DELIECN Delivers a Single-Rail Dual-Stacker-Crane AS/RS for a Global Compressor & Pump Manufacturer

A leading global manufacturer of compressors and pump equipment is expanding capacity and upgrading its product mix while developing a new plant designed around smart manufacturing. With products supplied to more than 50 countries and regions, the customer required a logistics system that could support higher throughput, mixed load types, and multi-floor production supply—within a complex building layout.

To respond to these requirements, DELIECNdesigned and implemented an integrated Automated Storage and line-feeding system combininga pallet AS/RS and a tote AS/RS, connected by conveying, vertical transfer, and rail-guided transport. The program was engineered to link storage, picking, delivery, and line-side replenishment under unified warehouse software and interface capability to ERP/MES.

Project Drivers

As production volumes increased, the customer faced a typical set of constraints seen in high-end equipment manufacturing:

• Limited construction space: the AS/RS needed to be built in the corridor between two factory buildings, with complex structural interfaces.
• Multi-floor line support: the system had to serve production lines on both the first and second floors and enable kitting and accurate delivery.
• Mixed material profiles: bulky palletized items and high-SKU small parts in totes needed to flow efficiently under tight production takt time.
• End-to-end process linkage: cross-floor and cross-process coordination required traceable data and stable execution logic.

System Architecture

DELIECN delivered an integrated automation program centered on "Pallet AS/RS + Tote AS/RS", supported by key equipment and software modules:

• Pallet Stacker Cranes (single-rail, dual-crane deployment)
• Tote-handling robots and tote racking
• Vertical lifters for cross-floor transfer
• RGV units for pallet transport and buffering
• Conveyor modules (roller and Chain Conveyors)
• High-precision racking
• WMS with integration capability to ERP/MES (and related control subsystems)
• This architecture was designed to cover the full internal logistics cycle—from storage to picking and delivery—while enabling reliable line-side supply for assembly processes.

Pallet AS/RS Configuration

To maximize use of the restricted inter-building corridor, the pallet AS/RS adopted a single-rail dual-stacker-crane configuration, enabling parallel operations within a compact footprint.

Tote AS/RS Configuration

For small parts with high SKU diversity and frequent access needs, the tote AS/RS supports refined inventory control and high-frequency replenishment.

Material Flow Optimization

To improve carrier circulation and reduce floor footprint, the conveying system separates pallet carrier return flow:

• Upper level: loaded pallets
• Lower level: empty pallets
• This routing improves carrier turnover and helps stabilize delivery rhythm across production.

By splitting bulky items into the pallet AS/RS and small high-SKU parts into the tote AS/RS, the plant can better support mixed-model production and strengthen kitting completeness and JIT (just-in-time) delivery capability.

Outcomes (Reported by the Project Team)

The customer's target was to improve storage density, line-feeding efficiency, and digital traceability under restricted construction conditions. Based on project reporting:

Takeaways for High-End Equipment Manufacturing

This project illustrates how an integrated pallet + tote AS/RS can be applied to manufacturing plants facing:

• restricted building geometry,
• multi-floor production supply,
• mixed load profiles, and
• high requirements for kitting accuracy and delivery rhythm.
• By combining high-density storage with structured transport and software connectivity, the system supports scalable internal logistics while keeping execution controlled and traceable.