An automated storage and tracking system is a specialised handling solution used to manage, store, and monitor products throughout a manufacturing process. At Incotech, we have designed a system for applications that can automatically store components for defined periods, track their location, and retrieve them when they are ready for the next stage of production.
But what exactly is an automated storage and tracking system, how does it work, and what advantages does it bring into a production setting?
How Does It Work?
• A new product enters the production system and is assigned a unique location. After each action has been completed, it returns to a storage bay until it is ready for the next operator action.
• A PLC tracks product identity, storage position, and dwell timing requirements.
• Automated handling equipment can move products between storage and workstations in a safe and secure manner.
• The system monitors dwell times and prevents products from being removed too early, applicable to a variety of applications.
• After dwell timers are complete, products are automatically retrieved through HMI selection for the next production stage.
• After the entire part process is complete, the part is removed from the system and a new part takes its place.
The Benefits of Automated Storage
Automated storage systems have significant advantages for improving organisation, traceability, and production efficiency within a working environment. By automatically storing and tracking products, the system reduces reliance on manual record keeping and significantly reduces the risk of operator error, with live step-by-step instructions provided by a Human Machine Interface (HMI).
Automated storage systems can also allow for more efficient use of space. Vertical stacking with an automated pickup system allows for a higher volume of storage within a working environment. These systems can be integrated into an existing production line or made to work independently through the use of controls technology and communications.
When Do You Need an Automated Storage System?
Whether an automated storage solution is required depends on the nature of the operations process, the scale of products being produced, and the required accessibility of the products.
If your production process involves multiple product variants that must be tracked throughout manufacturing, an automated storage system can significantly improve accuracy and efficiency.
By reducing reliance on manual data handling and allowing the entire process to be controlled by a PLC, you can reduce workload while improving accuracy.
The Sheeting Machine
A customer approached us with a requirement for an automated storage solution capable of housing up to 12 boards, each with its own configuration and curing schedule, while providing continuous tracking throughout the manufacturing process. We recognised early on that the project had the potential to streamline operations and deliver significantly in efficiency improvements.
Our proposed solution was an automated vertical storage system capable of accommodating up to twelve boards, each stored and accessed independently. The system was designed to handle resin-coated sheets, with each production run following a specific preset that determined the coating product, curing duration, and processing sequence required. Given the variety of configurations involved, it was essential to implement a robust tracking system capable of monitoring the location, status, and curing progress of every board throughout the entire process.
The storage system was engineered to automatically transfer boards from the storage rack to one of two operator workstations, where processing could be carried out before the board was returned to its original storage position for curing. As curing times varied depending on the material and coating used, the tracking system ensured each board remained in storage for the correct duration before progressing to the next stage.
To further enhance process reliability, an integrated vacuum system was incorporated for specified material types. This prevented movement while boards were in storage, maintaining precise positioning throughout the curing cycle and ensuring consistent product quality from start to finish.
The completed system provided full traceability of every board, reduced manual tracking requirements, improved storage density, and ensured curing schedules were consistently met. This enabled the customer to achieve a more streamlined and reliable production process.
Summary
Automated storage and tracking systems offer a reliable way to control product flow, manage dwell times, and maintain traceability throughout the manufacturing process. By reducing manual handling, improving space utilisation, and giving operators clear step-by-step guidance, these systems help manufacturers improve efficiency while maintaining consistent product quality. For applications with varied materials, configurations, and dwell requirements, a bespoke automated storage solution can provide the structure, accuracy, and flexibility needed to support a smoother and more dependable production process.
Need Something Similar?
At Incotech, we design bespoke automated machines such as this storage and handling system, tailored to each customer’s manufacturing requirements. If you are looking to improve traceability, optimise floor space, or automate material curing processes, contact our team to discuss your application.