Tojiro Co., Ltd. Reduces Monthly Material Handling by 1,000 Times with Kachaka Pro AMR
Preferred Robotics has introduced its autonomous mobile robot 'Kachaka Pro' at Tojiro Co., Ltd.'s manufacturing factory. This initiative aims to reduce the physical burden of material handling between processes, which increased due to the new factory's layout. Over 1,000 manual transport tasks per month have been automated, allowing artisans to focus on their core tasks such as production and quality inspection. The system's intuitive operation and flexible routing are key benefits.
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- 📰 Published: May 22, 2026 at 21:50
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Preferred Robotics Inc. (Headquarters: Chiyoda-ku, Tokyo; CEO: Toru Isobe) has implemented its autonomous mobile robot, 'Kachaka Pro,' at the manufacturing facility of Tojiro Co., Ltd. (Headquarters: Tsubame-shi, Niigata). This initiative is designed to reduce the burden of material handling that increased with the opening of a new factory, enabling artisans to stop interrupting their work for transport and instead focus on high-value tasks.
## Background: Increased Transport Distance and Labor-Intensive Tasks
Since its founding in 1953, Tojiro has been manufacturing knives using the 'nuki-hamono' (blanking) method with stainless steel. Its products, combining traditional and latest technologies, are widely used by professionals overseas, with a production capacity of approximately 3,000 knives per day. Tojiro actively invests in automation and has introduced two Kachaka Pro units to handle transport between processes.
With the opening of a new factory in July 2025 to meet global demand, the physical distance between processes increased, leading to an increased burden on artisans. Workers were transporting boxes weighing up to 20 kg, raising concerns about physical strain and productivity loss, prompting the investigation of transport robots.
## Overview: Automated Transport Through Sheet Shutters
The two Kachaka Pro units are tasked with transporting products identified with micro-scratches in the inspection process back to the polishing and repair processes. They operate across nine routes connecting five processes: packaging (inspection), polishing, sharpening, blasting, and handle insertion. The route includes four sheet shutters, which the Kachaka Pro units traverse automatically.
The units can be intuitively configured via tablet, allowing young staff to master them in just one day. They remain flexible, allowing for route reconfiguration when factory layouts change.
## Results: Over 1,000 Automated Trips per Month
The greatest impact has been the elimination of physically demanding manual transport tasks. The units perform an average of 54 automated trips per day, amounting to over 1,000 times per month that manual transport has been reduced. This not only eases physical strain but also frees up nearly one hour per day for production and quality inspection tasks.
## Background: Increased Transport Distance and Labor-Intensive Tasks
Since its founding in 1953, Tojiro has been manufacturing knives using the 'nuki-hamono' (blanking) method with stainless steel. Its products, combining traditional and latest technologies, are widely used by professionals overseas, with a production capacity of approximately 3,000 knives per day. Tojiro actively invests in automation and has introduced two Kachaka Pro units to handle transport between processes.
With the opening of a new factory in July 2025 to meet global demand, the physical distance between processes increased, leading to an increased burden on artisans. Workers were transporting boxes weighing up to 20 kg, raising concerns about physical strain and productivity loss, prompting the investigation of transport robots.
## Overview: Automated Transport Through Sheet Shutters
The two Kachaka Pro units are tasked with transporting products identified with micro-scratches in the inspection process back to the polishing and repair processes. They operate across nine routes connecting five processes: packaging (inspection), polishing, sharpening, blasting, and handle insertion. The route includes four sheet shutters, which the Kachaka Pro units traverse automatically.
The units can be intuitively configured via tablet, allowing young staff to master them in just one day. They remain flexible, allowing for route reconfiguration when factory layouts change.
## Results: Over 1,000 Automated Trips per Month
The greatest impact has been the elimination of physically demanding manual transport tasks. The units perform an average of 54 automated trips per day, amounting to over 1,000 times per month that manual transport has been reduced. This not only eases physical strain but also frees up nearly one hour per day for production and quality inspection tasks.
FAQ
藤次郎株式会社がカチャカプロを導入した背景は何ですか？
2025年7月の新工場稼働に伴い、工程間の物理的な距離が伸び、職人の搬送負担が増加したためです。約20kgの重い箱を運ぶ身体的負荷と生産性低下を課題としていました。
カチャカプロの導入によってどのような効果が得られましたか？
月間約1000回以上の搬送業務が自動化されました。これにより、職人の身体的負担が軽減され、生産や品質検査といった付加価値を生む業務に1日あたり1時間弱の時間を充てられるようになりました。
カチャカプロの運用上の特徴は何ですか？
タブレットによる直感的な操作が可能で、若手作業員がわずか1日で使いこなせる点や、レイアウト変更に応じて走行ルートを柔軟に再設定できる点が特徴です。また、シートシャッターを通過しての搬送も可能です。
カチャカプロはどのような工程間で利用されていますか？
包装場（検査場）、磨き場、刃付け、ブラスト、柄入れという5つの工程間を結ぶ9つの搬送ルートで活用されています。
株式会社Preferred Roboticsとはどのような企業ですか？
株式会社Preferred Networks（PFN）の子会社で、AI技術を活用したロボット開発を行う企業です。家庭用「カチャカ」や法人用「カチャカプロ」などを展開し、自律走行ロボット市場で高いシェアを有しています。