Consider an in-the-aisle order picking system based on the person-on-board AS/RS.

The user would like to store 7,000 loads in the system, where each load requires 18 ft2 of rack surface (including necessary clearances). The system must be capable of performing 215 picks per hour. On each trip, the picker performs eight picks; each pick requires 1.5 minutes. The S/R machine travels at a speed of 400 fpm and 100 fpm in the horizontal and vertical directions, respectively. Last, the picker spends 1.20 minutes at the P/D station between successive trips.

a. Assuming that the pick points are sequenced in an optimum fashion, determine the

“minimum” number of pickers and storage aisles required.

b. Determine the rack dimensions for the “minimum” number of storage aisles.

c. What fraction of the system’s throughput capacity will be utilized?