Started full-scale deployment of forklift work analysis system

2025年1月7日2025年1月21日

～ Promoting automation in logistics sites by visualizing forklift operation status ～

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overview

Industry Alpha Inc. (development base: Nagoya City, Aichi Prefecture, CEO: Takumi Watanabe), which operates a business to make warehouses and factories smarter, including developing and introducing low-floor AMRs (Autonomous Mobile Robots), has set a mission of “designing and realizing smart factories and smart warehouses,” and is now starting full-scale deployment of its proprietary forklift work analysis system. This initiative aims to improve productivity at logistics sites by visualizing forklift work in logistics centers and factories.

Industry challenges and automation policies

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 being forced to deal with how to manage the work that was previously done by forklifts in the future.

The following three approaches can be considered as a solution to the shortage of forklift operators:

Full automation with AGF (automated forklift)

By introducing an autonomous forklift, all operations from loading and unloading to transportation and loading are automated in a single go, replacing the currently operated manned forklift.

Semi-automation using AMR (autonomous mobile robot) and manned forklift

In this method, forklifts will continue to be responsible for loading and unloading operations, which are difficult to automate, and other transportation will be handled by transport robots such as AMR. For example, it will be possible to operate in such a way that AMR automatically transports pallets unloaded from a truck by a forklift to the receiving and storage location.

Improving work efficiency by improving the operation of existing forklifts

This is a method to improve productivity by optimizing operation methods based on work analysis while utilizing current equipment. Examples include reviewing forklift operator shifts and optimizing transport routes.

“1. Full automation using AGF (automated forklift)” is technically difficult, and is currently not widely adopted due to constraints such as takt time required at logistics sites. Through this forklift work analysis system, we will contribute to the realization of “2. Semi-automation in combination with AMR” and “3. Improving the operation of existing forklifts.”

About the Forklift Work Analysis Box

There are several challenges in semi-automation with AMRs and operational improvements to existing forklifts. For semi-automation, important considerations include “calculating the number of AMRs required” and “predicting the cost-effectiveness of automation,” while for operational improvements, “understanding the operating status of forklifts” are important items to consider.

Therefore, we have developed a work analysis box that can be installed externally on existing forklifts, and after acquiring the location information of the forklifts, we can visualize information such as “what percentage of each forklift’s operating time is spent loading/unloading and what percentage is spent traveling empty,” and “what route each forklift is taking,” which will be useful for semi-automation and improving the efficiency of existing forklifts.

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

Our effectiveness measurement box is equipped with a LiDAR sensor (infrared sensor). By analyzing the position information of forklifts using the LiDAR sensor, the following data can be obtained.

《Analyzable data》

Breakdown of work for each forklift

(What percentage of the operating time is loading/unloading work/horizontal transport/empty driving?)

Breakdown of the speed ranges traveled

(What percentage of the operating time is traveled at high/low/very low speeds?)

Heat map

(Which area of the site is frequently taken out of the cargo/which area is concentrated with forklifts?)

Difference in work efficiency between forklift operators

(How much difference is there in transport distance and work efficiency between forklift operators?)

Features

①Ease of installation

Conventional forklift work analysis required the installation of beacons on the ceiling and large-scale construction work in the warehouse or factory. In addition, in sites with high ceilings, the installation of scaffolding was required, and the construction costs could reach hundreds of thousands to millions of yen. Furthermore, it had an impact on on-site operations, such as the need to stop work in the relevant area during the construction period.

However, with this solution, there is no need to install equipment in the environment, and by selecting an inexpensive infrared sensor, low costs and ease of installation have been achieved.

②Operation optimization is possible through visualization

Through the analysis, the idle time that has occurred and the number of forklifts required by time period are clarified.

As a result, the number of forklifts and forklift operator shifts can be optimized, and the operation of existing forklifts can be improved.

③The effect of automation can be calculated

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

④Realize cooperative control of AMR and forklift

In addition to measuring the effectiveness, this solution can also be used for cooperative control of AMR and forklift. By expanding this solution and checking the location of the forklift in real time, safety management is possible when the AMR and forklift approach each other. One example is an operation to check whether a forklift is in the area where the AMR is heading, and if so, to stop the AMR before it enters the area. In addition, it is possible to implement cooperation between the two, such as automatically directing the AMR to the location where the forklift has loaded and unloaded the goods.

Future outlook

This solution can visualize the operation status of forklifts, which has been difficult to quantitatively grasp until now. Taking advantage of the ease of introduction, which requires no installation work in the environment and can be introduced simply by attaching a box to an existing forklift, we will promote its introduction at various sites.

The collected data will first be used to improve work efficiency at each site. In addition, based on the forklift work analysis data, we aim to achieve efficient semi-automation by combining AMRs and manned forklifts. Loading and unloading work, which is difficult to automate, will continue to be handled by manned forklifts, while horizontal transportation of pallets will be handled by AMRs, achieving efficient logistics operations.

In the future, we will utilize the vast amount of data collected from forklifts to contribute to the realization of next-generation smart factories in which all equipment and systems in the factory are linked.

Please see below for actual examples of use at the site.