Use Case

Yasuda Logistics Corporation

CATEGORY
CATEGORY:
Logistics
SOLUTION:
3PL

Delegate heavy lifting to robots for labor savings!
A collaborative workplace achieving 180% production efficiency with 2 operators and 7 AMRs.

For those responsible for considering the integration of robots to improve logistics warehouse operations, real-world case studies from companies that have already implemented such systems are highly valuable. Here, we will introduce the ‘real story behind AMR implementation’ with insights from interviews, focusing on actual cases of deploying Rapyuta PA-AMRs.


Yasuda Logistics Corporation Atsugi branch office

Industry: 3PL
Number of Units installed: 7 units
AMR Operation Date: April 2023 –


The warehouse where AMRs were introduced this time is Yasuda Warehouse’s Atsugi branch, located in Isehara City, Kanagawa Prefecture. As a 3PL provider, it handles logistics for office products, including heavy paper items such as labels and forms, and stationery such as writing instruments.

Spanning 1,900 square meters, the warehouse previously relied on manual single-picking with a large workforce. With the introduction of 7 AMRs, operations now involve just 2 staff members, achieving over 180% productivity compared to pre-implementation levels.

We interviewed team members who were involved in the implementation process from the planning stages. They shared insights into their experience with deploying Rapyuta PA-AMRs, their unique operational methods, and how they successfully achieved labor savings and increased productivity simultaneously, presented in a Q&A format.

Interviewees
Yasukazu Arai, Director of Business Planning and Head of DX Business Promotion Office, Yasuda Warehouse Corp.

Index

    • Characteristics of the introduced warehouse
    • Background of considering a logistics robot
    • Reasons and process of introducing Rapyuta PA-AMR
    • Thoughts on pre-deployment simulations
    • On-site reactions
    • Staff training
    • Unique efforts made during the operation of the system
    • Comparison of productivity before and after the introduction of Rapyuta PA-AMR
    • Use of large monitors
    • Rapyuta’s support system
    • Three key factors of warehouse environments ideal for AMR utilization

    Q. Could you tell us about the main products handled at this center and any unique operational aspects?

    We handle a wide range of office supplies and stationery, including items such as labels, forms, laminating films and machines, pens, and small notebooks. Before introducing AMRs, our operations relied on single picking from picking lists. However, items like forms were quite heavy, resulting in a high workload due to picking while pushing carts, which was particularly challenging for female and older staff members.

    Q. Please tell us about the background that led to considering the introduction of automated equipment in logistics operations and the challenges you aimed to address.

    The primary driver behind our decision was the shortage of labor. The Atsugi branch is located near the Tomei Expressway, providing excellent access to both eastern and western Japan, making it a highly attractive logistics hub in the country. As a result, large-scale warehouses and factories have recently been newly constructed, further exacerbating the labor shortage. Additionally, some warehouse operations heavily rely on skilled workers, and some work processes are physically demanding, such as transporting heavy loads. Therefore, our goal was to improve the working environment for staff, increase their motivation, and build a sustainable logistics site by introducing robots.

    Q. What options were considered to address the challenges? And what were the essential requirements that guided the final decision-making process?

    When we were exploring options, it was during the COVID-19 pandemic when e-commerce logistics were on the rise. The Goods-To-Person (GTP) solution was gaining attention, so we considered a wide array of options, including GTP, and identified that its implementation typically requires a substantial investment, posing challenges in justifying the cost-effectiveness of investments amounting to hundreds of millions of yen.

    Our company’s strategy for logistics digital transformation emphasizes conducting trials and Proof of Concept (PoC) to meticulously verify the benefits of automation in reducing labor and enhancing efficiency before proceeding with full-scale implementation. This approach ensures that we gather essential insights while evaluating these strategies.

    For instance, implementing GTP or automated warehouses often necessitates halting logistics operations for several days to over a week for installation. In contrast, AMR implementation allows us to continue operations seamlessly on-site. Additionally, the ability to adjust the number of robots enables us to manage throughput flexibly in response to fluctuating shipment volumes, highlighting its impressive adaptability.

