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Plant InformationLocation: Nantong, Jiangsu, ChinaOrder date: October 2012Completion: August 2013Sanyo Kasei (Nantong) Co., Ltd.Exapilot-based e-SOP System Provides 24/7/365 Guidance, Improving Both Product Quality and ProductivityExecutive SummaryFounded in Kyoto in 1949, Sanyo Chemical Industries Ltd. is a producer of performance chemicals such as surfactants, high water-absorbent resins, lubricant additives, pigment dispersants, and polymerization toner intermediates. Sanyo Kasei (Nantong) Co., Ltd. (SKN), a subsidiary of Sanyo Chemical Industries, was established in 2003. From its facilities at the Nantong Economic and Technological Development Area, SKN produces performance chemicals such as pigment dispersants, emulsifying surfactants, and glass fiber adhesives for high growth markets in China and elsewhere in Asia. Since 2004, SKN has relied on a Yokogawa CENTUM CS 3000 distributed control system to monitor and control its batch production processes.To improve the quality of the pigment dispersants produced at the SKN plant, and to raise the productivity of this batch production process, the company introduced Yokogawa's Exapilot operation efficiency improvement package. This is an innovative electronic standard operating procedure (e-SOP) system that draws on the knowledge and experience of skilled SKN operators. Functioning much like a car navigation system, the Exapilot e-SOP system displays the procedures for each operation on a large-screen display in the plant’s control room, providing less experienced operators the guidance needed to standardize work processes.The Challenges and the SolutionsTransferring knowledge to less experienced operators and improving their skills are common challenges worldwide, and is key to keeping plants operating safely and securely. The great variety of products and the many different recipes that are used at the SKN facility present a particular challenge. For example, there are approximately 30 different recipes for the production of the company’s flagship product, the Carrybon L-400 pigment dispersant, and this process makes use of multiple reactors and tanks. Before the introduction of Exapilot, less experienced operators often had to consult manuals and ask production line managers for assistance when, for example, the flow rate dropped as the result of a clogged pipe. Situations such as this added to operator workload and led to a drop in product quality.At the suggestion of Kazutoyo Kato, who was then the production manager at the Nantong factory and who had learned about Exapilot in a visit to the Yokogawa Shanghai office, SKN decided to use Exapilot with its pigment dispersant production process.24/7/365 guidance for standard operating proceduresWith the Exapilot system installed at the SKN plant, the plant’s engineers began collecting information about specific processes and other knowledge from their veteran operators. Based on this, they began inputting this information into Exapilot flowcharts. Throughout this process, Yokogawa's Exapilot experts frequently visited the SKN office to provide support.At many plants, operators have access to both the DCS and Exapilot windows at their terminals, and refer to the information provided in the Exapilot window to guide them through a process. However, because of the complexity of the production processes at the SKN plant, there was a concern that the use of both systems at these terminals would place too much of a burden on the operators. It was therefore decided to implement Exapilot as an e-SOP system that starts up automatically when the CENTUM CS 3000 system launches a The system architecture11Success Story CollectionChemical (Fine & Specialty Chemical, Biofuel)& Pharmaceutical

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