Mushiny Collaborates with Yamaha: Application of Smart Logistics Solutions in 5G Smart Factories

Mushiny Collaborates with Yamaha: Application of Smart Logistics Solutions in 5G Smart Factories

Recently, the first phase of the 5G smart factory transformation project at Chongqing Construction Yamaha, supported by Mushiny, was successfully completed and passed final acceptance. As a traditional motorcycle manufacturing company, how has Yamaha transitioned from conventional logistics and warehousing management to a "goods-to-person" smart logistics model? How does Mushiny's 5G logistics solution help Yamaha improve warehouse efficiency and reduce labor intensity? Let’s take a closer look inside Yamaha.

Project Background

As a traditional motorcycle manufacturer, Chongqing Construction Yamaha Motorcycle Co., Ltd. has been managing its logistics and warehousing with some legacy methods. For example, components were often stored as sub-components rather than as completed assemblies, leading to a wide variety of parts in the warehouse. In addition, the company's strict quality control standards required batch management for inbound and outbound components. This meant that components had to be processed in batches during inbound tasks and assembled according to production requirements during outbound operations.  

Due to limitations in its information management system, Yamaha had been using paper-based documentation for both inbound and picking processes. Logistics personnel handled the inbound and picking tasks manually. Employees had to memorize the storage locations of parts in their respective areas and walk an average of 20 km per day to complete picking tasks. This led to low operational efficiency and high labor intensity. An IE analysis of these operations revealed detailed data, as shown in Figure 1.

The analysis showed that walking and document verification accounted for about 64% of the average time spent. Could intelligent equipment be used to eliminate or reduce these inefficiencies, increase production efficiency, and reduce workers' labor intensity by transforming the traditional "person-to-goods" model into a "goods-to-person" model?

Practical Implementation

The warehouse at Chongqing Construction Yamaha Motorcycle Co., Ltd. operates on a fixed-location storage system with integrated storage and picking. Parts are sorted by production batch and sorted by supply zone, a process that differs significantly from the flexible storage and picking methods commonly used in e-commerce, where orders are sorted based on sequence and sometimes grouped.  

To optimize inventory levels and control operational costs, Mushiny designed a solution that integrates the characteristics of both processes. The logistics workflow includes flexible storage locations, separate storage and picking tasks, and sorting by production batch and supply zone:

1. Efficient Storage Management: Mushiny's WMS system manages storage locations efficiently. Fixed storage slots previously reserved for certain parts can now be repurposed for other items when they are out of stock, maximizing warehouse space utilization.

2. Separation of Storage and Picking: Mushiny's T series AMR are used for transportation tasks, significantly reducing the time personnel spend walking.

3. Batch and Supply Zone Picking: Picking is organized by production batch and supply zone to ensure quality control.

In conjunction with mid-term production volume forecasts, Mushiny developed a plan for the application of AMRs(Autonomous Mobile Robot) in Chongqing Construction Yamaha’s smart warehouse, as shown in the diagram.  

By optimizing and improving the existing warehouse processes with AMRs, the project is expected to reduce warehouse picking personnel by 50%. More importantly, Mushiny's equipment and management software enable smart management of warehouse components, enhancing warehouse precision and overall management. For example, at the end of each day, shelves containing parts needed for the next day’s production can be moved closer to the picking area, improving outbound efficiency for the following day.

5G Smart Factory

As one of Chongqing’s first “5G+ Industrial Internet” pilot demonstration projects, China Mobile Chongqing, Chongqing Construction Yamaha, and Mushiny have collaborated to create a 5G+AGV smart demonstration factory. This is also the first Yamaha factory globally to use 5G technology.  

With the application of 5G technology, Mushiny has achieved more flexible scheduling, collaborative multi-AMR production, and centralized transportation of production materials. Utilizing the 5G+MEC (Multi-access Edge Computing) approach, computing is centralized in the cloud, making traditional AMRs more lightweight while ensuring local business processing, with customer data remaining on-site. This reduces labor costs while significantly improving operational standards, production safety, and efficiency.

At today's Yamaha factory, after a single command is issued, Mushiny’s smart robots, powered by a 5G network, respond swiftly, automatically choosing the optimal route for material delivery. All vehicles operate in an orderly manner without the need for manual intervention, realizing true intelligent production.

Mushiny's 5G logistics solutions, with their deep application in the industrial manufacturing sector, provide a model for advancing the construction of smart factories through 5G technology. The era of intelligent manufacturing logistics has arrived, and Mushiny looks forward to collaborating with more partners to bring transformative changes to logistics in smart factories.