In an effort to revolutionize its operations, the ONCE Logistics and Production Center has embarked on an ambitious robotization project led by Innovantia. Based on the theories of Industry 4.0 and the Internet of Things (IoT), this project promises to modernize the distribution of lottery products and consumables, ensuring individual treatment and complete traceability from printing to delivery to ONCE’s 36,000 sales points throughout Spain.
ONCE, recognized for its responsibility and dynamism in the social lotteries sector, coordinates the distribution of these products from its center in Madrid, ensuring that both technical and human resources are safe and respectful of both people and the environment. The advanced technology implemented allows handling large volumes of production through three main areas: printing traditional cups, storing instant lotteries, and consumption.
With more than 44 robots and 400 automation systems, this robotized system ensures the efficient and precise delivery of products, with all robots located on a 1,500-meter-long ship. This advancement makes ONCE’s fleet of robots the largest in Madrid.
Collaboration with Yaskawa has been fundamental for the implementation of the automated system. The simplicity of the project, the scalable structure, and the ease of management were key factors in choosing this partner. The solution needed to be flexible, controllable, and easy to manage, both physically and cloud-based. Additionally, the integration of third-party commercial solutions simplified the automation process, ensuring minimal maintenance and effective manufacturer support.
The implementation process began with an exhaustive study of ONCE’s automation requirements, ensuring that the solution met their specific needs. After eight versions of the preliminary project and documents validated by all departments, the previous manual processes were optimized.
One of the main challenges was ensuring that the physical cycle time of a simple package did not exceed 4.35 seconds, using Yaskawa‘s intelligent 3D design software, and minimizing the processing time of large volumes of data. To ensure information integrity, a virtual server with VPN access was developed.
Furthermore, an absolute traceability system was created, allowing total quality control in order processing and eliminating errors in manual packaging. Thanks to real-time data visualization, ONCE and Innovantia can evaluate and optimize supply chain processes, improving efficiency and reducing environmental impact.
The implementation of a robotized warehouse allowed the integration of 33 existing logistics centers, ensuring traceability from order generation to final delivery. Among the installed equipment are 22 robots for handling passives, instant lotteries, books, and consumables, as well as other robots and automated vehicles for various operational functions.
The collaboration between Innovantia and Yaskawa has been essential for the project’s success, providing a synergy that facilitated operations and allowed for a dynamic selection of necessary technical specifications. Yaskawa‘s direct support in movement simulation with robots and the coordination of multiple robots simultaneously were key to improving the efficiency and capacity of the palletizing/de-palletizing areas.
The robotization of the ONCE Logistics and Production Center represents a milestone in the modernization of its operations, thanks to the combination of innovation, advanced technology, and effective collaboration with strategic partners.