Contact Us
Please feel free to contact us via the form below.
Loading...
Case study of automating refrigerated (chilled) warehouses | Streamlining sorting operation in a low-temperature environment
31/05/2023
TRUE Okura Co., Ltd.
TRUE Okura Co., Ltd. provides material handling equipment, including logistics robots and conveyance / sorting equipment to the Thai logistics market as the Thai subsidiary of Okura Yusoki. In this article, we would like to introduce a case study of a transport conveyor & conveyance system installed at a refrigerated warehouse for sorting cold foods by store in Japan.
Reducing the inability of working in a refrigerated (chilled) warehouse (low temperature environment)
This is a case study of a large chilled logistics warehouse for one of Japan's largest comprehensive food logistics companies. The warehouse sorts and delivers to as many as 68 retail stores. Specifically, orders were taken out of the refrigerators and moved by hand on trolleys, and approximately 5,000 cases were manually sorted each day.
Prior to the implementation of the system, the following issues existed at the site.
Challenges before implementation
・Sorting (moving from trolley to basket car) for 68 stores by manpower was time-consuming and labor-intensive.
・Long working hours in an environment of 2℃ places a heavy burden on the workers.
Automating all processes (from conveyance to sorting) of orders significantly reduced work time
In order to solve the above issue (shorten work time), we have implemented a sorting line that utilizes the Okura Yusoki's Case conveyor .
Following manual operations which have been challenges before:
・Transportation by trolley
・Sorting into basket cars by store
・Label application
are all automated and the company has succeeded in reducing work time drastically.
The previously time-consuming task can now be completed in about 2 hours and 30 minutes, contributing to improved work efficiency and reducing the burden on workers. In addition, there were many other improvements compared to manual sorting, such as improved shipping accuracy and enhanced product temperature control.
▲ Labels are automatically read on the conveyor and sorted by delivery route.
▲ Loading orders into the appropriate basket cars while looking at the labels on the cases.
Voice of customer
Working in a refrigerated environment is hard work, and we needed young, physically strong personnel, but the retention rate was poor and recruiting them was difficulty due to the labor shortage. We had been considering plans to automate the process since the beginning of operations, but the implementation had been delayed. With the installation of the new sorting equipment, human intervention has been reduced, work hours have been shortened, and productivity has greatly improved. Another major benefit is that the new equipment has made the work easier and has made it possible to hire employees of all ages and genders.
Compared to the Japanese market, Thailand is still behind in the automation of refrigerated and frozen warehouses. However, similar cases are expected to increase in Thailand in the future, coupled with the growing demand for cold food, especially in urban areas.
Working in a refrigerated environment is hard work, and we needed young, physically strong personnel, but the retention rate was poor and recruiting them was difficulty due to the labor shortage. We had been considering plans to automate the process since the beginning of operations, but the implementation had been delayed. With the installation of the new sorting equipment, human intervention has been reduced, work hours have been shortened, and productivity has greatly improved. Another major benefit is that the new equipment has made the work easier and has made it possible to hire employees of all ages and genders.
Compared to the Japanese market, Thailand is still behind in the automation of refrigerated and frozen warehouses. However, similar cases are expected to increase in Thailand in the future, coupled with the growing demand for cold food, especially in urban areas.
► Achievements in Thailand: Refrigeration robot palletizing and transport equipment
Our strength is the ability to provide one-stop services for conveyance equipment (conveyors) and total logistics systems tailored to customer demand. We will contribute to solving challenges in logistics warehouses in Thailand by making the most out of our accumulated know-how.
