Ito: Could you tell us about the features of "SAS-R," which Itoki develops and sells, and the situations in which you were involved?

Watanabe (Development): SAS originally existed as an Itoki product from 1985. It is a groundbreaking system that automates tasks in logistics that would otherwise require human intervention, such as sorting, picking*1, and shipping. However, with the increase in competing products, it became necessary to work on further increasing processing capacity and making it more compact. However, there were several hurdles to overcome in terms of the mechanism*2 with the technology available at the time, so we began to challenge ourselves with prototyping alongside manufacturing.

Matsumiya (Manufacturing): Just looking at the diagrams on a desk doesn't tell you things like where tools won't fit during assembly or where the assembly is too complicated, so I talked with Mr. Watanabe almost every day. Based on the assembly drawings we received from the development team, we made prototypes and compiled a list of areas with manufacturing concerns. This would be something like, "This is possible," "This is not possible," or "This is difficult to implement."
For example, the workbench was adjusted to be neither too high nor too low, and the space was made large enough to accommodate various sizes when assembling.

Watanabe (Development): Miniaturization was incredibly difficult. We had to pack the parts in with as little space as possible, but that meant we couldn't get our hands in, making assembly difficult. Even if it looked fine on paper, we couldn't fasten screws in places we couldn't reach. We had to go back and forth with the manufacturing team many times to find that perfect balance. I think it has one of the highest part counts of any Itoki product.

Kamibayashi (Software): It took nearly a year because we needed to rebuild the software after thoroughly understanding the existing software. We made the program, which was created about 30 years ago, more versatile so that it could be used in the future. We changed the microcontroller boards*1 to PLCs*2 for the horizontal travel cart (dolly) and vertical lifting device (reservoir), etc. Therefore, each had a person in charge, and three of us worked together to write the software. Many devices work in a complex coordinated manner, so one operation greatly affects the operation of others. We tried thousands of different patterns.

Yamane (Materials): From the prototype stage, we received parts lists from the design and development teams, and we were constantly thinking about where to purchase them and by when they could be delivered. Since parts were subject to change until development was complete, we were negotiating with various partner companies on a daily basis.

Ito: So, you were collaborating across departments right from the initial stages of prototyping!

Ito: Could you tell us about the unique features of "SAS-R," which has a large number of components and is quite complex?

Watanabe (Development): We had a lot of trouble with the vertical lifting mechanism (reservoir). To increase processing capacity, we needed to double the top lifting speed*1 and triple the lifting acceleration/deceleration speed*2 of the conventional model. Naturally, this increased the mechanical load, leading to problems such as damage to parts and increased vibration of the lifting mechanism itself. We solved each of these problems one by one and were able to complete a lifting mechanism that boasts industry-leading speed.

Matsumiya (Manufacturing): A large number of parts means a corresponding increase in the number of processes. The work becomes more complex and requires a variety of skills. Along with that comes a number of minute specifications where even a few millimeters of error is unacceptable... However, if there are differences in skill, it becomes impossible to continue supplying products stably. Therefore, we have reviewed the manufacturing process in detail and clarified the role of each process. We have established a system that allows us to manufacture with stable quality by clearly defining the parts that can be handled regardless of differences in experience.

Kamibayashi (Software): One of the development goals was to increase the movement speed of horizontally traveling carts and vertical lifts. Therefore, we focused not only on increasing the speed, but also on reducing the lag* in each instruction programmed into the machine. In addition, although the instruction for the next operation is normally given after the previous operation is completed, we adjusted it so that the instruction to the next machine is given once it has moved to the position of the reservoir, in order to make it move more smoothly.

Ito: It's like you start running even before you receive the baton in a relay race. So that's the secret behind your dynamic speed!

Yamane (Materials): We also had trouble gathering materials for the electrical control components*. For "SAS-R," we needed to gather materials from two areas: the electrical control components themselves, and the mechanical parts that support them.

Ito: As a manufacturer, could you tell us what you're proud of about "SAS-R" and what you'd like us to pay attention to?

Matsumiya (Manufacturing): Since these are precision products, we want to minimize the number of times they need to be moved... That's where our workbench comes in handy. Being able to transport everything to the construction site on a single table is something we're very proud of!

Yamane (Materials): When you think of Itoki, you probably think of office furniture, right? That's why we want as many people as possible to know that Itoki makes the "SAS-R."​ ​From development to manufacturing, everything is made by Itoki. The rows of "SAS-R" lined up in the warehouse after delivery are truly impressive. We're also proud that we can offer special orders where the covers can be customized to your company's corporate colors. The "SAS-R" has the versatility to meet any order.

Watanabe (Developer): I also think the appeal of "SAS-R" lies in the special order aspect tailored to the user. For example, some models have LED lighting that shines even in the dark. It has a somewhat futuristic and cool feel to it.

Kamibayashi (Software): I'd like you to see it in action, not just in one place. The way it sorts, picks, and ships items smoothly and without disruption is all thanks to our meticulously designed software!

Ito: That sense of speed is something that can only be truly appreciated by seeing the actual movements. I highly recommend you watch it.