Yokogawa Technical Report / English Edition 2006 No.42

MANABE Yoshitoshi^*1
*1 Sourcing and Manufacturing Business Headquarters

As a result of each individual's improvement activities founded on basic New Yokogawa Production System (NYPS) principles, our company has met QDC (Quality, Delivery, Cost) requirements which are directly reflected in enhanced customer value. However in recent years the prevalent environment of global competition has resulted in a strong demand for even further advancements in QDC. To realize this, it is essential to use an IT-driven systematization based on an NYPS framework. This paper introduces an example of the improvements made using this NYPS-based IT-driven system to realize increased QDC in manufacturing.

TATENUMA Yoshiyuki^*1 YOKOMORI Masao^*1
*1 Sourcing and Manufacturing Business Headquarters

Yokogawa Electric Corporation manufactures a wide variety of surfacemount boards, from those for PLCs and other small controllers to large multilayer high-density boards for LSI testers. In addition, it promotes Group-wide global management and therefore has many laboratories, factories and sales offices both domestically and abroad. This paper introduces the latest surface mount technology (SMT) lines of Yokogawa Manufacturing Corporation (YMG)'s Komine factory (located in Akiruno City, Tokyo), one of the Yokogawa Group's main factories. The Komine factory operates round-the-clock, manned for the most part by dispatched employees. The three latest SMT lines utilize information technology and have the flexibility to respond to the limited production of a diversified number of products.

OONISHI Yasuo^*1
*1 Sourcing and Manufacturing Business Headquarters

The accuracy and reliability of magnetic flowmeters, which play a key role in flow rate measurement, have become increasingly higher thanks to advances that have been made in electronics and the development of lining materials and manufacturing methods. This has led to the establishment of magnetic flowmeters' position across a wide range of applications. Lining in the context of electromagnetic flowmeters refers to applying resin or other alternative materials to the inner walls of a detector's measurement tube (metal pipe). Lining is important in order to efficiently detect generated very low electromotive force levels and ensure corrosion and abrasion resistance to the fluids being measured. The material for lining is selected according to the type of fluid to be measured. Using an in-house seamless process, Yokogawa produces every type of lining from raw materials to ensure high quality levels and realize minimum-cost production facilities and processes. This paper introduces the technologies for processing PFA, polyurethane rubber and ceramics which are our main lining materials for measurement tubes.

ITOU Akio^*1 MIMURA Shin-ichi^*1 KOYAMA Etsutarou^*1 ODOHIRA Tetsu^*1
NIKKUNI Masaaki^*1 MIYAUCHI Tatsuhiko^*2
*1 Industrial Automation Products Business Division
^*2 Global Service Headquarters

We have developed the EJX910 multivariable transmitter, an all-in-one instrument that integrates the functions of a differential pressure transmitter, a pressure gauge, a thermometer and a flow computer, while featuring high performance and space-saving design. The transmitter employs a unique flow rate calculation method, achieving a mass flow calculation cycle of 100 milliseconds. By adopting a Reynolds number compensation algorithm, etc., all flow calculation parameters were optimized and a mass flow accuracy rate as high as 1% was achieved. Furthermore, EJX910 complies with a wide range of primary devices, including orifices, nozzles and venturi tubes, and various types of fluid, including general fluids, steam tables, and natural gas. Application information, such as the primary devices and fluid data required for mass flow calculation, is input using the EJXMVTool, a mass flow parameter configuration tool that runs on a PC and is downloaded to the transmitter by means of field communication. A field test performed on a British natural gas test line showed an excellent mass flow measurement accuracy of 1%.

MINEO Tomohiro^*1
*1 Industrial Automation Business Headquarters

In recent years, many Japanese paper companies tend to invest not in partial improvement of their existing facilities, but in construction of new facilities from which a high return can be expected. In the Asian market, especially the Chinese market, many large paper plants are now being built for mass production. To meet these market trends, Yokogawa seeks to deliver the following four types of solutions for the paper and pulp businesses: 1) Machine Technology Solutions (MTS), 2) Pulp Technology Solutions (PTS), 3) Utility Technology Solutions (UTS), and 4) Information Technology Solutions (ITS). These types of solutions will be formulated not merely to add new products to the product lineup, but also to develop original and attractive solutions that integrate all kinds of relevant information. Through affording these solutions, Yokogawa aims to be a total supplier that can contribute to the businesses of customers.

MYOUEN Takashi^*1 TAHARA Motonori^*1 OBINATA Hirohiko^*1
*1 Industrial Automation Business Headquarters

The fiber orientation (fiber arrangement) formed when the paper passes through the wire part of the paper machine was found to be a key characteristic in determining paper quality. Conventionally, the fiber orientation characteristic has been measured offline after the production is complete. Nippon Paper Industries Co., Ltd. and YOKOGAWA have jointly developed the world's first fiber orientation sensor systems that can measure and control such a characteristic online, thus enabling stable production of high quality paper. This paper outlines the measuring principles and control method of fiber orientation.

SHIBATA Mitsuhiroi^*1
*1 Industrial Solutions Business Headquarters

In general, a pulp and paper plant is comprised of a pulp factory, paper machines, coaters, and utility facilities for power generation, wastewater treatment, and so on. Although it does not play a direct role in the paper manufacturing process, the power generation facility is critical for ensuring the continuous running of the pulp and paper plant. The power generation facility is comprised of units, each of which is composed of a boiler, a turbine, a generator, and auxiliary equipment, and each unit is traditionally controlled by an independent system. This paper presents an application of the Yokogawa CENTUM distributed control system that embodies integrated control as well as consolidated operation and monitoring of such a power generation facility, and also introduces implementation of new control methods required by these power facilities due to the diversification of fuel and reduction of global-warming gas emissions.