- Enhanced maintenance cycles are achieved through eServ utilization, and transformation from reactive maintenance to preventive maintenance is realized.
- Using the cloud system eServ, information can be shared both inside and outside the company, thereby promoting maintenance communication.
- Leveraging data accumulated in eServ to improve "loss of production opportunities," taking on the challenge of achieving a new target of 70% year-on-year
Otsuka Chemical's factory facilities were installed with 15 plants at the Tokushima Factory, two at the Matsushige Factory, and five at the Naruto Factory, with each plant having its own facility management.
"Are production weights as planned" and "are production times as planned?" developing an original index of "loss of production opportunities" which calculates the monetary value for the impact of equipment based on weight and time, in order to numerically figure out it using a common index.
In selecting the system we considered the facility maintenance systems of five companies and only the cloud system eServ of Yokogawa Solutions met the requirements of a user-friendly system that is visually superior and intuitively operable even at the site, being equipped with all required functions as well as utilizing iPad and QR-codes.
The introduction of eServ has resulted in a centralized system of facility information. The reason for the loss of production opportunities has become clear, and it has become possible for all members to follow up the progress of the measures.
In addition, the use of smart devices such as iPads for cloud systems has made it easy to record and confirm the status of failures, repairs, and replacement of components at the site.
In addition, the dashboard function makes it easy to perform various analyses and graphing. As a result, a cycle of strengthening maintenance has begun by repeatedly checking the progress and effect of improvements.
|Company name||Otsuka Chemical Co., Ltd.|
|Head Office||Chuo-ku, Osaka|
|Business Description||Hydrazine, inorganic materials, composites, pharmaceutical intermediates, etc.
Development and production of chemicals and soft drinks such as ORONAMIN C
The food and beverage industry must produce safe, high-quality foods and beverages for consumers. In addition to quality control, the manufacturing processes include many challenges such as managing ingredients, improving efficiency and handling global environmental issues. Yokogawa leverages its decades of technological expertise to help customers build and operate the ideal factory.
Chemical plants rely on continuous and batch production processes, each posing different requirements for a control system. A continuous process calls for a robust and stable control system that will not fail and cause the shutdown of a production line, whereas the emphasis with a batch process is on having a control system that allows great flexibility in making adjustments to formulas, procedures, and the like. Both kinds of systems need to be managed in available quality history of product, and to be able to execute non-routine operations. With its extensive product portfolio, experienced systems engineers, and global sales and service network, Yokogawa has a solution for every plant process.
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