1.0 warehouses have now become more capacity and

1.0             
Introduction

Daifuku Malaysia
Sdn Bhd (Daifuku) developed the first automated storage and retrieval system
(AS/RS) in Japan since year 1966. One of their core business are factory and
distribution automation. Daifuku has the automated warehouse, storage spaces
and sorting and picking system to satisfy the customer requirement in order to
distribute for the retailers, wholesalers and warehousing. (Research and Markets,
4AD) This program is use to manage the every single step
of warehouse including receive and retrieval inventory, replenishment and
picking. The objectives for developing this AS/RS system in to achieving
workload reductions and cost savings through improvements in storage
efficiency,  labor saving in warehouse
work and improvements in management levels. About forty years since using this
system, automated warehouses have now become more capacity and high performance
through the expansion of models, including stacker cranes and peripheral
equipment.(Corporation, 2AD)

 

 

2.0 
Quick
Response

Quick response
code have become a convenient way to communicate amounts of information from
physical objects to mobile devices. Quick response built up a lot of business
opportunity to speed up the flow of information and merchandise between
retailers and manufacturers and the warehouse system. Daifuku is using the
quick response to manage the warehouse system by many way. Quick response used
information technology, flexible processes and organizational structure to
manage product and services in order to make it efficient and convenient.
Nowadays, the number of user and use is increasing and quick response is
encourage to researchers and industries in developing business and convenient
in order to reduce error.

2.1             
Radio-Frequency
Identification

Radio-frequency
Identification (RFID) is an equipment that used in hundreds of applications
such as race-timing, assets tracking and tool tracking.(Ustundag, 2013) Besides, RFID is a wireless non-contact use of radio-frequency
electromagnetic fields to move the data for identifying and tracking tags
attached to assets. RFID is able to identify from distance unlike the barcode
technology. Its support a large set of ID than the barcodes technology and can
incorporate additional data from different way such as product type and
manufacturer. (Amit and Berghel, 2011)

RFID technology
consist three part in two combination, a transmitter or receiver and one of it
call antenna as a RFID reader. This two will combine and make a RFID tag. When
the FRID tag read, it will detect the radio signal that activate the transmitter
or receiver. (Pateriya and Sharma,
2011)

There are many
uses of quick response technology around us today, one of the quick response
that use by Daifuku is RFID. Daifuku is using RFID to the receiving
inspection.  Daifuku was using barcodes
operation with semi-automated to scan the label when received before they use
the RFID technology. It need several time to operate to complete it. (Kaur et al., 2011)Besides, once the products scanned, they have to
change a new label after the new orders. So, in order to reduce the labour cost
and time, Daifuku use RFID technology to replace the barcode technology. The
operator only need to pass the RFID reader gate by carrying all the tote
information.

2.1.1       
Fast
Order Picking

Order picking,
which is a key task in a warehouse that refer to the operation through which
item retrieved from storage locations to fulfill customer orders. The order
picking system is designing to identify the picking are understanding the
storage system and determine the storage policy like picking method, piking strategy,
material handling system and picking assist technology.(Pan et al., 2012) Order picking process is receiving goods in an amount
unit size and retrieving them from storage. It is a labor-intensive activity.
Recent industries have change the traditional trends by using the automated
system to run this task. However, the modern warehouse order picking is making
goods quickly to satisfy the customer requirement. This is due to the flexible
that able to meet the needs of the large customer base and huge amount of item.(Liu et al., 2015) Besides, it also can help in reduce the labor cost
that operate on the picking task. Furthermore, it also require high quality and
the item security that the product can available and deliver on time for the
customer. The order picking activity has easier compare to the traditional
order picking because it only need the operator to give command to the
automated system to do the picking.(Pan et al., 2012) Daifuku is using three type of picking system in
order to increase efficiency and accuracy to do picking that is pick-to-light
system, picking cart system and put-to-light system. One of the picking system
that used RFID is picking cart system. Picking cart system is the operator will
set an order to the car display and scan through the RFID to confirm the type
and quantity of pick items. The cart system will automated pick those item
needed that the instruction given. The cart system is a walk through picking
equipped with totes, weight scale and the inspection devices that is RFID.

