DKK-TOA Corporation Modernizes Warehouse Operations With AutoStore

DKK-TOA Corporation improves warehouse operations with AutoStore: 40% less storage space and 25% reduction in picking time.

DKK-TOA Corporation is a Japanese manufacturer of measuring instruments that support critical social infrastructure across water, gas, and medical industries. 
 
As the company expanded, its logistics operations became increasingly complex. Growing inventory volumes, long product life cycles, and rising outbound demand placed additional pressure on the warehouse, while labor shortages and transportation constraints added further operational challenges. 
 
To support future growth and modernize its warehouse operations, DKK-TOA Corporation implemented an AutoStore automated storage and retrieval system, empowered by Okamura, at its Sayama Integration Center in Saitama Prefecture, Japan. 
 
The system enabled DKK-TOA Corporation to store approximately 4,500 SKUs in a significantly smaller footprint while improving picking speed and outbound efficiency.

The Challenge: Managing Growth, Inventory Complexity, and Labor Pressure

As production volumes increased, DKK-TOA Corporation needed a warehouse operation capable of supporting a growing inventory footprint without sacrificing efficiency. 

The company’s products have long life cycles, requiring consumables and spare parts to remain in storage for extended periods. This created increasing pressure on warehouse space and inventory management as SKU volumes expanded. 

At the same time, outbound operations were handling approximately 400–500 orders per day. Labor shortages and restrictions on truck waiting times added further pressure to daily warehouse operations. 

DKK-TOA Corporation needed a solution that could improve storage density, streamline picking, and support future growth.

The Solution: AutoStore Enables Compact, Scalable Operations

DKK-TOA Corporation selected AutoStore to improve storage efficiency and support more stable outbound operations. 

The system combines high-density Bin storage with automated Robot retrieval and goods-to-person operations through CarouselPorts, enabling operators to access inventory quickly within a compact warehouse footprint. 

Approximately 4,500 SKUs are now managed inside the AutoStore system, representing around 75% of the company’s inventory items. 

By utilizing vertical warehouse space and partially embedding the system into the floor structure, DKK-TOA Corporation significantly reduced the storage footprint required for its inventory while creating additional capacity for future growth.

Key Benefits: 40% Less Storage Space and 25% Reduction in Picking Time:

Reduced Storage Footprint

AutoStore enabled DKK-TOA Corporation to reduce required storage space by 40%. By utilizing vertical space, AutoStore reduced the required storage footprint from approximately 530㎡ (5,705 ft2) to approximately 320㎡ (3,444 ft2).

Faster Picking Operations

The company reported a 25% reduction in picking time following AutoStore implementation. The AutoStore system supports performance of up to 154 Bins per hour, helping create a faster and more stable outbound operation. 
 
Before implementation, outbound order cut-off times were extended until around 18:00. After implementation, operations finish before 16:00, reducing wait time for scheduled truck collection times.

More Stable Outbound Operations

By automating storage and retrieval workflows, DKK-TOA Corporation improved the stability of its outbound logistics operations. The improved workflow helped stabilize outbound operations while reducing shipping delays and product disposal losses. 

Built for Future Growth 

The AutoStore installation was designed to support future SKU expansion associated with business growth and changing market demands. 

Built for Long-Term Growth 

Beyond operational efficiency improvements, DKK-TOA Corporation also focused on creating a more sustainable warehouse operation. 
 
By stabilizing outbound operations and improving workflow efficiency, the company reduced shipping delays while supporting long-term operational growth. 
 
With AutoStore, DKK-TOA Corporation established a more compact and scalable warehouse operation designed to support continued expansion while improving picking efficiency and storage utilization.

Project Specifications 

Facility size: Approx. 8,200 ㎡ (88,264 ft2)
Robots: 8 R5 Robots
Ports: 4 CarouselPorts