How ANA Cargo delivered Nikon's most precise semiconductor machine

Moving a shipment from one country to another is part of everyday business for an airline. But when the cargo is one of the most precise semiconductor machines ever built, the task becomes far more than a transport operation. It becomes a carefully planned mission where every detail matters.

That was the challenge facing ANA Cargo at the end of 2024, when it was entrusted with transporting a highly sensitive semiconductor exposure system from Japan to an industrial city in eastern Malaysia. The destination was outside ANA Cargo's scheduled network, requiring a dedicated charter flight, while the cargo itself demanded exceptional care because of its size, weight and sensitivity. The project brought together ANA Cargo, Nikon and "K" Line Logistics, each playing a vital role in ensuring the equipment reached its destination safely.

The shipment reflected the growing importance of eastern Malaysia as a manufacturing hub. Home to one of the country's largest industrial parks, the city has attracted manufacturers from around the world, driving demand for advanced semiconductor production equipment. Nikon's exposure system was destined for one of these facilities, where it would be used to transfer circuit patterns onto silicon wafers for semiconductor production.

According to Ryohei Itagaki, Logistics Department, Procurement and Logistics Sector, Production Technology Division of Nikon, the equipment presented unique transport challenges. "Semiconductor exposure equipment is an extremely large and sensitive precision machine," he said. Measuring around three metres in length and weighing more than 30 tonnes, even the slightest impact could damage its internal components. The machine was also highly sensitive to temperature changes, with fluctuations potentially affecting the performance of its precision lenses or causing condensation that could compromise accuracy. These requirements made air transport the preferred option, and Nikon selected ANA Cargo based on its experience in handling semiconductor equipment.

For ANA Cargo, the assignment was an opportunity to draw on years of experience transporting specialised cargo. While the airline regularly carries everything from general freight to live animals and delicate industrial equipment, this mission demanded an even higher level of planning because it combined a charter operation with one of the most sensitive shipments it had handled.

"When ANA was selected, I was determined to definitely make this transport a success," recalled Ryutaro Hamada, Tokyo Sales, International Cargo Sales Japan, ANA Cargo who led the project for ANA Cargo. Although it was the airline's first charter flight to the eastern Malaysian destination, previous experience operating a charter to Auckland gave the team confidence that the knowledge built across the organisation could be applied to another complex mission.

A key part of that preparation involved "K" Line Logistics, the freight forwarder responsible for coordinating between Nikon and the airline. The company managed transport arrangements, evaluated different options and ensured the customer's requirements were reflected throughout the planning process.

"ANA Cargo definitely is the right choice," said Takateru Fukami, Semiconductor Sales Section, Project Cargo Department of "K" Line Logistics. He explained that the recommendation was based not only on ANA Cargo's transport quality but also on its ability to respond quickly if unexpected situations arose. That level of trust, he said, gave the forwarder confidence that the shipment would be handled safely from start to finish.

Close cooperation between the three companies became the foundation of the project. Airlines, manufacturers and freight forwarders often work together, but in this case every stage of the operation was planned jointly. The timeline was particularly demanding. Charter flights to destinations outside an airline's scheduled network typically require around three months of preparation, yet this mission had to be completed in less than two months.

Beyond securing an aircraft, ANA Cargo coordinated internally on flight scheduling, aircraft allocation and operational approvals while simultaneously working with Nikon and "K" Line Logistics on the transport plan. The cargo itself added further complexity. Shock-watch devices were fitted to monitor any impact during handling, while specialised pallets and heavy-duty forklifts were arranged to move the oversized equipment safely.

Temperature control was another critical factor. The equipment had to remain within a strict temperature range despite travelling from Tokyo's winter conditions to the warm, humid climate of eastern Malaysia. To minimise exposure, ANA Cargo parked the aircraft directly outside the warehouse and prepared a detailed timeline covering every stage of loading. The order in which cargo was unloaded from trucks was carefully planned, and the aircraft's cargo compartment was conditioned several hours before departure.

Loading the Boeing 777F proved to be one of the most technically demanding stages. More than 40 pieces of cargo, each with different sizes, weights and handling requirements, had to fit inside the aircraft while meeting loading restrictions. Hamada said repeated discussions with ANA Cargo's Professional Unit helped the team develop a workable loading plan despite the limited deck space.

The greatest challenge came with the main component of the semiconductor exposure system, which weighed nearly 10 tonnes. It had to be loaded using a rotational technique, where the cargo was positioned vertically before being carefully rotated into place inside the aircraft. According to Junichi Ishihara from Nikon's Quality Assurance Department, "Thanks to the thorough preparations in advance, the handling proceeded smoothly." The successful loading reflected both the detailed planning and the specialised handling skills of the teams involved.

Even after take-off, the mission was far from over. Hamada travelled on the same flight, closely monitoring the operation until the cargo was safely unloaded. "Our only focus was to deliver the shipment safely," he said, recalling that the team remained alert throughout the journey.

The aircraft landed safely in eastern Malaysia, and the unloading operation proceeded without incident. The shock-watch devices confirmed that the equipment had experienced no impacts during transport, and by 3 a.m. all the cargo had been handed over successfully.

Looking back on the project, Hamada described the safe delivery as an emotional moment. "I was filled with relief by safely delivering the important shipment," he said, adding that the experience strengthened the relationship between everyone involved.

For Nikon, the operation reinforced confidence that even its most advanced equipment could be transported safely. Itagaki said the exposure system represented "the pride of Nikon's manufacturing" and expressed satisfaction with ANA Cargo's handling of such delicate cargo. Fukami also praised the collaborative approach, saying the three organisations overcame challenges by discussing different options and responding flexibly throughout the project.

The successful charter was more than the movement of a single shipment. It demonstrated how technical expertise, careful planning and close collaboration can overcome the challenges of transporting highly specialised cargo. For ANA Cargo, Nikon and "K" Line Logistics, the project not only delivered one of the world's most delicate semiconductor systems safely to its destination but also strengthened a partnership built on trust, precision and a shared commitment to quality.