Ensure stable operations for fine and specialty chemicals with flexible scheduling

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)

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.

OpreX Batch MES C1-T1

使用OpreX Batch MES C1-T1优化批量化学生产，无缝集成工作流与管理流程，实现快速更新和高效运营。
OpreX实验室信息管理系统

OpreX实验室信息管理系统（LIMS）是实验室信息管理系统的软件包，支持质量管理操作。它通过规范质量管理操作，可以降低成本并提高服务水平。
工作流自动化促进批量生产质量提升

借助横河电机的自动化解决方案变革批量流程制造。通过无缝整合电子批次记录（EBR）、仓库管理系统（WMS）和实验室信息管理系统（LIMS），实现实时决策、提升产品质量并优化运营流程。

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