    In our specific logistics operations, which involved a mix of piece picking and case picking simultaneously, AMRs demonstrated their capability to handle mixed product groups efficiently. This capability not only eliminates the need for extensive layout changes but also significantly reduces the workload for our staff, enhancing operational flexibility tailored to shipment volumes. Given these considerations, we concluded that AMRs are the optimal solution for achieving both labor reduction and operational efficiency enhancements.

    Q. Could you elaborate on the process that led to the decision to choose Rapyuta Robotics’ AMRs?

    Our decision to choose Rapyuta Robotics’ AMRs was shaped by a meticulous five-year process. Since our first visit to their lab, we have continuously tracked their advancements while gathering information from other companies. By 2022, as we evaluated AMR solutions, we engaged with nearly every major domestic vendor in the field. Through rigorous comparative analysis, Rapyuta’s AMR stood out for its robust track record in Japan and highly satisfactory maintenance and support systems, which we recognized as crucial for our operational needs. Furthermore, being able to closely examine the functions, actual movements, and operations of the AMR in the demo room at the Kiba office made it much easier to envision its deployment at our site.

    As I mentioned earlier, our company’s policy when implementing initiatives is to always conduct trials and Proof of Concept (PoC) to assess their potential effectiveness. In line with this approach, Rapyuta Robotics proposed a ‘Risk-free plan.’ This proposal was highly appealing and significantly streamlined the internal approval process, playing a crucial role in our decision-making.

    Q. When did you start considering and ultimately decide to implement AMRs?

    For the Atsugi project, we began exploring AMR implementation in April 2022 and initiated a ‘Risk-free plan’ PoC in June. The PoC ran for several months starting in November, and we made the final decision for full implementation in April 2023. The PoC facilitated the collection of essential data for our decision-making process, enabling us to promptly proceed with the deployment.

    Q. Could you provide your honest feedback on Rapyuta’s AMR from your experience with the pre-simulation (rapyuta.io™)?

    Rapyuta thoroughly analyzed our operational site, discussing work times and processes with concrete data. They provided detailed explanations of how productivity would change with AMR implementation through simulations, which helped us make an informed decision. While we had a sense that AMR would be suitable for our site, having specific numbers presented was crucial in the implementation process.

    Q. Were there any unique development requirements from your company during the preparation for AMR implementation?

    In our case, we didn’t have any further requests. Typically, integrating AMR with WMS involves API integrations, but during the PoC, we managed with CSV integration. As a result, we found that Rapyuta’s existing software meets our needs sufficiently. Of course, detailed configurations were necessary beforehand, such as picking logic, item sizes, and whether they fit into totes or cases, but all of this was managed within Rapyuta’s software.

    Q. Were there any changes or adjustments made to operations or locations in preparation for AMR implementation?

    During the on-site survey prior to operation, we made minor layout adjustments after identifying areas where robots tended to encounter traffic congestion. Throughout the PoC phase that followed, we continued to make minor adjustments, avoiding major layout changes. This was possible because all robot activities were visualized through data, clearly highlighting congested AMR areas. Rapyuta promptly provided improvement suggestions, such as creating spaces where AMRs could cross paths.

    Q. Could you share feedback from on-site staff or the results of AMR site acceptance?

    The veteran staff had developed their own unique methods over the years, so there was initially some resistance. However, as they were able to pick items hands-free and without the need to push carts, staff began to gradually realize the benefits. It was at this point that they started to appreciate the advantages of collaborating with robots.

    Introducing AMRs has enabled us to clearly visualize the work times for each staff member’s tasks. Utilizing this data, we’ve been able to identify insights to enhance productivity. During regular meetings with Rapyuta, it has been reported that specific staff members efficiently handle picking tasks. As warehouse managers, we ensure effective communication to recognize these efficient staff members and facilitate knowledge sharing with others. Rather than focusing on individual evaluations, we use the data to uncover the best practices of our most productive staff members and provide feedback to the entire team. Thanks to this data-driven approach, we feel the on-site staff’s performance has been revitalized.

