Supporting Critical Infrastructure Through Intelligent Logistics Automation

Reliable power infrastructure depends on logistics that operate with precision every day.

TEPCO Logistics is responsible for storing and distributing a wide range of materials used to maintain and support Japan's electrical infrastructure. The operation handles thousands of products with different dimensions, weights, packaging formats, and shipment requirements.

To improve efficiency while maintaining the high level of accuracy required for infrastructure logistics, TEPCO Logistics implemented Mujin's Robotic Case Picking (RCP) solution powered by MujinOS.

The system automates the complete process, from shipment planning and AGV coordination to robotic mixed-case palletizing, creating a more scalable and resilient operation.

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The Challenge

The materials handled by TEPCO Logistics vary significantly in size, shape, weight, and packaging configuration. Every shipment must be assembled accurately according to customer orders, placing significant demands on warehouse operations.

Before automation, several challenges limited operational efficiency.

• Labor-Intensive Material Handling

Order fulfillment relied heavily on manual picking and palletizing. Operators were required to repeatedly handle a wide variety of cases, creating physically demanding work and increasing dependence on labor availability.

• Operational Knowledge Concentrated in Individuals

The large number of SKUs created complexity throughout the picking process. In many cases, the same product could arrive from different manufacturers in different packaging formats and dimensions.

To maintain shipment accuracy, experienced personnel with detailed operational knowledge were required. This created a risk of reduced performance when key personnel were unavailable.

• Extensive Verification Requirements

As a logistics provider supporting critical infrastructure, shipment accuracy is essential.

Manual verification processes were used to prevent shipping errors, adding significant workload and reducing overall operational efficiency.

Looking Beyond Transport Automation

The project initially focused on introducing AGVs to improve internal material transport.

However, during the evaluation phase, TEPCO Logistics identified an important challenge. Automating transport alone would simply shift bottlenecks downstream into order sorting and palletizing operations.

Rather than optimizing a single process, the company expanded the project scope to automate the entire workflow.

This led to the adoption of Mujin's Robotic Case Picking solution.

The Solution

Mujin implemented an integrated Robotic Case Picking system that combines palletizing simulation, AGV coordination, 3D vision, robot motion planning, and execution into a single automated workflow.

Powered by MujinOS, the solution coordinates every stage of the operation as one connected system.

Based on shipment orders, the system automatically determines pallet building sequences, orchestrates AGV material delivery, identifies cases using 3D vision, calculates optimal placement patterns, and executes robotic palletizing without manual intervention.

Because the solution was deployed within the existing warehouse environment and integrated with existing warehouse management systems, TEPCO Logistics was able to modernize operations without requiring large-scale infrastructure changes.

Key Solution Features

• Physical AI for Multi-SKU Case Picking

Using 3D vision and Mujin's Physical AI technology, the system autonomously recognizes and handles cases with varying sizes, shapes, and weights.

This enables robotic mixed-case palletizing that would traditionally require complex fixed automation or extensive manual work.

• Flexible Deployment Without Large Fixed Infrastructure

The solution was integrated into the existing warehouse and operational environment, reducing implementation complexity while maximizing use of existing assets.

• Data-Driven Operations

Operational and equipment data are continuously collected, providing greater visibility into warehouse performance and enabling ongoing process optimization.

Results

The implementation delivered significant operational improvements.

• 90% of Target Case Handling Automated

The majority of targeted case-picking operations are now performed automatically through the integrated robotic system.

• Picking Labor Reduced from Four Operators to One

Automation significantly reduced manual labor requirements while maintaining operational performance.

• Manual Shipment Verification Eliminated

The automated workflow reduced reliance on manual inspection processes while improving consistency and shipment quality.

• Improved Safety and Operational Stability

By reducing repetitive manual handling, the solution improved workplace safety while creating a more stable operation that is less dependent on individual experience and labor availability.

• Stronger Business Continuity for the Future

With labor shortages continuing to affect logistics operations worldwide, the system provides a scalable foundation that helps ensure reliable logistics support for critical infrastructure.

Software-Defined Automation for Complex Logistics

TEPCO Logistics' deployment demonstrates how intelligent robotics can automate far more than a single task.

By orchestrating robots, AGVs, vision systems, and execution software through MujinOS, the company transformed a complex, high-mix logistics operation into a connected and data-driven workflow.

The result is a safer, more efficient, and more resilient operation capable of supporting the critical infrastructure that millions of people depend on every day.