2.2             
Automated
System and Retrieval System

AS/ RS is an
equipment in order to manage the inventory and material handling. AS/ RS is
widely used by a major automated manufacturer or warehouse.(Salah et al., 2011) AS/ RS can briefly meant as combination of machine
and controls automatic store and retrieve inventory speedy.(Research and Markets,
4AD) Daifuku used AS/ RS to manage the logistic system.
AS/ RS used in automated manufacturer and warehouse and play an important role
in production systems. One of the AS/ RS is Unit load AS/ RS.(Chakole, 2013) This is one of the popular AS/ RS system around the
world. The unit load of AS/ RS has a flexible design up to 40 meter and
versatility make Daifuku’s Unit load AS/ RS the best-selling of AS/ RS. The
second AS/ RS is mini load AS/ RS. Mini Load AS/ RS used to carry small amount
weight that are in bins or shelves in the storage system. It provide the
fastest and efficient storage and retrieval containers.(Rashid et al., 2011) It help in high speeds to ensure the item carry for
the order picking and production operation on time. Besides, Daifuku also used
the rack-supported building AS/ RS. The rack supported building AS/ RS is a
racking constructed as a building with a codes. It help the space efficient and
reduce cost due to the high rise AS/ RS. In addition, vehicle type mini load AS/RS
also one of the AS/RS system that used by Daifuku. Vehicle type mini load AS/
RS is a fast and vehicle type AS/ RS designed to provide space and function by
group.

2.2.1       
Easier
storage space

Basically, the
AS/ RS will be able to recommend suitable storage space to the operator to
place the item or Stock Keeping Unit (SKUs) at the certain space. This
inventory management system able to control and tracking include easier storage
space.(Sproles and Kuehn,
2014) Daifuku is using the mini load AS/RS to manage the
warehouse. The mini load AS/ RS maximize more vertical space as building than
the shelves systems. The SKUs is placed vertically on shelves with high
precision to utilize the storage density. Many researchers found that design of
AS/ RS with the vertical rack is consider have larger storage space to store
the inventory or SKUs. Both AS/ RS offer high-density storage capacity with a
wide space.(Chakole, 2013) Besides, it also suitable for storage of heavy items
on shelves units especially the racking system in building AS/ RS. This able to
Daifuku to reduce cost and utilized the storage space. The effectiveness of
picking order also can reduce lead time and labor costing in order to the
efficiency of inventory storage. Furthermore, by using the AS/ RS to store the
inventory with systematic, it is easier to know where the product placed and
this will reduce the time to track the inventory. Daifuku will able to manage
more inventory and maximize the use of warehouse space. Daifuku’s AS/ RS
required a high level of above keep with the high technician and mechanical.

 

3.0  Recommendation

In order to run
the RFID and AS/ RS smoothly, Daifuku recommend to send their employee to
training and have some course to understanding how the equipment run and
operate.(Whittington et al.,
2011) Once the employees know how to operate the AS/ RS and
RFID, it will help to reduces the human error that will course to the running
down of equipment or human error.

Besides, Daifuku
can hire some professional that know at the maintenance equipment in order to
reduce the cost if some of the minor problems detect from the AS/ RS or RFID.(Sproles and Kuehn,
2014) By hire a professional, Daifuku can save up some of
the maintenance fees especially for the minor problem from getting outsources
to do the maintenance.

4.0  Evaluation

The disadvantage of
using the RFID and AS/ RS technology is it need the high maintenance fees in
order to keep the effectiveness of the machine. The main purpose to the
maintenance is to ensure the equipment run and operating smooth and fully
efficient all the time.(Ustundag, 2013) It need to have inspection on all those equipment
in order to constantly having a well productivity.  If the problems found, it need to make an
adjustment and correct before the major problems detected. An equipment run
down true cost is difficult to estimate and of course it need a higher cost to
do the maintenance compare to the labor and material if need to make repair.

The next disadvantage
that bring from RFID and AS/ RS is professional needed in operate those
technology. The AS/ RS and RFID required skills, experience and knowledge to
function it, In order to hired a professional to operate this, Daifuku need to
give some training or bring out the professional to operate this kind of
equipment.(Hu et al., 2016) (Gulcharan et al.,
2013)
This need some times and money to give some course to those selected to operate
the equipment. Besides, especially the AS/ RS has a lot of sub systems to
memorize. So, Daifuku have to do this expenses to send them to the course in
order to make sure them know well of all this equipment.

 

5.0 
Conclusion

In the nutshell,
Daifuku have a high quality in manage the warehouse by using the quick response
technology where is RFID and AS/ RS. By using the RFID technology, Daifuku will
able to fast order picking with those system. The order picking activity has
easier compare to the traditional order picking because it only need the
operator to give command to the automated system to do the picking. Besides,
the AS/ RS also help Daifuku to manage the storage space in order to utilize
the space as well due to those AS/ RS such as the mini load AS/ RS is a
vertically building to store the inventory. It save a lot of space and easier
to pick and put the inventory on the shelves by using the machine operate. The
disadvantages that bring out from RFID and AS/ RS is high maintenance fees
required and professional required in operate them. Daifuku recommend to train
the employees to ensure them understanding the equipment well and reduce the
maintenance fees by hiring the professional. 

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