Toyota Boshoku Accelerates Logistics DX with Mujin Intelligent Automation

Customer: Toyota Boshoku Corporation, a leading global automotive parts manufacturer
Location: Sanage Plant (Aichi, Japan)
Scope: Finished goods storage and transport automation

Background

Like many global manufacturers, Toyota Boshoku faced increasing pressure on its finished goods logistics operations. Growing product volumes, a wider mix of parts, and limited available floor space made traditional logistics processes difficult to scale.

At the same time, labor shortages and physically demanding manual handling created urgency to rethink how finished goods were stored and transported. While production lines were already highly automated, logistics required a software-driven approach capable of delivering flexibility, visibility, and long-term scalability.

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Challenges

Toyota identified several key challenges:

• Scaling finished goods logistics within a fixed factory footprint

• Reducing manual handling of heavy returnable totes (10+ kg)

• Achieving high-accuracy palletizing across diverse product types

• Moving beyond fixed, location-based storage toward a more flexible model

• Establishing real-time visibility and traceability across logistics operations

• Standardizing logistics control to support future expansion and replication

Solution

Mujin designed and delivered an integrated finished goods storage and transport system, combining robotics, AGVs, and logistics software under a single intelligent software platform.

The solution includes:

• A high-precision palletizing robot for returnable totes, powered by Mujin’s intelligent motion planning and 3D vision

• Seven AGVs, centrally orchestrated to enable flexible, automated transport

• An integrated Warehouse Execution System (WES) for logistics control and visualization

• Dynamic, location-free storage logic, replacing fixed shelving with real-time space optimization

• Digital twin–based visualization for live monitoring, traceability, and continuous improvement

All components are fully orchestrated by MujinOS, enabling seamless coordination between robots, AGVs, and storage operations.

Results

• The automation system was fully operational in approximately six months, from planning to launch

• Thousands of heavy returnable totes are now handled automatically, significantly reducing physical workload

• Space utilization improved through dynamic storage allocation without fixed locations

• Accuracy and traceability enhanced through QR code verification and real-time visual monitors

• Centralized control enabled greater operational flexibility and simplified system scaling

Long-Term Impact

This project demonstrates how manufacturers can move beyond isolated automation toward software-defined logistics systems that are scalable, interoperable, and future-ready.

By combining intelligent robot control, AGV orchestration, and digital twin visualisation within a single platform, Toyota Boshoku established a foundation for continuous improvement and logistics DX—without being locked into fixed layouts or rigid automation structures.