To respond quickly to market conditions, as well as the diverse needs of consumers and customers, Coca-Cola Bottlers Japan has been working on the "Shinsei Project" since May 2016 to optimize logistics. As part of these efforts, the Mega DCs (automated distribution centers) were built as hubs equipped with the largest product storage and shipping capacities of the Coca-Cola System in Japan. In February 2021, the Saitama Mega DC began operations on the premises of our Saitama Plant. In July 2022, the Akashi Mega DC also began operations to support our logistics systems in the Tokyo metropolitan area and Kinki region.
Automation of Facilities for Efficient Warehouse Operations
The mega DCs integrate product sorting, picking, and other logistics processes as well as the inventory and storage into one location. This allows us to build a network that achieves timely end-to-end delivery from production to customers and vending machines. In addition, by promoting automation of facilities, such as in the warehouse, mixed-load palletizing robots, and RORO (roll-on/roll-off) stations which are rare on land, the Mega DCs are now able to store products efficiently and shorten the work process of personnel and the time required for outbound operations.
Logistics flow within mega DC
Receipt
Storage
Picking and Packing
Shipping
Logistics flow within sales center
Before the Mega DC operations, our sales centers would operate as stock-type sites. Products received were stored within sales centers before being loaded into the route cars for shipping.
With the introduction of Mega DCs, sales centers in the target areas have been transformed into cross-docking sites with no inventory. This reduces warehouse work in the sales centers, leading to a reduction in inventory management staff. In addition, products are received sorted by each route car, so that they can be loaded without picking work, reducing the salesperson’s workload.
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Receipt
Storage
Picking
Loading
Shipping
Current
Receipt
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Shipping
Mega DC overview
Saitama Mega DC
| Location | Saitama Plant premises, 943-1 Shimohosoya, Yoshimi-machi, Hiki-gun, Saitama Prefecture |
|---|---|
| Total building floor area | 33,943 sq. meters |
| Storage capacity | Approx. 60,000 pallets |
| Shipping capacity | Approx. 85,000,000 cases per year |
| Operation start | February 2021 |
| Shipping area | Tokyo and Saitama Prefectures |
Akashi Mega DC
| Location | Akashi Plant premises, 152 Nishiwaki, Okubo-cho, Akashi City, Hyogo Prefecture |
|---|---|
| Total building floor area | 33,056 sq. meters |
| Storage capacity | Approx. 60,000 pallets |
| Shipping capacity | Approx. 80,000,000 cases per year |
| Operation start | July 2022 |
| Shipping area | Osaka and Hyogo Prefectures |
Facilities
Mixed-load palletizing robot
A robot that stacks multiple products together on a single pallet for delivery. It efficiently loads assorted sizes of products onto pallets.
Automated warehouse
The high-density storage system is adopted, and both Saitama and Akashi DCs can store 60,000 pallets.
High-speed transport trolley
A facility that receives incoming products to an automated warehouse and transfers loaded mix-loaded pallets to the shipping area. Products can be transported quickly at a speed of 200 meters per minute.
RORO (roll-on/roll-off) station
An automated facility that loads and unloads approximately 1,500 cases＊ of products in one batch. Compared to forklift operation, the time required for loading and unloading trucks can be reduced by approximately 70%.
* For 500ml PET bottle products