handling systems: two-stage approach using simulation and data-envelopment analysis

Z. U. Rizqi,Shuo-Yan Chou,Nian-Zu Zheng,A. Dewabharata

Published 2025 in Journal of Industrial and Production Engineering

ABSTRACT

ABSTRACT Automated Storage and Retrieval Systems (AS/RS) and Shuttle-based Storage and Retrieval Systems (SBS/RS) are two widely used Automated Material Handling Systems (AMHSs) aimed at enhancing warehouse efficiency, safety, and accuracy. They replace labor-intensive systems struggling with high-variety demands. This study conducts a comparative study between AS/RS, tier-captive SBS/RS, and tier-to-tier SBS/RS using simulation. A Taiwanese warehouse was used as real case study, with 108 configurations simulated across 3 AMHSs, 3 rack designs, 3 speed configurations, and 4 storage policies. Throughput, utilization rate, and wait time were analyzed, revealing 14 key observations. In essence, tier-captive SBS/RS excels in throughput and wait time reduction. The ABC storage policy is superior in all AMHSs. AS/RS benefits from high-level rack design, while SBS/RS suits high-bay racks but it faces more challenges for balancing utilization due to complex components. Given trade-off performance, Data Envelopment Analysis is used revealing the most efficient system and its configuration.

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