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Revolutionizing Parts Supply with MujinOS

In an era marked by rapid changes in consumer demands and shorter product cycles, the automotive manufacturing sector in the Kanto region of Japan is experiencing a surge in mixed production involving multiple varieties and small lots. This evolution poses significant challenges for suppliers in adapting their operations to meet these volatile production plans. Japanese logistics leader Nippon Unyu has risen to the occasion by partnering with Mujin to establish a next-generation digital warehouse based on the integrated automation platform, MujinOS.

The Challenge of Manual Operations

Traditionally, the manual picking processes for parts supply in Nippon Unyu's warehouses heavily relied on human labor and individual decision-making. The increasing complexity of operations necessitated a rethink, especially in light of anticipated labor shortages in the future. Nippon Unyu sought to redefine their logistics framework by automating heavy manual labor and digitizing processes that are prone to variability and human error. Through this collaboration with Mujin, they have leveraged robots, Automated Guided Vehicles (AGVs), and digital twin technology to create an advanced logistics digital transformation (DX).

Three Key Innovations Driving Change

The deployment of MujinOS has resulted in three primary innovations:

1. Automated Replenishment of 97 Product Types

Using intelligent robots combined with AGVs, Nippon Unyu has achieved automatic replenishment for 97 different product types. The robots handle the depalletizing and palletizing of returnable containers and show remarkable versatility, managing everything from precise alignment in the millimeter range to accommodating a mix of sizes in returnable boxes. This precision facilitates the stacking of products, after which AGVs seamlessly transport them, automating the entire process from replenishment to empty container collection.

2. Error-Proof Parts Picking

At the parts picking stations, digital aids like the Digital Picking System (DPS) and the Projection Picking System (PPS) support workers by providing real-time digital instructions. This digital assistance allows operators to accurately identify which parts to pick and where to place them, ensuring alignment with the production plan while significantly reducing the likelihood of errors in picking operations.

3. Unified Control through Digital Twin Technology

The entire operational workflow is managed by MujinOS, which is integrated with the production schedules from automotive manufacturers via a Warehouse Execution System (WES). This integration provides a real-time digital twin visualization of the warehouse, enabling operational improvements based on actual performance data and affording remote maintenance capabilities. The result is a robust logistics foundation that is well-equipped to handle the demands of mixed production.

Outcomes of the Next-Generation DX Warehouse

The implementation of MujinOS at Nippon Unyu has brought about several noteworthy improvements:

• - Standardization of Manual Tasks: The digitalization of previously subjective tasks, such as replenishment counts and priorities, has led to a more standardized approach guided by production plans.
• - Enhanced Safety and Reduced Load on Heavy Tasks: The automation of tasks like sorting and transporting containers heavier than 10 kg has significantly enhanced workplace safety and reduced physical strain on workers.
• - Quality Enhancement and Error Prevention: By strengthening error-proofing mechanisms through DPS and PPS, Nippon Unyu has been able to deliver high-quality picking experiences with minimal mistakes.
• - Space Optimization and Cost Reduction: Innovations such as automatic tool changers that adjust to different container sizes have streamlined operations, allowing for a reduction in the number of robots needed from two to one.
• - Smooth Implementation and Launch: Mujin's end-to-end support from design to installation has ensured that the warehouse became operational immediately following its transformation.

Vision for the Future

The success of this logistics revolution is deeply rooted in Nippon Unyu's commitment to addressing core issues with a unified team approach that spans from management down to the operational level. The company is eager to leverage these advancements to enhance its competitive edge in the future. Mujin remains dedicated to supporting Nippon Unyu’s ambitious goals in the continually evolving landscape of logistics.

About MujinOS

MujinOS is an integrated automation platform that synchronizes various automated machinery, including robots, AGVs, and storage systems within a digital twin environment. It facilitates advanced autonomous automation that adapts flexibly to changes in the real world, thus supporting DX initiatives in industrial sites. With features like dynamic optimization and data analytics for remote operations, MujinOS stands at the forefront of transforming supply chain efficiency.

To learn more about Mujin’s automation solutions, visit MujinOS or explore their robotic solutions and AGVs.