batch production process. Monitoring the process via an Exaopc interface, the e-SOP system displays the correct procedure on a large screen in the central control room. Operators thus have all the information needed to issue the right commands to the CENTUM CS 3000 system and correctly carry out the process. By clicking the appropriate item in the Exapilot window, they can also access all necessary documents and image data. And when an alarm occurs, Exapilot navigates the operators to a quick solution.As a result, procedures have been standardized, product quality has been improved, paper documents have been digitized, and operator workload has been dramatically reduced. Exapilot has helped to improve the overall skill level of operators by giving younger operators access to the know-how and expertise acquired by their more skilled and experienced colleagues. Moreover, to ensure traceability and enable the detailed analysis of data for each batch production process, Exapilot automatically reports data on flow, level, reactor temperature, problem causes, and operator inputs.Customized Exapilot screen for complex batch production operationsOne must frequently switch between CENTUM CS 3000 screens when monitoring and controlling complex batch processes that use multiple reactors, and this is a challenge for less experienced operators. To address this issue, Yokogawa engineers were able to create customized screens that use ActiveX controls in Excel to display up to four workflows at one time. Operators are thus better able to stay on top of simultaneous related processes, improving both ease of use and efficiency. Taisuke Ishida, a Yokogawa Exapilot engineer, had the following to say about this feature: "We were able to get four windows to refresh at the same time by using Microsoft Excel macros and ActiveX controls. In addition to giving us the information we need to safely operate the process, we also can monitor the overall progress of the production process and view other data that is not stored on the DCS, including photos of materials that are to be charged and real-time video feeds. Exapilot is a useful tool that guides the operators through complex processes."Customer SatisfactionProblems with variation in product quality with SKN’s pigment dispersant production process were resolved: in the year preceding the introduction of Exapilot, the plant reported 10 product defects; in the following year there were zero defects, a 100% product quality rate. In addition, standard production time was reduced 10%, a significant increase in productivity.Mr. Kato: "At SKN we called Exapilot the "mother's love" system because, like a mother with a child, it is constantly at the side of our less experienced operators, giving them the help they need. With only basic training, a newcomer can perform standard operations. This also frees up the production team leaders so that they can devote their time to more high-value added tasks.”He went on to say: “We built a good relationship with Yokogawa after the CENTUM CS 3000 system was installed in 2004, and were like brothers: we communicated well with each other and I felt free to speak my mind with them. Yokogawa understood Sanyo Chemical Industries’ unique production policies, and helped us construct our system. In addition to helping us improve product quality, Yokogawa helped us localize our operations by providing engineering training to Chinese nationals. The mother's love system, so to say, is a system that our local staff built up on their own, in collaboration with Yokogawa." Definition of work processes in an Exapilot flowchartProduction records for a batch production processCustomized screenSKN and Yokogawa engineersThe e-SOP system screen: 24/7/365 procedural guidanceMr. Kazutoyo KatoEngineers at SKN. From the left, Messrs. F. Yang, Y. Li, L. Zhu, Q. Dong, and F. LiuSuccess Story Collection12Sanyo Kasei (Nantong) Co., Ltd. / China

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