Toyota Material Handling Partners with Bastian Solutions on 100th AutoStore Installation
Toyota Enhances World-Class Parts Distribution Center with Advanced AutoStore Integration
Thursday, October 31, 2024
COLUMBUS, Ind. (October 29, 2024) – Toyota Material Handling, a North American leader in material handling solutions, unveiled a significant upgrade to its parts distribution center (PDC) at its Indiana headquarters on October 28, in collaboration with Bastian Solutions, part of Toyota Automated Logistics. This milestone marks Bastian’s 100th AutoStore system installation, underscoring its automation expertise and enhancing Toyota’s capacity to process and deliver parts efficiently.
“At Toyota, we will always be driven by what is best for our customers. This AutoStore integration will allow us to deliver parts to customers across North America faster than ever before, ensuring their forklift fleets are up and running when they need them most,” said Bret Bruin, Toyota Material Handling Vice President of Aftermarket Operations. “It’s amazing to see this project come together, in partnership with the teams at Bastian and AutoStore, to eliminate unnecessary waste and add efficiencies for the benefit of our customers.”
The AutoStore integrates cutting-edge robotics, automation and artificial intelligence into Toyota’s operations. In alignment with Toyota’s 2050 Vision for sustainability, the AutoStore system operates on rechargeable battery-powered robots, consuming energy only when in motion.
The innovative system leverages vertical storage, maximizing unused space within the PDC. While the facility typically stocks an average of 55,000 stock-keeping units (SKUs), the new system dramatically increases storage capacity—from 40,000 to more than 128,000 storage locations—allowing Toyota to house more parts. This contributes to operational cost savings and is indicative of Toyota’s philosophy of Kaizen – or continuous improvement.
“Today, we can reach over 80% of our customers with two-day shipping. Our goal is to reach 98% of our customers with next-day ground by 2030,” Bruin said. “This new AutoStore integration and enhanced Parts Distribution Center will play a significant role in helping us achieve that goal.”
The AutoStore system minimizes manual labor by utilizing 28 autonomous robots that operate on a grid. These robots retrieve and deliver totes to four picking ports, each capable of processing up to 175 totes per hour. With the ability to fulfill up to 700 orders per hour, the system ensures faster and more accurate order processing.
To further enhance operational efficiency, AI-driven software strategically positions high-volume inventory for quicker access and provides real-time visibility, ensuring Toyota Genuine Parts are readily available. The natural slotting system places low-volume parts at the bottom of the grid while keeping high-demand parts easily accessible to expedite order processing time. With the AutoStore system, Toyota ensures reliable order fulfillment, faster turnaround times, and improved customer satisfaction from its industry-leading North American dealer network.
“Bastian is proud to support Toyota Material Handling in their efforts to deliver even greater customer service through an innovative, sustainable automation system,” said Aaron Jones, President and CEO of Bastian Solutions. “That focus on continuous improvement and quality solutions is at the heart of everything we do as Toyota group companies, and leveraging an incredible partner such as AutoStore is that final connection to ensure success now and into the future.”
While the robots and AI handle repetitive tasks, Toyota's commitment to Jidoka – or automation with human touch – ensures associates to spend their time on more strategic tasks. This allows Toyota to focus on problem solving, innovation and quality control, emphasizing the importance of human insight in driving operational excellence.
During Toyota’s ribbon-cutting event at its Indiana headquarters, executives hosted guided tours to give stakeholders an exclusive firsthand look at the cutting-edge innovations and capabilities of the new AutoStore capabilities.
Learn more about Toyota Material Handling’s parts distribution innovations at ToyotaForklift.com.
About Toyota Material Handling
Toyota Material Handling offers material handling products and solutions, including forklifts, reach trucks, order pickers, pallet jacks, container handlers, automated guided vehicles, and tow tractors, along with aerial work platforms, fleet management services, and advanced automation engineering and design. Toyota’s commitment to quality, reliability and customer satisfaction, the hallmark of the Toyota Production System, extends throughout more than 230 locations across North America. With access to an industry-leading lineup of material handling products, Toyota dealers are uniquely positioned to help solve wide-ranging challenges in warehousing and distribution. Built for every application, Toyota can provide the most complete set of solutions for material handling, automation, energy, advanced logistics, and warehouse optimization. For more information or to learn more, visit ToyotaForklift.com.
About Bastian Solutions
Bastian Solutions, a Toyota Automated Logistics company, is a trusted supply chain integration partner committed to providing their clients a competitive advantage by designing and delivering world-class distribution and production solutions. The expertise Bastian Solutions delivers includes exceptional results through a proven process of analytical consulting, engineering and design, simulation, project management, and installation services, while sourcing the best material handling equipment and automation technologies available. With innovation at the forefront, the company also develops Exacta supply chain software, conveyor and sortation systems, custom automated material-handling equipment, robotics, autonomous vehicles and robotic shuttles, and state-of-the art industrial controls. Bastian Solutions serves domestic and global markets, covering the United States, Canada, India, Mexico and South America.
Contact
Justin Albers
Toyota Material Handling
812-350-9739
Megan Shore
Bastian Solutions
317-575-9992 x1298
