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Mini Load AS/RS Case Studies

Company	Industry	Download
Canon Europa	Electronic Components	Download
Canon Europa, the European sales subsidiary of Canon Inc., operates two parts plants outside of Amsterdam. Canon Europa is responsible for distributing all Canon products to a wide-ranging sales area, which includes the Middle East and African regions. In order to accommodate the increasing number of orders in a timely manner, Canon Europa selected Daifuku to update its Unit Load and Mini Load Automated Storage/Retrieval Systems (AS/RS). The retrofits of both systems took place without impacting the operations of the plants. As part of the retrofit, Canon Europa worked to increase the speed of the cranes and peripheral equipment. Also involved in the retrofit of the old systems was the replacement of five cranes and upgrading the old pallet system to five STVs. After the retrofit, storage space increased by 20% and the processing capacity per hour improved by 75%.
Company	Industry	Download
Cox Target Media	Printing	Download
Every year Cox Target Media mails over 500 million of the familiar blue, #10 Valpak envelopes containing more than 19 billion coupons. Faced with rising variable costs and looming capacity constraints, Cox managers could see a rapidly approaching day when the company’s growth would overtake its production capacity. To automate the material flow between the printing and envelope wrapping processes and the buffer storage areas, Cox called on the expertise of Daifuku America Corp.’s Factory and Distribution Automation division in Salt Lake City.
Company	Industry	Download
Dell Inc.	Electronic Components	Download
Many technology companies are following the outsourcing trend for manufacturing, but Dell Inc. is expanding its own manufacturing facilities worldwide to realize the benefits of its supply chain management system and “Dell Direct Model” sales strategy. Each of Dell’s seven factories around the world operate with less than four days inventory, which enables Dell to produce each computer system at a competitive price with specifications that meet each customer’s individual needs. To accomplish its manufacturing and customer goals, Daifuku helped Dell by installing a Mini Load Automated Storage/Retrieval System (AS/RS) and a 15 chute Parcel Sorter. With these in place, Dell’s material handling system achieves quick shipping after production. Dell has plans to expand its material handling system to increase the variety of products it handles as well as to increase its production capability.
Company	Industry	Download
Nagai	Apparel	Download
In January 2003, one of Japan’s top manufacturers of medical apparel and medical goods, Nagai Leben, built the new Nishi-Nippon Distribution Center to better serve customers in Japan’s western region. Nagai Leben and its distribution centers ensure the accurate picking of more than 4,200 medical goods and 450 types of clothing articles. The picking, sorting, and storing operations that were done manually at other factories prior to the Nishi-Nippon Distribution Center were replaced with a Mini Load Automated Storage/Retrieval System (AS/RS). The Nishi-Nippon Distribution Center also employs other Daifuku products including the Warehouse Management System (WMS) WareNavi, automated replenishing system Space Carrier (SPC) and Picking Cart System (PCS) to greatly enhance physical distribution capabilities.
Company	Industry	Download
NGK Spark Plugs	Manufacturing	Download
NGK Spark Plugs Co. holds 70% of Japanese market and is the world’s top manufacturer of spark plugs. NGK built its Nagoya Distribution Center in 1999 in an effort to centralize the delivery operation of three factories and four offices/warehouses in Japan. Its Unit Load Automated Storage/Retrieval System (AS/RS) enables pallet storage of 2,912 pallets and eliminated mixed load storage and other resulting errors. Its Mini Load AS/RS stores 2,496 totes and special small-lot items. Its RF Handy Terminal has greatly increased work efficiency and decreased the labor force by 10%.
Company	Industry	Download
O.C. Tanner	Manufacturing	Download
In the early 1990s the trend line for merchandise awards continued up for O.C. Tanner - but so did the requirement for storage space, requiring the leasing of off-site warehouses. Eventually, O.C. Tanner built a new, automated Award Distribution Center in Salt Lake City. The craftsmanship content of the merchandise awards process was not changed, but the manual material handling and the chasing back and forth to complete orders was automated. Previously, a worker walked as much as 5,100 feet to take an order through the manufacturing and shipping processes. With the new system, merchandise is conveyed to and from the workstations to minimize walking. Output increased dramatically from 1,800 awards per day to 3,000. Worker efficiency went from 3.5 awards per worker hour to 5.5 awards per hour with 45% fewer people. Cycle time from order entry to shipment was reduced by half to three to four weeks.
Company	Industry	Download
Okamoto Corp.	Apparel	Download
Okamoto Corp recognized the need to improve its automation system to meet the needs of its customers and six distribution centers throughout Japan, China and Thailand. Okamoto is a leading manufacturer and distributor of leg wear products like socks and pantyhose. In February 1992, Daifuku installed a case storage Mini Load Automated Storage/Retrieval System (AS/RS) at Okamoto’s Kasugai Logistics Center. Handling volumes and item variety increased, and a high-speed Ski Sorter was added in 1997 to handle small items. The Mini Load AS/RS stores and retrieves 300 cases per hour while the Ski Sorter sorts 5,000 pieces per hour at a speed of 328 feet per minute. Expertise gained by Okamoto Corp. at this center has been used in the development and operation of newer logistics centers in five locations throughout Japan.
Company	Industry	Download
Ryoshoku Limited	Food & Beverage	Download
When Ryoshoku, a major food wholesaler with its headquarters in Tokyo, built its new Aikawa Specialized Distribution Center in November 2002, it wanted to implement a more advanced material handling system to satisfy a higher level of service. With the new distribution center, the level of delivery service increased dramatically. With Daifuku’s Mini Load Automated Storage/Retrieval System (AS/RS), Ryoshoku was able to increase the order accuracy and decrease the missed sales opportunities. Ryoshoku uses both the Mini Load and Unit Load AS/RS in addition to the Digital Pack System (DPS). Aikawa’s results are described as “unprecedented AS/RS for case picking.” With automation, Ryoshoku’s Aikawa’s distribution center was able to achieve a reduction in operation costs and meet customers’ high demands.
Company	Industry	Download
Utah State University	Libraries	Download
Utah State University (USU), located in Logan, Utah, brought Daifuku America Corporation on board to help it with some issues the university library was facing as it moved to a new facility. The university needed an innovative solution to accommodate growth through the year 2027. To meet USU’s needs, Daifuku provided the expertise and equipment to get the new facility up and running. USU implemented a Mini Load Automated Storage/Retrieval System (AS/RS). USU’s Merrill-Cazier Library system is the only library in the world to use an automated retrieval system with materials in call number order. The system allows patrons the opportunity to pull up a chair and browse approximately 200 to 250 volumes at a time once the shelf they need is automatically brought to them.

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