Trajectory of Challenges

"Twisting", which is a process of twisting the spun yarn to give it strength, is an important process before the yarn is placed onto the loom. Development of the Two-for-One Twister, a twisting machine capable of twisting yarn twice while the spindle rotates once, began in 1964 as a joint project, No.300*, with a major Japanese synthetic fiber manufacturer. The first machine exhibited at the International Textile Machinery Exhibition, ITMA (1967), which is still the largest exhibition in the industry, was a Two-for-One Twister. We followed this up with development of spun yarn, and released superior products one after another for half a century, boasting a total of 5.4 million spindles delivered. It was the main model of the textile machinery business until the 1990s. The entry of emerging countries, however, placed severe pressure on profitability that prompted the decision to withdraw from the segment in March 2015, which marked the end of production of twisters for industrial materials. Even after the end of production, the supply of parts continued, and the " No.310" for synthetic fibers and "No.363" for spun yarns, which can be called masterpieces, are still being used by many customers.
*For filament (synthetic fiber) yarns

Spinning involves many processes, and a large amount of materials and finished products of various shapes are transported throughout the spinning mill. In the past, Muratec also took on the challenge of automating transportation of the entire factory and actively incorporated its own transportation technology. A large booth was set up at ITMA exhibitions from 1987 to 1995, at which we demonstrated a factory automation system designed to automatically transport containers (cans) for combed raw cotton slivers and finished yarn packages using "SKY-RAV" and Laser Guided Vehicles (LGVs) that use ceiling space. In addition, for the previous stage of the spinning process, we also took on the challenge of automating the "Cans Robot" with the aim of having it play three roles in one unit: kens transport, replacement, and sliver jointing (piecing). Although it has been withdrawn from use for transportation that connects processes, this experience is still passed down as an example of striving to develop variations of automation within the process.

As consumer needs expanded and fabric production became more diverse with fewer lots, weaving factories had to prepare yarns of different colors, materials, and thicknesses, resulting in a large amount of residual yarn. In addition, the weaving process required manual replacement of yarn every time the color or pattern changed, which was especially burdensome for weaving factories with few employees. To respond to requests from customers facing these issues, we worked with a partner company to jointly develop an arrangement winder that applies splicer technology. The arrangement winder allows the creation of a package that connects leftover threads of different colors and thicknesses by patterning them from the color and pattern of the desired fabric. Using the yarn created with the arrangement winder made it possible to create a single piece of fabric of different colors and patterns without having to change the threads. Arrangement winders are mainly delivered to the Banshu area of Hyogo Prefecture, and have also been introduced to universities and research institutes. In 2005, this innovation was recognized with the "1st Monozukuri Japan Grand Prize Prime Minister's Award".

In 1975, Muratec launched a computer system for AS/RS named the Murata Automatic Information and Control System (MAICOS). MAICOS handles both crane control and inventory management; and the microcomputer controller and operating systems (OS) used for the inventory management terminal were also developed by Muratec. This was before the launch of Windows and other OS, when computer manufacturers were competing for the development of their own products. The production of microcomputers by a machinery manufacturer was unique.
With the rapid advancement in computers that followed, minicomputer software was developed to control large-size AS/RS, and computer software was developed to control small-size warehouse systems. Responding to the increasing need for automation and systematization for the management and operationsystems (ories and warehouses, Murata Systems, Ltd. was founded as a company specializing in software development. The warehouse management systems(WMS) it developed based on the above-mentioned systems have become a respected strongpoint of Muratec logistics systems.

For the creation and temporary storage of intermediate-product kits and at factories, the need for storage equipment capable of retrival in timely manner to meet production schedules increased. The old case-type AS/RS functions were inadequate; therefore, in 1982, Muratec launched its “BUCKET RUNNER” with an automated rotating carousel that made it possible to capture and deliver intermediate products to the picking area. Previous to its introduction, all racks rotated at the same time. However, to meet the requirement for higher capability, it was improved to enable each rack to turn seperately. At the same time, a continuous lifter system capable of high-speed loading and unloading in 4.5 sec/time was developed. While it had been extremely difficult to develop a control system capable of dispensing items at high speed after setting the dispensing order, the BUCKET RUNNER provided a very effective solution.

