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PROJECT

Synchronize the shelf-transport AGV and the system to automate inter-process transportation and eliminate personalization in storage.

YKK AP Inc.

YKK AP Inc. is the leading manufacturer of aluminum sash in Japan, serving as the core company for the YKK Group's building material business. They handle the design, manufacture, construction, and sale of housing building materials, mainly windows and sashes, as well as building materials for buildings. They have automated the inter-process transportation from parts storage locations to work stations by coordinating the shelf-transport AGV and WCS. Furthermore, at the work stations, they have introduced the PPS (Projection Picking System) to realize reduction of work errors in warehousing and leveling of operations.

Situation before the introduction of AGV and system

In the company's logistics center, the variety of small parts used for assembling window frames was so large that they could not fit into the conventional shelves, leading to storing them in places other than pallets and shelves. As a result, the travel distance increased, causing a decrease in operational efficiency and physical burden.
Additionally, only a few operators knew where things were stored, leading to a form of personalized management and variation in work hours.
Given these on-site issues and the concern over the accelerating shortage of workers, it was decided to experimentally introduce an automation system to aim for efficient and level operations

Image of the introduced system

Operation (Warehousing & Delivery)

  1. ➀The customer's higher-level system gives instructions for warehousing and delivery to the WCS.

  2. ②The AGV, upon receiving the instructions, automatically transports the designated shelf to the work station.

    1. ③At the work station, the PPS (Projection Picking System) is introduced.
      1. （1）Warehousing: The PPS projects onto the entrance of the shelf that is to be filled, indicating this to the worker. This prevents work errors.
      2. （2）Delivery: The PPS projects onto the entrance of the shelf that is to be cleared, indicating this to the worker. The SAS (Shutter Assortment System) is linked and indicates the shipping destination. The designated shutter opens to prevent set mistakes.

Introduction of AGV and system leads to reduced worker burden and leveling of personalized tasks

The introduction of the system resulted in two major effects.

  1. ①Workers no longer needed to walk long distances, reducing work efficiency and physical strain.
  2. ②The personalization of picking tasks was leveled, making it possible for anyone to perform the task.

In this way, we were able to achieve the improvement goals set at the beginning of the introduction. In addition to these, there is also the effect of preventing work mistakes before they occur, significantly improving the working environment.

Related product catalog

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LOGITO is a logistics automation solution provided by DJK.

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