Summary
Aspire to solve issues in the logistics industry by automating the laborsome searching and collecting goods within the warehouse
Mr. Tadashi Iwasaki,
Group Manager in charge of Next Generation Logistics Technology Group Logistic Innovation Division
When picking goods in a 3,300-4,000㎡ (35,000-42,700ft²) warehouse, operators end up covering a lot of distance, leading to fatigue, which brings down the speed and accuracy of their work.
While we have taken measures such as changing the layout of the warehouse, we still could not eliminate walking, so we decided to introduce an AMR system.
As a result, the work process became more efficient, and the amount of picks per person per hour almost doubled.
Furthermore, we see a significant improvement in the quality of picks, as there are now fewer picking errors, thanks to color coded labels and instructions.
Testimonials: SBS Toshiba Logistics Corporation
Start of operation: February 2021
Mr. Tadashi Iwasaki,
Group Manager in charge of Next Generation Logistics Technology Group
Logistic Innovation Division
Solution adopted
Autonomous Mobile Robots
The autonomous mobile robot (AMR) system "finds" and "brings" the shelf with the Goods-To-Person. This solution greatly reduces the time needed to search for the goods, work processes, as well as risks such as picking errors and delays.
Decisive Factor
Mr. Yuji Otake
Manager, Kita-Kanto Branch
Mr. Yuji Otake
Manager, Kita-Kanto Branch
- Growing market for robotics in logistics
- Improve work efficiency, and respond to labor shortage
The challenge was that we needed a lot of workforces (personnel, human resources), as operators had to walk long distances due to the size of the warehouse. In addition, when considering storage efficiency, we had to make the aisles narrow, which meant that picking carts could not pass each other, resulting in traffic jams within the aisles. We tried to make improvements through various analyses based on shipment frequencies and industrial engineering, but we had not been able to solve the issue fundamentally.
During that time, we noticed the growing use of robotics in the logistics industry over the past few years, so we visited logistics sites utilizing robotics, and saw that such technologies were coming within our reach. From then, we started to seriously consider how we could also implement robotics. Anticipation built up inside all of us, including our operators, we thought "we can significantly change the way we work."
The decisive factor:
- Customizability and maintenance support structure
- Careful consideration of the entire work process during installation
We narrowed it down to four companies in the end and then compared their references, prices, how customizable their software is, as well as how their maintenance support structure is, etc. As a business operator, one of the most important points is whether you can have long lasting confidence in the solution as well as the supplier. Based on these points, and that we were able to have high expectations for even more improvements after implementation, we decided to go with Toshiba Infrastructure Systems & Solutions.
What we had to consider the most upon implementation was the impact the system would have on the processes before and after the AMR system. We inspected each process one by one to ensure that the efficiency of the entire shipping process would not be compromised while still getting the most effectiveness out of the AMR system. We were all so surprised to see the AMRs carrying the shelves without breaking a sweat, and the operators were amazed, saying "the shelves are coming right up to me."
- Picks per hour per person doubled
- Picking quality also improved thanks to error preventing features
With the introduction of the AMR system, the picks per person per hour has almost doubled. I think this is because we were able to significantly reduce the time we spent walking around the warehouse and getting stuck in traffic jams between aisles. The operators are happier now, as there is less physical strain for them. We are already seeing positive results, but when considering long term use, for the next 5-10 years, we want to target triple, or even better results.
Moreover, the AMR system has improved the quality of our work, as in the past, we sometimes had stocking errors or miss counts during inspections, but as the AMR system has color coded storage areas, we have much fewer errors now.
Significant reduction of overtime hours with AMR system
Effective for improving the work environment
Accurately predicting the daily order volume and securing the right number of workers is an extremely difficult task. However, for days when the amount of goods is higher than predicted, overtime will occur and the burden on operators will increase. Even in such situations, the implementation of the AMR system has reduced overtime hours and has been effective in improving the work environment. By further increasing the efficiency of AMRs, we aim to create a more comfortable workplace.
Future Outlook
Less workforce and saving labor are the trends in the logistics industry
Enhance performance with the early adaptation of robotics
As the labor shortage becomes even more severe, robotics which contributes to saving the workforce and labor will continue to trend in the future.
That's why it's important to implement a mechanism as early as possible and build up experience. Once you have enough know-how, the work structure can be simplified, which is not only effective when employing foreign workers but can also be expanded to other businesses.
We want to continue exercising wisdom together with Toshiba and focus on further improving our capabilities.
Comments from our Key Account Manager
Toshiba Infrastructure Systems & Solutions Corporation
Security & Automation Systems Division
Logistics & Postal Solutions Sales & Marketing Department
Hiromitsu Muraki
The logistics industry (in Japan) is currently in a situation, where there is an accelerating labor shortage due to the declining birth rate and aging population, but a booming e-commerce market is frequented with orders in small-lots, so there is a great demand for improving operational efficiency. Therefore, in order to address these exact issues that SBS Toshiba Logistics was facing, we proposed a combination of our shelf transporting AMRs and customized software and were awarded this opportunity. Even after implementation, SBS Toshiba Logistics regularly shares data, operator feedback, issues, and countermeasures with us, so we can aim for better results together, as well as improve the level of our software.
It was a great experience for us to be able to work with SBS Toshiba Logistics, a group of logistics professionals, from the very beginning of implementing the system. For the next step, we want to propose more solutions that will contribute to further improvement of the processes before and after the AMR system, such as a de-palletizer and picking robots, as well as a tailored overall optimization of our customer's sites and operations.
Customer profile
SBS Toshiba Logistics Corporation
Company information
Location
Shinjuku, Japan
Number of employees
722 (as of the end of March 2021)
Capital
JPY 2,128 million
Business description
-Warehousing
-Cargo transportation
-Machinery and equipment installation
-Flying and earthwork business Customs clearance
-Air transport agency business
-Logistics consulting
URL
https://www.sbs-toshibalogistics.co.jp/logi/corporate/outline.html
Location
Number of employees
Capital
Business description
URL
Shinjuku, Japan
722 (as of the end of March 2021)
JPY 2,128 million
-Warehousing
-Cargo transportation
-Machinery and equipment installation
-Flying and earthwork business Customs clearance
-Air transport agency business
-Logistics consulting
https://www.sbs-toshibalogistics.co.jp/logi/corporate/outline.html
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