May 18, 2022

Kao: Will Establish a New Flexible and Efficient Production System and Logistics Model at Toyohashi Plant







  • Press release
  • Business / Finance


Kao will establish a flexible and efficient new production system and
Logistics model at the Toyohashi plant

Transformation into an integrated production and logistics base to realize a sustainable supply chain

Kao Corporation is transforming its Toyohashi factory into a supply chain base with integrated production and logistics functions, aiming to build a flexible and efficient new logistics model and production system that is friendly to people and environment. environment, able to deliver products to consumers and customers in a stable manner.

At the Toyohashi factory, which produces a wide variety of products, mainly skin and hair care products, Kao is working on building a flexible production system using robots and AI to create an environment comfortable workplace in response to fluctuating demand caused by changing clientele. purchasing behavior as well as a shrinking workforce due to the declining birth rate and aging population. At the same time, through the construction of a new fully automated warehouse and the integrated operation of factory automated logistics and the logistics center that handles distribution functions, Kao aims to realize a Toyohashi connected flexible factory capable of a coordinated and flexible supply of products. .

Toyohashi Connected Flexible Factory

The new warehouse, whose construction began in February 2022, is intended to materialize this new logistics model. It will have an area of ​​approximately 7,150 square meters, an automated warehouse storage capacity of 1.2 million cases and automated equipment to provide receiving and shipping capacity of 40,000 cases per day. Construction is expected to be completed and operations to begin in the first half of 2023. With the introduction of automated equipment using advanced technology such as crate sorting robots, automated guided vehicles (AGVs) and automated forklifts, the warehouse is designed to achieve a high degree of freedom and full automation, with sorting robots and AGVs freely loading products onto pallets and unloading products from pallets at the same time, without the need for a storage area. fixed job. With a switch to the use of renewable energies through the deployment of solar panels for electrical energy, as well as the use of NEWTLAC 5000*1 Kao’s proprietary technology for an asphalt modifier made from waste PET, the facility will exhibit outstanding environmental performance for which Kao plans to achieve both CASBEE Aichi Rank A*2 and BEAUTIFUL 5 stars*3 certification.

By working with leading companies in the fields of architecture, control systems and logistics equipment, Kao aims to co-create a sustainable supply chain by streamlining logistics, improving the working environment and reducing the environmental impact.

Concept drawing of Toyohashi’s new automated warehouse

Sorting robots and automated guided vehicles (AGVs) should be deployed

To make intra-factory truck transportation smarter, Kao is also working with the Automated Forklift Demonstration Project*4 , as part of FY2021 promoting enterprises for greater transport efficiency using AI, IoT, etc. publicly requested by the Natural Resources and Energy Agency of the Ministry of Economy, Trade and Industry, to automate loading and unloading work. Kao promotes sustainable logistics campaign*5 thanks to intelligent management of the entry and exit of trucks to and from the plant, reducing truck waiting times and allowing drivers to operate with complete peace of mind. In addition, Kao participates in the Logistics Warehouse Technical Committee of the Robot Revolution & Industrial IoT Initiative, which aims to establish a robot-friendly environment in logistics warehouses.*6

The goal of these efforts is to build a new logistics model capable of achieving efficiency across the entire supply chain and realizing consumer-oriented logistics services that are respectful of both people and environment. ‘environment. These include the supply of low-fat products; shorter lead times; traceability management; control of logistics costs; deployment of electric and fuel cell trucks; reduction of environmental impact thanks to the production of solar energy; and an improved work environment through automation and unmanned logistics operations.

Recognizing its responsibility as a company providing products that people use regularly in their daily lives, Kao takes active steps to reduce the environmental footprint of its products throughout their life cycle. As part of the Kirei Lifestyle Plan, its ESG strategy, the company aims to move from mass production, mass consumption and mass disposal to a sustainable and waste-free supply chain, contributing to “zero waste” through the efficient use of resources and energy and by reducing waste and aiming for “Decarbonisation” by CO2 emission reductions for a healthier planet. Kao will work to further prevent global warming with the aim of decarbonizing by reducing CO2 zero emissions by 2040 and become carbon negative by 2050.


Related Information

  • Kao Sustainability website

  • Kao launches a new ESG strategy “Kirei Lifestyle Plan” to support consumers’ lifestyle changes

  • Kao’s New Challenges for the Future: Accelerating Deliberate Business Engagement with ESG

  • Kao beats its target year to see 100% of the electricity the company purchases in Japan and around the world come from renewables

  • Kao aims to reduce his CO2 Zero emissions by 2040 and carbon negative by 2050


About Kao

Kao creates high value-added products that enrich the lives of consumers around the world. Through its portfolio of more than 20 leading brands such as Attack, Biore, Goldwell, Jergens, John Frieda, Kanebo, Laurel, Joyful, and Molton Brown, Kao is part of the daily life of people in Asia, Oceania, North America and Europe. Combined with its chemical division, which contributes to a wide range of industries, Kao generates around 1.42 trillion yen in annual sales. Kao employs approximately 33,500 people worldwide and has a 135-year history of innovation. Please visit the Kao Group website for updated information.


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Kao Corporation published this content on March 30, 2022 and is solely responsible for the information contained therein. Distributed by Public, unedited and unmodified, on March 30, 2022 02:04:06 UTC.

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