Campaigns, hazards, multi‑stage batches—drive production efficiency in a complex fine-chemical world
Yokogawa unites a flexible scheduler with end‑to‑end services to overcome the unique complexity of fine & specialty chemical plants—enabling safer, more stable operations
- Campaign sequencing:
Optimizes product changeover sequence to reduce cleaning cycles - Hazardous & solvent constraints:
Models concurrent‑use limits and warehouse capacity for safe operation - Multi‑stage & parallel batching:
Synchronizes reaction‑filtration‑drying trains, automatically revealing bottlenecks - QC release integration:
Plans lab workload to prevent hold‑ups at final release - Bi-Directional data linkage:
Integrates seamlessly with ERP and MES—eliminates redundant data entry - Knowledge standardization:
Captures expert know-how to ensure consistent schedules even with new personnel
These benefits are enabled by FLEXSCHE products. For more product features, specifications, and case studies, visit the official FLEXSCHE website.
Implementation roadmap
- Assessment & prototype (2-3 months)
- Design & model build (3-4 months)
- Testing & training (2-3 months)
Details
Challenges
Planning complexity, hazard constraints, and cross-functional bottlenecks lead to waste, increased costs, and delivery delays
Unstable plans & knowledge silos
- Volatile small‑lot demand disrupts campaign continuity
- Complex sequencing increases planning risk and manual effort
- Know‑how concentrated in a few individuals, risking inconsistency and disruption
Cleaning, changeovers, and hazard management
- Solvent‑line concurrency limits can halt production
- Validation bottlenecks during changeovers extend downtime and disrupt throughput
Cross-functional bottlenecks & lack of synchronization
- Lab overload stalls batch release
- Raw material expiry management, warehouse stock shortages, lab bottlenecks, and misalignment with production floor progress
Solutions
Flexible algorithms and integrated optimization effectively manage variability and operational constraints
Instant rescheduling & campaign sequencing
- Detect changes and adjust campaigns instantly
- Captures expert rules so to enable consistent planning by any user
Unified optimization including hazards
- Optimizes cleaning schedules, hazardous material storage, and utility usage in one engine
Integrated scheduling across warehouse, lab, and production
- Scheduling aligned with warehouse stock, QC capacity, and real-time production progress
Benefits
Improved productivity, enhanced visibility, and synchronized operations across the plant
Stable operations
Reducing night changeovers and maintaining on-schedule line operation, leading to lower manufacturing costs and shorter lead times.
Real‑time visibility
Provides live KPIs, progress tracking, and warehouse status to enable timely decisions and proactive management.
End-to-end synchronization
Scheduler-driven integration of QC, warehouse, and production breaks down silos and enables efficient cross-departmental operations.
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OpreX Intelligent Manufacturing Hub
Transformieren Sie Ihre Fertigungsabläufe mit dem OpreX Intelligent Manufacturing Hub. Integrieren und visualisieren Sie vielfältige Daten für Echtzeit-Einblicke und steigern Sie so Effizienz und Rentabilität.
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Lab-Aid
Lab-Aid ist ein Laboratory Information Management System (LIMS) (Laborinformationsmanagementsystem), das Qualitätsmanagementaktivitäten unterstützt. Darüber hinaus standardisiert es Qualitätsmanagementaktivitäten, um Kosten zu senken und den Service Level zu verbessern.
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Elevate batch production quality with workflow automation
Transform batch process manufacturing with Yokogawa’s automation solution. Seamlessly integrate EBR, WMS, and LIMS for real-time decision-making, enhanced product quality, and streamlined operations
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