Shikoku Kenpan Co., Ltd. (Headquarters Plant)

Challenges

With a large number of stored items managed across conventional shelving, locating and picking the required parts was time-consuming.
Warehouse space was near capacity, leaving no room to add shelving.
Occurrence of human error in picking.

Results

Implementation of AutoStore eliminated search time, enabling rapid picking of required parts.
Vertical storage up to 7 meters above floor level significantly reduced the required footprint for parts storage.
Projection picking dramatically reduced picking errors.

Background

Parts Picking Challenges in Supporting Rapid Equipment Recovery

Shikoku Kenpan Co., Ltd., headquartered in Matsuyama, Ehime Prefecture, is an authorized dealer for Caterpillar—the world’s leading construction machinery manufacturer. It provides comprehensive services across three prefectures in Shikoku (Ehime, Kochi, and Tokushima), including sales, maintenance, preventive maintenance, and repair of construction equipment.

The company’s head office plant had been facing operational challenges in its parts warehouse. When construction equipment malfunctions on a job site, it is essential that parts be immediately picked and sourced to the site to service it as soon as possible. However, with approximately 10,000 SKUs in storage, the conventional shelving and drawer-based management system made it extremely difficult to quickly locate the required parts.

Using the relocation of the warehouse as an opportunity to improve the operation, Shikoku Kenpan implemented AutoStore with the goal of enhancing parts warehouse functionality.

Results

Increased Storage Capacity while Reducing Footprint with a 7-Meter AutoStore Installation

Prior to the use of AutoStore in the new facility, parts were stored and managed on conventional shelves and in drawers, which required a large footprint, and was near maximum capacity, leaving no room for expansion.

The newly implemented AutoStore utilizes dedicated containers called bins, stacked vertically to make full use of space up to 7 meters above floor level to achieve high-density storage. Internal bin dividers further allow multiple SKUs to be stored in a single bin, enabling efficient storage of a wide variety of parts in a compact footprint.

Streamlined Warehouse Management and Reduced Operator Workload

Under the previous shelving system, staff were required to manually assign storage locations upon receipt and walk throughout the warehouse during picking—resulting in a significant time and physical burden.

Following the AutoStore implementation, the system automatically assigns and manages inventory locations. During picking, robots transport the required bins directly to the operator’s workstation where the operator picks from a fixed position, substantially reducing both physical strain and time spent.

To further reduce human error in picking, Projection Picking was also adopted. During picking operations, the bin with the correct parts to be picked is illuminated, and the part name and pick quantity are displayed prominently in front of the operator, improving visibility and operational accuracy. As a result, any associate can perform accurate picking after only minimal training.

Future Outlook

Building Toward the Next Stage of Growth

For Shikoku Kenpan, the AutoStore implementation was not the end goal—it is the first step in embracing cutting-edge technology to drive the company’s next phase of growth. In ongoing collaboration with Toyo Kanetsu, the system continues to evolve toward an even more user-friendly, site-adapted solution.

Toyo Kanetsu is the only AutoStore dealer in Japan that actually uses the same system in its own operations. Drawing on the practical expertise gained through that real-world operation, we remain committed to being a trusted partner that keeps our customers’ operations running without interruption.

※ Information in this case study reflects conditions as of December 2025.