    Q. Could you describe how training for on-site staff was conducted?

    The training was conducted over a short period of 1 to 2 days. Since the screen operations are intuitive and straightforward, most staff members grasped the operations within a few hours for regular tasks, except error recovery and handling irregular situations. After several demonstrations, all staff members had a good understanding of the basic functionalities. Following this, we focused on how to move and work efficiently with AMRs. From then on, we refined staff movements through continuous trial and adjustment, adopting an on-the-job training approach.

    Q. How are the large monitors being utilized in the warehouse?

    The large monitors display floor maps, which have been well-received by staff. Those involved in picking operations find it beneficial to oversee AMR positions from a bird’s-eye view, making it easier to understand the overall floor status.

    Additionally, during AMR picking tasks involving two staff members, there are instances where the AMR may not return promptly from unloading areas to picking areas. In such cases, other staff members can quickly assist by referring to the map on the large monitor, ensuring efficient support and coordination.

    Q. What kind of support did you receive from Rapyuta?

    Until achieving stable operations, we received extensive on-site support almost continuously. The on-site staff promptly addressed any irregularities or queries, which was reassuring. When challenging issues arose, the on-site staff resolved them by coordinating with the engineering team at headquarters.

    Currently, with stable operations in place, we conduct regular meetings to discuss various topics while sharing daily data. Rapyuta has proposed improvement measures to enhance productivity, which we have implemented. We engage in discussions to refine these solutions, whether they prove successful or not, aiming to find the best outcomes.

    Q. How smooth and cost-effective was the overall Rapyuta AMR implementation project in your experience?

    Rapyuta’s team impresses with their strong individual capabilities, which have left a lasting impression. The project team demonstrates a high level of expertise and cohesion. The sales, customer success, and engineering departments collaborate closely, ensuring a robust project framework. Additionally, the project manager effectively oversees operations, ensuring a well-managed project progression.

    Q. Are there plans in your company to expand AMR implementation to other locations or facilities in the future?

    We are currently considering introducing AMRs in a warehouse near the Port of Yokohama. This region also faces challenges in securing human resources, prompting our consideration of AMR adoption.

    Last year, as part of our efforts to attract new customers, we proposed a solution utilizing Rapyuta’s AMRs, which received high praise from our clients. Unfortunately, we were unable to secure the client for other reasons, but we received feedback such as, “Yasuda Warehouse was the first company to propose such an advanced solution.” Moving forward, we intend to actively propose this solution not only to streamline and automate our existing operations but also as a solution tool for new customers.

    Q. From your experience with implementation, what are three key factors that make a warehouse environment suitable for AMRs?

    We consider the greatest benefit of AMR implementation to be the reduction in transport time. However, if workers spend extended periods picking at the location where they arrive, this could offset the time savings. Therefore, the first point is that environments where picking times in front of shelves are short are highly suitable for AMRs.

    Another point is facilities with large picking areas and long transport distances. In terms of reducing transport distances, robots are more effective than humans. Therefore, environments with long transport routes are well-suited for AMRs.

    The third point is warehouses with low ceiling heights. Since AMRs operate horizontally, an environment with a ceiling height of around 2.5 meters is sufficient. This makes them particularly suitable for warehouses resembling office environments with many medium and lightweight shelves.

    In warehouse operations, maximizing storage efficiency is crucial, aiming to store as much inventory as possible within limited space. Therefore, leaving upper warehouse spaces unused is inefficient. While current legal regulations require discussions with local authorities, we believe that warehouses can be utilized more efficiently by installing a mezzanine to create additional space. The first floor could then serve as an operational area for AMRs, while the mezzanine could function as a backyard. Such configurations are ideal for AMR suitability. Additionally, repurposing office building floors as warehouse spaces is another effective way to operate AMRs.

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