[Manned forklift x AMR] Industry Alpha begins analyzing existing forklift operations in Asahi Soft Drinks’ logistics center to automate operations using AMR

Promoting automation through forklift operation analysis

Industry Alpha Inc. (Head office: Itabashi-ku, Tokyo; CEO: Takumi Watanabe; hereinafter referred to as “Industry Alpha”), which operates a business to make factories and warehouses smarter, will begin analyzing forklift work and considering automation of logistics at the logistics center of beverage manufacturer Asahi Soft Drinks Co., Ltd. (Head office: Sumida-ku, Tokyo; CEO: Taichi Yoneme; hereinafter referred to as “Asahi Soft Drinks”).

Industry Challenges

The manufacturing and logistics industries are facing a labor shortage due to the declining birthrate and aging population, and the need for automation is increasing. In particular, the shortage of forklift operators is becoming more serious, and each site is required to reduce the number of forklifts required for operation.

Until now, the use of AGFs (automated forklifts) has been aimed at, but the technical difficulty has been a barrier and the introduction to actual sites has not progressed very well. Therefore, semi-automation in the form of using AMRs (autonomous mobile robots) and manned forklifts in combination is attracting attention. AMRs and manned forklifts work together, and the loading/unloading tasks, which are difficult to automate, will continue to be performed by forklifts, while other transportation will be performed by AMRs. A specific example is a case where an AMR receives pallets unloaded from a truck by a forklift and automatically transports them to the destination.

The first barrier to the above-mentioned automation is the calculation of “how many AMRs are needed,” “how many forks can be reduced by automation, and what the cost-effectiveness will be.” Industry Alpha has therefore developed a work analysis box that can be installed externally on existing forklifts to visualize information such as “what percentage of each fork’s operating time is spent loading/unloading, and what percentage is spent running empty,” which can be used as a first step in considering automation.

(Reference image: Forklift work analysis box using infrared sensors, etc.)

Forklift Work Analysis Box

The Industry Alpha effect measurement box is equipped with an infrared sensor and a camera, and can collect the following data:

《Available data》

Based on the acquired data, we will conduct the following analysis:

《Analyzable Data》

Breakdown of work for each forklift (What percentage of the operating time is loading/unloading/horizontal transport/empty driving) heat map (Which area of ​​the facility is frequently carrying out cargo/Which area is the concentration of forklifts?) Differences in work efficiency between forklift operators

Previously, forklift work analysis tools using beacons and other devices had been considered, but the cost and effort required for installation were concerns.

However, this solution does not require the installation of equipment in the environment, and by selecting inexpensive infrared sensors, it is both cost-effective and easy to install.

Initiative with Asahi Soft Drinks

Asahi Soft Drinks’ warehouses were also considering further efficiency improvements and automation, but they had challenges understanding the current operating status of forklifts and calculating the benefits of introducing automated machines.

Therefore, they will introduce Industry Alpha’s forklift effectiveness measurement box to visualize the breakdown of work performed by each forklift and heat maps, which will be useful for improving current operations and considering the introduction of AMR in the future.

Taking advantage of the solution’s easy installation feature, they will also conduct similar verification at other locations to promote efficiency and automation at logistics centers nationwide.

Benefits of this solution

① Improve operations through visualization

Through analysis, the number of forklifts required by time period and the idle time currently occurring become clear. As a result, the number of forklifts and forklift operator shifts can be optimized.

In addition, heat maps within the facility can be visualized, and inefficiencies in location placement can be improved.

② Calculation of automation effects

Based on the visualized data, it is possible to clarify points such as “how many AMRs can be introduced to reduce labor costs,” making it possible to formulate future automation policies for factories and warehouses.

③ Cooperative control of AMRs and forklifts

This solution can be used not only to measure effects, but also for cooperative control of AMRs and forklifts.

Specifically, cooperative control of the two refers to safety management and delivery of goods. By acquiring the real-time location of the forklift using this solution,

if the AMR and forks are approaching, a signal can be sent to the forklift operator, or the AMR can be directed to the location of the forklift,

so that when the forklift unloads the pallet, the AMR can come right up to pick it up and hand the goods over from the fork to the AMR.

Future outlook

The strength of this solution is its simplicity.

There is no need to install any equipment in the factory, warehouse, or other environment; simply attach the box to existing forks and you can visualize the fork’s operating status.

We believe that the above method will promote visualization in factories and warehouses and contribute to improved efficiency and automation.

In addition to providing this solution, Industry Alpha will continue to contribute to Japan’s industry by solving challenges in the manufacturing and logistics industries.