In the maintenance parts sorting process, repair delays were prevented, and a sustainable workplace was achieved.

Introduction video of the case study.

The sensor-based Projection Picking System 🄬 PPS is being introduced.

By introducing the Projection Picking System, work efficiency is improved, and picking errors are prevented.

Background of the implementation

When delivering directly to the site, there are many entrances for each destination, requiring additional shelves, a larger space, and more personnel.

There was a need to shorten the lead time from ordering to delivery and improve service in response to a wide variety of orders from users.

Since there are many input entrances, it takes time to find the sorting entrances.

Previously, it was necessary to prepare docks for all customers scheduled for shipment that day and search for the appropriate dock. However, by dividing batches, the number of docks was reduced, successfully shortening the time workers spent searching.

Sorting is performed by comparing slips with shelf numbers, which can result in sorting errors due to placing parts in the wrong locations.

The slips contained a lot of information unrelated to the workers, which often led to mistakes by the workers.

The deciding factor for implementation

A new system using a projector, featuring a poka-yoke function that was not achievable with traditional display devices.

There are many sites that use digital displays, but there are no other sorting systems that utilize projectors. Since Komatsu representatives will be visiting, we wanted to create a system that would surprise them.

Since a projector is used, flexible layout changes are possible.

With wired displays, readjusting the equipment is necessary when the opening size changes, but with a projector, it can be handled simply by modifying the system.

Impact after implementation

Shipping operations that used to take two days can now enable next-day delivery.

Previously, the shortest time for shipping replacement parts took 2 days, but by streamlining the sorting process, it is now possible to deliver the next day without delaying repairs.

Reducing the workspace.

When delivering directly to the site, there are many entrances for each destination, requiring additional shelves, a larger space, and more personnel. However, by using the PPS🄬 system and dividing the batches, the space could be reduced to just two flow racks.

Improving productivity through standardization of operations.

The introduction of PPS has simplified the sorting process, eliminated variations in work speed among workers, and increased the productivity of sorting operations by standardizing work.

Significantly reducing human errors in operations.

Since workers were comparing slips with shelf numbers to perform sorting, sorting errors caused by placing parts in the wrong locations occurred. However, with the poka-yoke function of PPS®, the system detects the position of the worker's hand and alerts them to mistakes with warning sounds and lights, significantly reducing sorting errors.