Originally, the warehouse was a high-rise building used to consolidate products through various processes such as Lamination (packaging creation), Forming (molding), and Printing. This necessitated the storage of molds, raw materials, and Work In Progress (WIP) within the limited warehouse space, using conventional manual selective racks. The dense and disorganized storage led to frequent errors in locating items, such as “items not found, incomplete orders, or incorrect items picked.” This resulted in redundant workflow steps, increased labor costs, equipment expenses, material handling, and production delays.

AEI Solution proposed removing the existing storage racks to redesign the building’s layout and prepare for the full installation of an ASRS Solution. This includes implementing an SRM Double Deep Crane System to expand storage capacity to a depth of 2 pallets with a height of 20 meters, accommodating the number of items per SKU. The solution also features a front material handling system using rail-guided vehicles (RGV) and an additional RGV for storing WIP and molds, which streamlines product integration into the production line and distribution to the crane. Additionally, AGV-FMR vehicles will handle the transportation of goods, raw materials, and molds between production lines, integrating all systems via PDA in conjunction with WMS and MES systems. This comprehensive approach results in a highly effective and efficient ASRS system, enhancing product receiving accuracy through barcode scanning, weighing, and dimension measurement, and fully addressing all previous warehouse management issues.