Nissin Enterprise (Nissin EP), which supports the domestic logistics network of the Nissin Foods Group—the leading player in the instant noodle market—hosted a tour of the logistics operations at Nissin Foods’ Kansai Factory for the eight member companies (including this publication) of the Instant Ramen Press Club. Even at the state-of-the-art factory that began full operations in October 2018, Nissin EP actively utilizes advanced systems and equipment. With sustainability as the key word, the company is pursuing logistics efficiency and burden reduction.
Dramatically Shortening Truck Loading Times
The Kansai Factory’s shipping operations have achieved complete palletization. The rear space features 10 loading bays lined up. On busy days, as many as 120 large trucks come and go, but orders are picked and placed in shuttle racks the day before, enabling smooth loading. Incidentally, a single 10-ton truck can load 2,160 cases of “Cup Noodle” (equivalent to 43,200 servings).
To improve loading efficiency, the company continuously explores ways to stack cases higher. It also uses automatic wrap machines to prevent load shifts and enhance ease of handling.
A key point is the proprietary truck reception and guidance system, which reduces waiting times.
According to the company, conventional operations required a total of 2–3 hours for truck waiting and loose cargo loading, but at the Kansai Factory, this has been shortened to an average of 53 minutes.
Pallets (T12 type) have a storage capacity of up to 20,000 units, primarily self-owned. They are inspected for dirt or breakage, and approximately 4,000 are washed daily at about 60°C and dried at about 100°C.
Automated guided forklifts (AGF) are used for pallet transport within the warehouse. Amid labor shortages, robots operate 24/7 to replace burdensome manual tasks.
“Actively Utilizing AI and Robots” – Fukai Executive Director
Masahiro Fukai, Executive Director and General Manager of the Business Operations Headquarters at Nissin Foods, who also serves as Well-being Promotion Director, stated during the on-site interview, “Nissin EP will actively utilize AI and robots.”
As a council member of the Physical Internet Center (JPIC), which collaborates closely with the Ministry of Economy, Trade and Industry and the Ministry of Land, Infrastructure, Transport and Tourism, he appears focused on realizing next-generation shared transport and delivery systems that apply internet communication concepts to all aspects of logistics.
By maximally automating operations related to product inbound/outbound handling—including trucks and forklifts—“we can approach an ideal world where robots work 24/7 without accidents. In the past, all tasks were done by hand. AI is evolving remarkably day by day and will be a crucial avenue for boosting logistics productivity,” he said.
