Okaso Co., Ltd. - Updated Its AS/RS to Store Screws in Stages, Enabling Stable Facility Operations And Improving Input/Output Throughput.
Okaso Co., Ltd. (headquartered at Osaka, Japan) is a general trade company, which handles engineered fasteners such as screws, bolts, and nuts. The company reconstructed an Automated Storage and Retrieval System (AS/RS) at its core distribution site, Yao Distribution Center. Updating the Storage and Retrieval machines (S/R machines) and the loading/unloading equipment helped stabilize operations of the material handling systems and improved input/output throughput.
In 1993, the core distribution site opened featuring several material handling systems
Okaso was established in 1926 as a pioneering screw trade company. Okaso’s business expanded over the years to include 500 suppliers and a sales network of 2,000 companies nationwide, which are mainly agents. In January 1993, Yao Distribution Center opened to support Okaso’s thriving distribution business. The distribution center’s site area is 3,025 sqm (32,560 sqf), and the total floor area is 5,192 sqm (55,886 sqf). The center is open 9:30 a.m. - 6 p.m. on weekdays. The center features several material handling systems including a building-supported unit load AS/RS “Rackbuil System” for standardized items, a mini load AS/RS for fractions of standardized items, an inventory controller “AWC” (Automated Warehouse Controller), and a vertical carousel rack with a digital scale for non-standardized items. The systems accurately controlled an inventory of over 80,000 SKUs and significantly enhanced distribution efficiency allowing for same day delivery when orders were received by 5 p.m.
The problem was twelve years had passed since the center opened making it difficult to maintain. Additionally, both maintenance frequency and cost were increasing. Therefore, in December 2005, the first step was renovating the warehouse for stable information processing. After a year of consideration and analysis of other companies’ automation, Okaso decided to update the SR machines and control devices.
Construction was divided into five phases to continue distribution operations during renovation
The warehouse renovation accomplished the following points; 1) distribution operations continued during construction, which took place in five phases over long holidays. The phases began in May 2008 during summer and new year holidays over two years, 2) the processing throughput was increased by changing the cart-type loading/unloading equipment to two-tiered conveyors for the mini load AS/RS, 3) the new conveyors were assembled and tested to confirm actual movements and allow for easy installation. The new systems were completed in January 2010. With the new systems, the maintenance frequency and cost have been drastically reduced. The cycle time of the mini load AS/RS improved 1.5 times, speeding operations. Currently, approximately 14,000 cases and 500,000 pieces are shipped monthly. Previously, supplied products were stored after picking because the product volume was too much to handle in the collection area of the mini load AS/RS. The two-tiered input/output conveyors double the processing throughput. The two kinds of operations are performed simultaneously, which reduces overtime during busy seasons.
Furthermore, Okaso also began using Daifuku’s Remote Monitoring Service called “DREMOS”. DREMOS constantly monitors the operation status of the AS/RS and detects potential errors. This decreases errors, as well as a system down time.
Motivating our staff
“Our operation staff has participated in the project since the early stages. Functions of the distribution center were strengthened. And our staff’s motivation improved greatly because of the project’s achievements,” explains Ms. Maki Okada, General Manager. “We also improved the staff’s individual skills by conducting simple maintenance ourselves.”
