Kao: Will Establish a New Flexible and Efficient Production System and Logistics Model at Toyohashi Plant

Kao will establish a flexible and efficient new production system and
Logistics model at the Toyohashi plant

Kao Corporation is transforming its Toyohashi factory into a supply chain base with integrated production and logistics functions, aiming to build a flexible and efficient new logistics model and production system that is friendly to people and environment. environment, able to deliver products to consumers and customers in a stable manner.

At the Toyohashi factory, which produces a wide variety of products, mainly skin and hair care products, Kao is working on building a flexible production system using robots and AI to create an environment comfortable workplace in response to fluctuating demand caused by changing clientele. purchasing behavior as well as a shrinking workforce due to the declining birth rate and aging population. At the same time, through the construction of a new fully automated warehouse and the integrated operation of factory automated logistics and the logistics center that handles distribution functions, Kao aims to realize a Toyohashi connected flexible factory capable of a coordinated and flexible supply of products. .

The new warehouse, whose construction began in February 2022, is intended to materialize this new logistics model. It will have an area of ​​approximately 7,150 square meters, an automated warehouse storage capacity of 1.2 million cases and automated equipment to provide receiving and shipping capacity of 40,000 cases per day. Construction is expected to be completed and operations to begin in the first half of 2023. With the introduction of automated equipment using advanced technology such as crate sorting robots, automated guided vehicles (AGVs) and automated forklifts, the warehouse is designed to achieve a high degree of freedom and full automation, with sorting robots and AGVs freely loading products onto pallets and unloading products from pallets at the same time, without the need for a storage area. fixed job. With a switch to the use of renewable energies through the deployment of solar panels for electrical energy, as well as the use of NEWTLAC 5000^*1 Kao’s proprietary technology for an asphalt modifier made from waste PET, the facility will exhibit outstanding environmental performance for which Kao plans to achieve both CASBEE Aichi Rank A^*2 and BEAUTIFUL 5 stars^*3 certification.

By working with leading companies in the fields of architecture, control systems and logistics equipment, Kao aims to co-create a sustainable supply chain by streamlining logistics, improving the working environment and reducing the environmental impact.

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Kao creates high value-added products that enrich the lives of consumers around the world. Through its portfolio of more than 20 leading brands such as Attack, Biore, Goldwell, Jergens, John Frieda, Kanebo, Laurel, Joyful, and Molton Brown, Kao is part of the daily life of people in Asia, Oceania, North America and Europe. Combined with its chemical division, which contributes to a wide range of industries, Kao generates around 1.42 trillion yen in annual sales. Kao employs approximately 33,500 people worldwide and has a 135-year history of innovation. Please visit the Kao Group website for updated information.

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