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PROJECT

Automation of Regular Box Sorting and Palletizing for Labor Reduction

Background of the Problem

In this customer's factory, there are transactions with over 100 suppliers, and more than 400 types of parts delivered daily in reusable containers. After distributing the parts to the production line, the emptied reusable containers need to be sent back to the suppliers, a sorting task that required significant effort.
Ten people were working daily on this task, with the number of empty containers sent back being 22,000 per day, and exceeding 30,000 per day during peak times. Additionally, because the arrival order of the reusable containers was irregular, it was necessary to store them until a certain number accumulated, and securing that storage space was also required.

LOGITO's Solution

Solution Overview

1.Analysis

We analyzed the distribution data for each reusable container. Although irregular, a detailed analysis made it possible to identify trends and groupings. By analyzing not only the daily distribution numbers but also the numbers for each reusable container, we were able to consider the optimal solution.

2.Equipment Selection

Based on the analysis data, we proposed management using an automated shuttle-style warehouse. Additionally, we proceeded with simultaneous introduction of AGVs, stacking devices, palletizing robots, and image processing (automatic box recognition) devices for warehouse import and export.

3.Objective

Since the objective was to reduce labor, this was accomplished by introducing automated warehouses, AGVs, and palletizing robots. Furthermore, we were able to simultaneously eliminate the initial sorting process for reusable containers and achieve space-saving by introducing an automated warehouse.

Effects of Implementation

Reduction of workforce from 10 to 3 people (7 people reduction)
Elimination of initial sorting process
20% reduction in workspace

Strengths of LOGITO

Combination of Multiple Solutions

We can provide the optimal solution to customers by not only introducing simple equipment but also combining various devices. By selecting devices from various manufacturers, such as palletizing robots, AGVs, and automated warehouses, we make proposals that capitalize on each device's strengths.

Detailed Pre-Implementation Simulation

By using simulation software, we share the pre-implementation image with the customer. It allows for a complete understanding of the required space, layout, etc., within the customer's organization. Moreover, we can quantify the effects after implementation and demonstrate the investment return needed at the time of application approval.

CONTACT

LOGITO is a logistics automation solution provided by DJK.

We will contact you within one day after receiving your inquiry, excluding weekends and national holidays.
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