Senko Co., Ltd. (Center expansion)
Mr. Kazuaki Maruyama (Deputy Branch Manager, Saitama Main Branch)/ Mr. Takeshi Wakita (Director, Urawa PD Center, Saitama Main Branch)
Challenges
- Sorting processes have increased in conjunction with expansion of stores.
- Improvements for around-the-clock work.
- Operations cannot be stopped during upgrade.
- Effective use of space.
Results
- Doubled the sorting capacity by introducing a high speed, high capacity sorter.
- Workload was redistributed to reduce work hours.
- Construction was divided into blocks, and the expansion was achieved without disturbing the current operation.
- By using a fold-up chute, the space underneath can be used as a temporary storage when chutes are not being used for shipments.
BackgroundThe number of stores we ship to had doubled. There was an urgent need to significantly increase sorting capacity.
Background
The number of stores we ship to had doubled. There was an urgent need to significantly increase sorting capacity.
When we started construction of the Urawa PD Center, the number of Don Quixote stores was 150, but every year that number has risen and current equipment cannot keep pace. The average capacity of existing sorter was 3,000 cases/hour, and it was impossible to reach an average of 70,000 cases per day of demand, so we were adding sorting by hand. Adding manual sorting only created an additional 2,000 cases/hour so even with operations going 3 shifts a day, we could not handle a peak of 120,000 cases/day.
Reasons We Chose Toyo Kanetsu Solutions:Toyo Kanetsu not only has the experience but also has a solid track record of successful, innovative solutions. We knew this project was in good hands.
Reasons We Chose Toyo Kanetsu Solutions:
Toyo Kanetsu not only has the experience but also has a solid track record of successful, innovative solutions. We knew this project was in good hands.
We urgently needed to improve sorting capacity but could not shut down our current operation. So we consulted Toyo Kanetsu who designed the original warehouse operation. They had an excellent plan to do the upgrades without impacting our current operation. Toyo Kanetsu came up with a detailed, concrete plan, clearly developed on a wealth of industry experience and expertise.
After ImplementationWork could be done during working hours without overttime or resorting to manual sorting processes.
After Implementation
Work could be done during working hours without overttime or resorting to manual sorting processes.
The expansion work was divided into several blocks so as not to affect normal operations. The center consists of two areas, the West and the East, but prior to the improvements, automated sorting was done only in the West center. We introduced a high-speed sorter, the New Posi-Sorter, to supplement capacity of sorter in the West center. The new installation increased throughput 1.5 times to 7,000 cases per hour without the need for manual sorting.
We also added 22 chutes on the second floor, in addition to the ones on 1st floor. This has allowed us to concentrate shipments for Kanto area on the 1st floor, while sorting and shipping for other regions is handled on the second floor. This has helped improve the flow of goods at those processes. In addition, a part of the 2nd floor was used as a temporary storage place for products, but since space was exhausted due to the sorter equipment, a flip-up chute was installed. Therefore, when the chute is not in used for shipping purposes, it is flipped up using a chain, taking it out of the way and allowing for the space to be used for temporary storage. It was a useful and creative idea to maximize the use of space. Toyo Kanetsu also proposed the Ecoloveyor® which contributed to a significant decrease in energy consumption and therefore, operating costs.
What’s Next?Setting the standard as a warehouse/distribution operation that fully maximizes features of the system and equipment capacity.
What’s Next?
Setting the standard as a warehouse/distribution operation that fully maximizes features of the system and equipment capacity.
We had to find a way to continue operations while completing the construction work, and now we have the foundation that is able to flexibly respond to the growing needs of our customers. After this project, we will begin to replace the aging equipment, and can therefore, expect further improvement in capacity. Our warehouse is the first to adopt a seismic base isolation structure toward ensuring the safety of our customers’ assets and our employees. We also added a nursery school for our working parents. We would like to differentiate ourselves from our competitors by embodying the various benefits and advantages of a state-of-the-art warehouse that our competitors do not have.
* Source: Based on an interview conducted November 2012. Data, organizational departments and personal names appear as they were at time of interview.
Products and Services Introduced