Muratec strived to develop mechanical multistory parking garage systems utilizing its AS/RS technology. The mechanical-type system reduced waiting time for leaving with improved speed compared with regular gondola-type systems. In order to reduce vibration, noise, and running costs traditionally associated with stacker cranes for AS/RS, Muratec first implemented a traction-type elevator mechanism to ensure balance with loads and weights. Muratec installed a prototype multistory parking garage inside its 45-meter-high building “Dream Center,” which was built for experimentation of high-rise AS/RS at the Inuyama Plant.
In addition to the elevator mechanism, Muratec implemented other technologies not found in conventional products. The Geneva mechanism (intermittent rotation) was applied to achieve smooth start and stop of the turntable to realize safe, high-speed rotation. The functions, including the safety performance of the entrance space where people get on and off, the intuitively operable entering/exiting setting panel, and the control of the crane, were realized by PLC control.
After delivery, further development was discontinued due to economic recession in the real estate industry caused by the bankruptcy of sales agents and collapse of the bubble economy; however, the traction drive system was later applied to high-performance stacker cranes and the know-how to propose high-speed and energy-saving cranes remains.

In the 1990s, the demand for large delivery centers increased in the mail-order industry, and Muratec responded with the manufacture of case transportation and sorting equipment to handle containers and corrugated cardboard cases. One of these products was a steel belt sorter, which Muratec had first obtained from an overseas manufacturer to enhance logistics system processing capabilities. The steel belt sorter comprised a belt conveyer with a metal board and a diverter to push goods to a shoot that sorts into delivery directions. In 2005, Muratec succeeded in manufacturing a new steel belt sorter capable of handling 10,000 cases/hour (listed as 8,500 cases/hour in the catalogue), a rate that significantly exceeded the processing capability of competitors, and provided it to customers in the home-delivery industry. Then in 2012, Muratec implemented cross belt sorters to further enhance capability and respond to requests for the handling of smaller items. Muratec developed a system combined with cross belt sorters and AS/RS for customers in the medical and pharmaceutical wholesale industries, and in the daily commodity wholesale industry.
Currently, logistics systems for cases and pieces of various sizes and shapes require high processing capacity. The technology cultivated in the development of equipment to accommodate case and piece handling has since been expanded into the development of products such as Uni-SHUTTLE HP, SHUTTLINER, and ALPHABOT.
The case and piece handling field is still in development, and the ability to propose systems that achieve the required capacity, rather than relying on the equipment itself, is becoming increasingly important. The know-how gained from in-house production of various transport and sorting equipment, including sorters, is being put to good use.

LCD panels were initially manufactured for electronic calculators and word processors; however, in the 1990s, application in computer monitors led to the start of mass production. In 1993, Muratec also developed automatic guided vehicles (AGV) for the transport of LCD panels. The leading-edge correction function that employed positioning plates and sensors during transfer was highly regarded, and orders for the system came in from major domestic manufacturers. The transportation vehicle was used for laser-guide vehicles (LGV), and overhead shuttles (OHS) were used for general logistics as well as AGVs.

At that time, it was common to use a manual Japanese typewriter to create documents. These had a dial to select and print type; but the lack of an editing function made it inconvenient to use, and major electronics manufacturers were advancing rapidly in this field.
Hoping to enter the market, we teamed up with an American venture company that was developing a Japanese word processor.

Mobile phones appeared in the 1980s; and the race to develop smaller phones heated up around 1987, when NTT started service. Seeing significant potential, Muratec also started developing a mobile phone in collaboration with a wireless equipment company in Hachioji, Tokyo.
Muratec had been concentrating on improving a "wireless facsimile" for taxi radios that was being developed jointly with a partner company. As signals were unstable, however, and progress was slow, we shifted our focus to mobile phones, which were quickly gaining popularity.
Since development was already well underway by major electronics manufacturers in the domestic market, we targeted the American market by proceeding with development at "Murata Communication Research" near Dallas, Texas.