DESIGN CONCEPT

Job:

ASRS Project

Client :

Global Green Chemical (PTTGC)

Location:

Rayong, Thailand

Status:

Completed in October,2022

Pallet type/size

Close face / 1.2mx1.2mx1.6m

Capacity

About 5,000 location

Rack Type

Multi Deep

System type

Stacker crane
Multi deep

Max Load Weight

1,350 KG
(Include Pallet)

The design approach behind GGC’s project, which AEI Solution had the opportunity to participate in at every step—from designing and planning the warehouse to constructing the building and systems—focused on a crucial objective: to maximize the storage capacity within the existing warehouse space. At the same time, the existing ERP (Enterprise Resource Planning) system had to be integrated and aligned with AEI Solution’s WMS (WarehouseManagement System) to develop the most efficient ASRS (Automated Storage and Retrieval System). Above all, every step of this transformation had to be carried out with safety exceeding international standards, given that the stored goods include biochemical materials and flammable substances. Therefore, careful planning of every process was essential to ensure high quality and effective coordination with safety as a top priority.

Initially, the warehouse was organized for manual storage of goods using selective racks in a limited and relatively dense space. The system was disorganized, leading to issues such as ‘unable to find items, incomplete orders, or incorrect items picked,’ among others. Additionally, the workflow involved redundant steps due to the limited warehouse space. Once production was completed, products had to be transported to another storage area,increasing costs related to labor, equipment, material handling, and warehouse rental.

AEI proposed removing the existing storage racks and upgrading the building’s floor. Since increasing storage capacity also increases the load, additional excavation was necessary to modify the building’s structure, including adding new foundation piles and beams. The plan was to prepare the site for installing an ASRS system to ensure efficient operation. We selected an SRM with Shuttle (Crane with Shuttle) system, allowing storage in a depth of up to 10 pallets. The shuttle’s battery can be charged automatically, and an automatic pallet handling system was added at the front to efficiently receive products from the production line. The system also improved accuracy in receiving goods by incorporating barcode scanning, weighing, and dimension measurement, fully addressing all previous warehouse management issues comprehensively.

“Imagine if we were actually using it ourselves. Start by identifying the most critical
problems and the most important factors. 
No matter how limited the space or how high
the standards, we must make it
 feasible and ensure it truly meets our needs”

Therefore, AEI Solution has integrated a fire protection system by installing ceiling-mounted sprinklers to enhance the safety of current storage areas for items such as methyl esters, fatty alcohols, and glycerin. This is part of a strategic plan to support customers committed to developing sustainable innovations in chemical products, biofuels, and bioplastics, without causing environmental impact. We prioritize safety beyond the highest international standards. Additionally, we are integrating the existing ERP system with the WMS developed by AEI Solution to create a Smart Warehouse 4.0. This approach aims to elevate storage standards creatively and efficiently, aligning with the executive vision to foster business growth, enhance capabilities in chemical production for the environment, and add value sustainably.