Automated Storage System: Saving Time and Space
The Chiba factory’s Pump Division assembles one of Maruyama’s core technologies—pumps. Until now, parts were stored in large mesh pallets and manually transported by forklift, requiring wide aisle space and time-intensive handling.
To address this, a stacker crane system was introduced. This automated storage solution enables the same quantity of parts to be stored and moved using just one-fourth of the space previously needed. It has also significantly reduced retrieval time—from over 10 minutes to just around 4 minutes, even for the farthest items.
With much of the process now automated, worker burden is reduced, and operational efficiency has improved. The system also supports FIFO (First-In, First-Out) usage of components, improving stock rotation and inventory accuracy—without manual checks.
Repurposing Smart Agricultural Robotics for Logistics
A second major upgrade is the addition of AGVs (Automatic Guided Vehicles)—unmanned transport robots that automate the movement of parts from the storage area to workstations.
One of these AGVs is a creative adaptation of Maruyama’s own Smart Shuttle, a self-driving agricultural sprayer. In this new role, the Smart Shuttle has been fitted with a cart and programmed to navigate factory floors instead of farm fields.
While it was originally designed to operate without GPS in greenhouses, here it uses 2D barcodes placed throughout the facility to recognize its location and transport instructions. Its compact, rounded shape and playful motion—accompanied by a classical tune—add a bit of charm to its high-functioning role.
The result is reduced human workload, improved transport accuracy, and stronger overall productivity.
Originally developed for use in GPS-free greenhouse environments, the Smart Shuttle is a prime example of how Maruyama repurposes its own technologies—from field to factory.
Cleaner Operations with Ultra Fine Bubble Technology
Another noteworthy improvement: the factory smells cleaner. Previously, coolant fluids used in machining could spoil over time, releasing a strong odor. Now, the factory uses Maruyama’s own MUFB Ultra Coolant Fresher—a device that leverages ultra fine bubble technology to suppress coolant deterioration without additives.
Thanks to this system, workers have reported that the odor has noticeably decreased. Combined with daily 5S practices (Sort, Set in order, Shine, Standardize, Sustain), the environment now feels tidier, more comfortable, and better suited for high-quality work.
Toward a Smarter, More Sustainable Factory
The upgrades at the Chiba factory represent a meaningful step in Maruyama’s digital transformation. With automation now reducing manual labor, minimizing error, and optimizing operations, the factory is moving toward a more sustainable and future-ready model.
These systems reflect more than technological progress—they show Maruyama’s commitment to innovation, worker well-being, and operational excellence. Smart manufacturing, cleaner processes, and thoughtful design: it’s all part of building the next chapter of Maruyama.
