Otsuka Chemical Co., Ltd. CMMS solution

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Solution Overview

  • 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


Introduction Background

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.


Introduction Effect

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.


system overview



Company Overview

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


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    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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    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.

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Related Products & Solutions

  • eServ

    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.

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