Minebea AccessSolutions Thai Ltd. (hereafter MAS), a manufacturer of automotive lock mechanisms, door handles, and other components supplied globally to Honda, implemented an inventory management system in its procurement warehouse in 2024. The system was developed by Tomas Tech, a company specializing in operational efficiency solutions for manufacturers. Leveraging its proprietary inventory management platform, “PEGASUS”, Tomas Tech built an integrated solution connected to Minebea’s core “AS400” system, resulting in improved warehouse efficiency and a significant boost in inventory accuracy.

Eliminating Dependence on Individual Expertise and Manual Excel Work in Warehouse Operations

▲ MAS procurement warehouse

Previously, the MAS procurement warehouse used Excel to track inbound and outbound movements as well as inventory levels. Because label formats varied by manufacturer, barcodes and QR codes could not be utilized effectively.

“Often, only the person in charge knew exactly where items were stored in the warehouse. This became particularly challenging during the COVID-19 pandemic, when limited staffing sometimes caused delays in procurement,” said Mr. Morikawa of MAS.

The primary objective of the implementation was to eliminate reliance on individual expertise and establish an environment where inventory information could be shared seamlessly.

Key challenges on the warehouse floor included:
▲ Errors caused by manual data entry
▲ Differences in management rules depending on the person in charge
▲ Inconsistent label formats

Field-Oriented Proposals and Seamless Implementation Through Team Collaboration

“What made Tomas Tech stand out was their willingness to think flexibly together with us from the perspective of the warehouse staff. During meetings, we reviewed the details carefully, envisioning actual usage scenarios and making continuous improvements. Enhancements identified during the test-run period—such as adding product photos to labels to prevent mislabeling and using both fixed and mobile printers—were incorporated with a strong focus on usability from the field's perspective,” said Mr. Morikawa of MAS.

▲ Left: Fixed label printer Right: Mobile label printer

“During the implementation process, close communication between Japanese and Thai team members from both companies proved extremely valuable. The ability to share on-site challenges in real time and discuss potential improvements on the spot enabled a smooth rollout within just six months. It was also greatly helpful that Mr. Morikawa and the Minebea team openly shared the actual conditions on the warehouse floor,” said Mr. Nozaki of Tomas Tech.

Improved Inventory Accuracy Through Data Integration and Visualization

After implementation, inbound and outbound data are digitized using handheld scanners. By integrating the system with the MinebeaMitsumi Group’s existing core system, the company can now track incoming shipments and distribution to the production floor in real time.

“Currently, the system inventory and the actual inventory are almost fully aligned. With the warehouse now ‘visualized,’ accurate information can be shared across the team. Digitization has also freed up capacity to pursue KAIZEN activities that were previously difficult to undertake,” said Mr. Morikawa of MAS.