Japan’s largest pharmaceutical distributor needed a fast, safe, and accurate way to supply medical products to more than 100,000 institutions nationwide. With frequent natural disasters in the region and increasing pressure from labor shortages, customer demands, and rising costs, the company sought an advanced logistics solution that could automate distribution, boost accuracy, and ensure uninterrupted delivery of life-saving medicines, even in emergencies.

As Japan’s largest pharmaceutical distributor, the company needed a way to ensure a fast, safe, and accurate supply of medical products to over 100,000 medical institutions across the country. Operating in a region frequently impacted by natural disasters like earthquakes and typhoons, the company prioritized building a logistics network that could maintain uninterrupted delivery of life-saving medicines even during emergencies. Facing labor shortages, increased customer demands, and rising cost pressures, they required an advanced logistics solution that could automate their distribution processes, improve accuracy, and strengthen disaster resilience, all while maintaining cost competitiveness.

To meet these complex challenges, the company partnered with Muratec, leveraging the company’s advanced automation technology and engineering expertise to build a next-generation logistics network.

Key initiatives included:
Nationwide logistics centers: With Muratec’s support, the company established a network of Area Logistics Centers (ALCs) and Front Logistics Centers (FLCs), capable of storing approximately 50,000 SKUs and delivering directly to customers, reducing lead times dramatically.

Automated demand forecasting and inventory management: The company’s internal demand forecasting system was integrated with Muratec’s storage and retrieval technologies, balancing optimal inventory levels with shipping needs to achieve a delivery rate of over 99%.

Six Sigma shipping accuracy: Muratec helped design barcode scanning and electronic scale checking processes throughout the logistics centers to eliminate human error, achieving 6σ (99.9997%) shipping accuracy.

Complete packaging and no-touch system: Muratec’s material handling expertise enabled the implementation of an automated “no-touch” delivery system, ensuring that once products were packed, they remained sealed until opened by the customer.

Deployment of AUPUS: Muratec’s development of the “Automatic Piece Picking Ultimate System” (AUPUS) mechanized the storage, dispensing, and sorting processes. This greatly accelerated operations while reducing human error and labor dependency.

High-density and High-speed storage Systems: Muratec installed the A3 Tray ASRS for compact, efficient storage of slow-moving products and the Uni-SHUTTLE HP for rapid storage and goods-to-person picking of fast-moving products, optimizing space and improving throughput.

Delivery reliability: With Muratec’s automation solutions, the company achieved a delivery success rate of over 99%, ensuring essential medical supplies consistently reached hospitals and pharmacies on schedule.

Shipping precision: Thanks to Muratec’s barcode and scale verification systems, the company maintained a 6σ shipping accuracy, resulting in fewer than 3.4 shipping errors per million transactions.

Operational efficiency: Muratec’s AUPUS and goods-to-person systems significantly reduced picking, packing, and inspection times. Medical institutions could stock shelves in less than half the usual time, freeing up time for patient care.

Disaster resilience: By partnering with Muratec, the company built logistics centers capable of operating through earthquakes and typhoons, ensuring a continuous, life-saving supply chain.

Labor optimization: Automation and ergonomic delivery systems, such as Muratec’s unit load solutions, lightened the physical burden on warehouse and medical staff, addressing challenges posed by labor shortages.

Through a strategic partnership with Muratec, Japan’s largest pharmaceutical distributor transformed its operations to create one of the most resilient, accurate, and efficient pharmaceutical supply networks in the country. Muratec’s advanced logistics solutions enabled the company to strengthen its disaster preparedness, reduce operational costs, improve customer service, and future-proof its business against labor shortages and changing healthcare needs.