Case Study
Trusco Nakayama Japan
TRUSCO NAKAYAMA automated mixed-SKU palletizing operations at its flagship distribution center using MujinOS, enabling real-time pallet building while products flow continuously through the facility. The solution combines intelligent robotics, advanced motion planning, and warehouse orchestration to improve throughput, reduce manual handling, and increase fulfillment efficiency in one of Japan’s most advanced logistics environments.
Challenge
As order volumes and SKU diversity continued to grow, TRUSCO NAKAYAMA sought a more efficient way to manage palletizing operations within its highly automated distribution center. Traditional palletizing approaches struggled to keep pace with continuously moving products and the complexity of building stable mixed-SKU pallets while maintaining the speed required for modern logistics operations.
The company needed a solution capable of handling diverse product dimensions, weights, and order configurations while supporting high-throughput fulfillment without sacrificing flexibility or operational reliability.
Solution
Using MujinOS, TRUSCO NAKAYAMA deployed an advanced on-the-fly mixed-SKU palletizing system that dynamically calculates optimal pallet configurations in real time. The system continuously analyzes incoming products, determines the best stacking pattern, and executes palletizing operations without interrupting material flow.
Powered by Mujin’s intelligent robot controller and warehouse orchestration technology, the solution coordinates robotic palletizing with surrounding logistics processes to create a seamless fulfillment workflow. The system automatically adapts to changing order requirements and SKU combinations while maintaining pallet stability and operational efficiency.
Results
Automated on-the-fly mixed-SKU palletizing operations
Increased throughput without disrupting continuous product flow
Reduced dependence on manual palletizing processes
Improved pallet quality and load stability
Enhanced flexibility for diverse SKU combinations and order profiles
Optimized warehouse workflows through intelligent orchestration
Scalable automation platform capable of supporting future growth
Key Technologies
On-the-Fly Mixed-SKU Palletizing
Products are palletized in real time without stopping conveyor flow, maximizing throughput and operational efficiency.
Intelligent Pallet Building
MujinOS automatically calculates optimal stacking patterns based on product size, weight, and order requirements.
Autonomous Motion Planning
Robots dynamically generate collision-free motion paths and adapt to changing conditions without manual programming.
Warehouse Orchestration
MujinOS coordinates robotic palletizing with upstream and downstream logistics processes through a unified control platform.
High-Mix Fulfillment Automation
The system handles a wide variety of product types and order configurations while maintaining consistent performance and pallet quality.