- 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
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.
In the food manufacturing industry, in addition to the conventional challenges of achieving both "ensuring food security and safety" and "cost reduction," ｍanufacturers are also working to cope with infectious diseases and labor saving.
YOKOGAWA supports ｍanufacturers to create comfortable workplaces by working closely, coping with challenges together, and proposing ideal factories suitable for operations.
The pharmaceutical industry currently faces a major challenge in taking full advantage of the opportunities presented in large emerging markets. Now, more than ever, pharmaceutical companies need to introduce lean manufacturing techniques that will enhance profitability. As one of the world's leading industrial automation suppliers, Yokogawa is committed to delivering the best possible solutions for your best manufacturing practices.
The eServ plant maintenance system supports maintenance operations with foresight, and is effective everywhere. Quick and easy to use, it leverages the expertise of Japanese professionals and optimizes the CMMS and EAM concept.
Yokogawa provides highly adaptable solutions based on a wealth of experience acquired through long years of support for manufacturing customers. Reliable systems can be introduced in a short period of time using industry-specific solutions for the oil, chemical, paper and pulp, iron and steel, non-ferrous and ceramic, power and gas, food, electric, electronics, and automobile industries.
Through the use of measurement, control, information technology and life science, radically improve productivity across the entire value chain, from basic research to logistics and services.
Contact a Yokogawa Expert to learn how we can help you solve your challenges.