Power-Smart Warehouse： A Four-Way Shuttle-Powered Intelligent Hub for Grid Materials

The traditional warehousing model faced three major challenges: low space utilization (only 35%) due to the diverse sizes of power materials (from precision instruments to large equipment); slow response times for emergency repair materials (averaging over 6 hours), impacting fault recovery speed; and high inventory discrepancies and difficult traceability due to manual record-keeping. An intelligent upgrade via a four-way shuttle-based AS/RS was urgently required.

• High-Density Storage: A combination of four-way shuttles and heavy-duty racks, with customized locations for different material sizes, created 20,000 storage units. Space utilization increased to 82%, expanding capacity by 134% compared to traditional warehouses.

• Full Automation: 25 four-way shuttles, 8 heavy-load elevators, and intelligent conveyors enabled automatic storage, retrieval, sorting, and inventory of power equipment, achieving a throughput of 1,000 pallets/hour.

• Smart WMS Integration: A Warehouse Management System integrated with ERP enabled demand forecasting, automatic replenishment, batch tracking, and full lifecycle management. Linkage with the grid dispatch system ensured rapid response for emergency repair materials.

• Heavy and Precision Compatibility: The system needed to handle both heavy transformers (over 5 tons) and precision instruments, requiring strict standards for rack load-bearing and shuttle stability.

• Complex Environment Adaptation: Some power equipment required constant temperature and humidity storage, demanding shuttle operation reliability under specific environmental conditions.

• Deep System Integration: Seamless 对接 with the grid's existing ERP and dispatch systems was necessary to achieve real-time data synchronization and closed-loop business processes, presenting significant integration challenges.

• Efficiency Improvement: Emergency repair material response time was reduced to under 1 hour, improving fault recovery efficiency by 6x and strongly supporting grid safety.

• Cost Optimization: Labor costs were reduced by 70%, space utilization increased by 134%, resulting in annual warehousing cost savings exceeding 5 million yuan.

• Management Upgrade: Full lifecycle digital management of materials was achieved, with inventory discrepancy rates below 0.1%, providing data support for lean grid operation.