Reducing Workload and Solving Manpower Shortage! V-MAX” has revealed a solution to the problem of flexible container bag filling.

There are various issues involved in filling flexible container bags, such as the possibility of them tipping over during transportation and the workload caused by a lack of manpower. A general chemical manufacturer that handles chemicals and cement and has installed Taiyo Kogyo’s V-MAX is one such company that has been troubled by issues related to flexible container bags. In this interview, we asked the person in charge of manufacturing at this company about the background of the introduction of Taiyo Kogyo’s “V-MAX” and their efforts to reduce the workload.

My first impression of Taiyo Kogyo was "a tent manufacturer. Now, "When it comes to flexible containers, it's Taiyo Kogyo."

Q. What made you consider flexible container bags made by Taiyo Kogyo?

A. At first, we were using one-way flexible container bags from another company. Our business unit ships quantitative products to overseas customers every month, and one day we received a request to improve the stability of our flexible container bags because they sometimes toppled over. So we were looking for a manufacturer that could meet the customer’s needs. That is when we learned of the “V-MAX” manufactured by Taiyo Kogyo. We thought that if we used these so-called “bulkhead flexible containers,” they would retain their shape even when transported to China and other foreign countries and stacked locally.

Q. What was your initial impression of Taiyo Kogyo?

A. To be honest, I had a strong image of you as a “tent manufacturer” (laughs). Recently, you used membrane screens to make roofs for the 2020 Dubai International Expo. I had seen that on TV, so I was aware that the manufacturer was “highly skilled in the field of sheeting. In fact, we have had several tent warehouses built by them. But since the introduction of “V-MAX,” I have the image that “when it comes to flexible containers, it’s Taiyo Kogyo.

Q. Has the image of Taiyo Kogyo changed since the introduction of flexible container bags?

A. At first, I only had the impression that you were a “tent manufacturer,” but you were always very attentive in your approach regarding the proposal of flexible container bags. It took us a little less than two years before we were able to introduce the “V-MAX,” so we were very happy that they were so kind to us during this time. After the actual introduction of “V-MAX,” I believe that we have established a trusting relationship where we can consult and request for flexible container bags with confidence.

Q. Thank you very much. I understand that you have used flexible container bags from other companies in the past, but is there anything that you would like to see improved?

A. The pallets we used were a special type specified by the manufacturer, so they were weak and unstable. We had to devise our own way to stabilize the packing and select shrink-wrapped flexible container bags, which took a lot of time and effort. On the other hand, after we switched to Taiyo Kogyo’s flexible container bags, we were able to unify the packing style and reduce the amount of time and effort required, which made loading the flexible container bags much easier.

Taiyo Kogyo's Fukui Plant can also test the strength of flexible container bags. Actual testing can be used for improvement.

Q. As you proceed with the introduction of flexible container bags made by Taiyo Kogyo, what were the advantages of consulting with us?　Could you also tell us about the advantages of adopting them?

A. When using flexible container bags, some customers said that some pellets remained when discharged, so we asked them if we could improve the opening or the shape of the discharge portion. We asked them to make several more samples and conduct discharge tests at our plant in Fukui. By actually testing them, we were able to understand the problem of residual pellets, which we were able to utilize in our improvement patterns.

When we actually introduced flexible container bags, we were concerned about the stable supply because of the large quantity used and the fact that we were purchasing from overseas. However, Taiyo Kogyo responded early and promptly to secure the number of bags, and we are very satisfied.

Q. Thank you. Next, please tell us about the current challenges in onsite operations and what your company is doing to address them.

A. First, regarding the issue of onsite operations, our biggest concern is the flexible container bag filling equipment we have. It has been more than 40 years since it was installed, and we are wondering if it is about to reach the end of its useful life. If we can obtain a budget in the future, we would like to install equipment that can be packaged by one or two people. In other countries, robots are now capable of loading flexible container bags into filling machines, weighing them, and discharging them. I think it would be ideal for Japanese manufacturers to eventually achieve this.

As for other efforts, we place importance on the “comfort” of the work environment. In summer, in particular, it is very hot and there is no ventilation, and there is also glare from the roof, so it is important to maintain a comfortable environment. We use fans, air conditioners, and spot coolers to make the work environment as comfortable as possible.

To reduce manpower and workload, we would like to work with Taiyo Kogyo to create a system for a new era.

Q. As a final question, if you have an opinion on what you would like to see in the future, please let us know. Also, what do you expect from Taiyo Kogyo in this context?

A. As I mentioned earlier, I think the biggest problem now is the shortage of human resources. In order to increase the number of bearers, I hope that the introduction of flexible container bags, which can be expected to improve work efficiency, will be promoted. I also feel that we need to consider a system of automatic compensation. With the difficulty of attracting people to rural areas and the difficulty of obtaining workers from abroad, I think it is necessary to make reforms and secure human resources with a view to the next five to ten years. As I mentioned earlier, I am highly interested in working toward automation, and I would like to work together with Taiyo Kogyo to create a mechanism for the new era.

 

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