On March 4, Mujin announced that it had built a digital transformation (DX) system for a parts supply warehouse for finished vehicle manufacturers at Nippon Transport's Ota Interchange Sales Office, based on its integrated automation platform "MujinOS".
This will become a next-generation logistics hub that responds to the increasing trend of high-mix, low-volume automobile production, and achieves automation and digitalization linked to production plans.
<Digital Transformation of Nippon Transport's Ota Interchange Sales Office>
Nippon Transport is a comprehensive logistics company that provides integrated logistics services from packaging to transportation and warehousing.
In recent years, mixed-model, variable-volume production has been expanding among finished vehicle manufacturers in the Kanto region, driven by diversifying needs and shorter product cycles. Consequently, flexible and resilient operations are required more than ever in parts supply operations. On the other hand, warehouse operations still rely heavily on manual labor and the judgment of experienced workers, raising major concerns about future labor shortages and skill transfer.
In response to these environmental changes, Nippon Transport has begun automating heavy lifting tasks and digitizing decision-making processes that tend to be dependent on individual expertise. They have partnered with Mujin to implement an integrated solution combining robots, AGVs (automated guided vehicles), and digital twins.
Three innovations for logistics automation
The two companies have tackled three innovations to revolutionize logistics. The first is the automated replenishment of 97 different product types. By linking intelligent robots and AGVs that handle the depalletizing and palletizing of returnable containers, they have built a system that automatically sorts and stacks parts collected from suppliers.
<97 types of products are automatically refilled by product type>
The Chiken Robot can flexibly handle fittings requiring millimeter-level precision, pallets with mixed left and right parts, and returnable containers with large size differences. After stacking, AGVs automatically transport the items, and the entire process, from replenishment by product type to collection of empty containers, is automated.
The second improvement is the sophistication of the parts picking process. By utilizing DPS (Digital Picking System) and PPS (Projection Picking System), workers are instructed on the parts to be picked and the input opening via digital displays. Accurate picking support based on information linked to the production plan prevents errors such as incorrect input. The determination of replenishment quantities and priorities, which previously relied on intuition and experience, has also been systematized, leading to standardization of work.
<Integrated control of the entire process using a digital twin>
The third feature is the introduction of "MujinOS," which provides integrated control of the entire warehouse. Equipped with a WES (Warehouse Operations Management System) that links with the production plans (MES/WMS) of the finished vehicle manufacturers, it centrally manages robots, AGVs, and various automated equipment on a digital twin. It visualizes the operating status of the entire warehouse in real time, enabling data-driven operational improvements and remote maintenance. A key feature is the establishment of a foundation that can flexibly follow even highly variable production plans.
The benefits of the system are already becoming apparent. By having robots handle the sorting and transport of returnable containers weighing over 10 kg, the workload on workers has been reduced and safety has been improved. In addition, the tool changer function, which automatically changes the hand according to the size of the returnable container, has allowed for the consolidation of two robots into one, resulting in space savings and reduced equipment costs. Mujin provided comprehensive support from design to construction and commissioning, which ensured smooth operation even after the warehouse changeover.
In the automotive industry, where the trend towards high-mix, low-volume production is progressing, improving parts supply is a crucial issue that will determine competitiveness.
Nippon Transport states that the integrated efforts from management to frontline staff in implementing reforms have led to the promotion of digital transformation (DX), which will strengthen the company's competitiveness.
Mujin will continue to support digital transformation in industrial settings and the optimization of the entire supply chain through the deployment of its integrated automation platform.
■Mujin Implementation Case Study: Nippon Transport
Mujin/AGV lineup expands to include 300kg compact and 1500kg heavy models.
