Lead the way to Autonomous Operations
Industrial autonomy is the ultimate pathway for manufacturing industries toward autonomous operations. By leveraging advanced, digital technologies, such as Artificial Intelligence (AI) and machine cognition, it creates learning and adaptive capabilities that enable automated responses to emerging situations without human operator interaction.
We empower businesses to transition from Industrial Automation to Industrial Autonomy (IA2IA)—enabling sustainable, digital transformation in a inter-connected System of Systems world.
Details
How We Power Autonomous Operations
Reinforcement Learning AI Enables Stable Operations & Lower Emissions
Jointly developed by Yokogawa and the Nara Institute of Science and Technology (NAIST), Factorial Kernel Dynamic Policy Programming (FKDPP) is an autonomous control AI protocol that makes use of reinforcement learning technology. It can control and autonomize areas of plant operations that have been beyond the capabilities of existing control methods and have up to now necessitated manual operation. Yokogawa put FKDPP into practical use by utilizing the company’s know-how regarding plant operation and control, and successfully autonomized manual operations of a distillation column during a field test at a chemical plant.
Robotics Improves Safety and Efficiency in Plant Operations
OpreX Robot Management Core is a key product in the Yokogawa robot operations solution. By integrating the management of various types of robots that perform plant maintenance tasks conventionally carried out by humans, this software will help customers maintain their facilities in a safer and more efficient manner. In addition, when connected to a plant’s control and safety systems, it enables the utilization of manufacturing site data that has been acquired by robots, and the issuing of procedural instructions to robots, thus enabling the first step to be taken toward autonomous plant operations.
Control of Work Enables Safe Industrial Autonomy
Even as Industrial Autonomy advances, ensuring human safety and managing risks remain essential.
Control of Work (CoW) provides strict oversight of who performs which tasks and how they are executed, thereby ensuring the safety of hazardous operations. This oversight ensures that, even in autonomous systems and work environments, appropriate qualifications and procedures are consistently followed, helping to prevent accidents and incidents. As such, CoW serves as a foundational element for maintaining safety in the implementation of Industrial Autonomy.
Pathway to Autonomous Operations in Refining and Petrochemicals
IA2IA in Action (Case Studies)
AI-driven Anomaly Detection
Vetter Pharma partnered with Yokogawa to enhance the reliability of ultra-low temperature freezers using AI-based anomaly detection. The solution enabled early identification of potential failures, providing 6–8 hours of advance warning and preventing product loss. This remote-implemented system significantly improved safety and operational efficiency.
Smart Manufacturing (SIRI) Assessment for 5 Manufacturing Plants
Syngenta partnered with Yokogawa to assess and enhance the digital maturity of five manufacturing plants across Asia. Utilizing the SIRI framework, the assessment identified key areas for improvement, leading to a five-year transformation roadmap. This plan supports Syngenta's goals of sustainable agriculture and operational excellence.
Reduce Abnormal Events and Manual Interventions Through DX
Tuas Power Utilities in Singapore needed a solution to mitigate the risk of production disruption due to human errors and equipment failures. Through collaboration and Co-Innovation, Yokogawa was able to help Tuas Power reduce abnormal events and manual interventions during operations by 80%.
Industry 5.0 Enabled Control of Work For Interconnected Worker Safety
Implement Industry 5.0 ready Control of Work software systems and monitoring safety critical asset items, plants can ensure a safer working environment, reducing the risk of accidents and enhancing overall operational efficiency.
Resources
ENEOS Materials successfully achieved the world's first long-term autonomous operation of a plant using Yokogawa's AI. FDKPP saves energy and reduces operator workload while maintaining manufacturing quality.
- Yokogawa provided control solutions for expansion project in sugar and bio-energy plant.
- Consolidated central control room was designed for safe, comfortable, and efficient work environment.
Syngenta aimed to promote sustainable agriculture as a social responsibility through digital transformation. Syngenta selected Yokogawa to start the smart manufacturing transformation journey.
Honshu Chemical has successfully improved product quality by process data analysis.
On-site capabilities were further strengthened by sharing each other's knowledge in the project.
A virtual network system that securely connects OT-IT built on existing network resources.
Yokogawa experts monitor the network remotely like customer's information system department.
Yokogawa provided Mewah, one of the largest vegetable oil processors, with a structured Smart Manufacturing Assessment Workshop.
The company's Industry 4.0 roadmap was clarified through the Smart Industry Readiness Index (SIRI) based workshop.
- Yokogawa provided digital transformation solution to TP Utilities power plant under Co-innovation program.
- Operation Management solution digitized shift handover and knowledge base for safe and efficient operations.
DIC Corporation co-developed the Data Utilization Platform with Yokogawa. The solution dramatically reduces data preparation work for data analysis.
Osaka Metro selected Yokogawa's Sushi Sensors to monitor vibration of huge ventilators.
Monitoring vibration trends prevents unexpected failures of air-conditioning systems in subway stations.
- 16,000 FOUNDATION Fieldbus devices
- Main Automation Contractor (MAC)
- DCS anywhere concept integration with site SAP system
- Long term maintenance contract
- Sustainable development
A Malaysian Gas Processing and Transmission Company a subsidiary of the national oil & gas major, plays a prominent role in the gas business value chain. The company operates as a throughput service company providing the services of processing and transmission of gas to the power generation sectors and various customers.
Kuraray Engineering provides IoT big data analysis solution in collaboration with Yokogawa.
Collaborative process data analysis achieved a high level of quality stabilization at a customer site.
GlyTech have introduced Yokogawa's Electronic Lab Note of Oprex Informatics Manager.
The ELN enables has made it possible to share data and standardize work.
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