Yokogawa Collaborative Information Server (CI Server) allows immediate improvement to production efficiency (DX: digital transformation) and reduction of operational maintenance whilst building a digital transformation framework.
Plants are often scattered among remote base sites. These sites can contain multiple plants, each with their own array of equipment and devices, utilizing various systems to carry out management and operations tasks according to their respective functionality. In turn, each piece of equipment and system may connect to a variety of devices.
The Collaborative Information Server integrates this complex hierarchy to unlock critical process data required to achieve data-driven optimization.
Many plant industries are confronted with problems such as complicated raw materials, a retiring workforce, and a decrease in skilled workers due to globalized supply chains and the diversification of product needs.
Achieving next level profitability in operations requires optimizing local and overall sites while addressing these challenges.
In recent years, the movement toward utilizing big data, AI (Artificial Intelligence) & machine learning, and robotics for plant operations is accelerating.
The first step in the digital transformation is “digitalization” of the plant. This requires changing a huge amount of data across each site and plant into value-added information that can be used for plant operations; in other words, "informatization” of data. Without this mechanism, it would be extremely complicated and difficult to realize the transformation to overall and data-driven optimization.
To overcome these challenges, we must gain a clearer understanding of our plants by “digitizing” them. This means “informatizing” the huge amount of data across sites and plants to add value to it—achieving the transformation to overall optimization without this mechanism would be extremely complicated and difficult.
Through blended management of the various data and information from production and operation at individual plants, Collaborative Information Server can achieve system integration, and combine operation monitoring of the many systems (such as DCS and equipment management systems) that make up the plants. As a result, you combine systems, equipment, and devices throughout the multiple plants across a site.
By managing each site in a centralized manner with a hierarchical structure suitable for each role, authority, and field of responsibility, you can promote consolidated operations with a bird’s eye view of the entire company.
To achieve both efficient operations and increased productivity throughout, collaboration between all parties is essential—namely, between on-area operators and management, specialists in each field located far from sites, and each business division.
However, such specialists cannot always be present at remote areas and sites, so a higher-level view is important to remotely operate each site and plant seamlessly.
The Collaborative Information Server facilitates the connection between geographically distributed plants and processes, and presents the operations into a central location. This provides on-site and office personnel members a clear view of all aspects of production in real time. You can increase productivity and operational stability with higher efficiency through remote operations and collaboration of connected business personnel.
Client operation and monitoring screens can be browser-based (HTML5) for remote access.
The client supports PCs, tablets, and smartphones, ideal for remote operations.
For example, specialists and production managers at HQ can provide smooth, targeted support to field operators located far away. This hassle-free ability to cover the need for specialized knowledge and skill without dispatching personnel from the headquarters saves labor and increases the autonomy of your plants.
Web-based solutions come with concerns about security threats such as network-based attacks, direct attacks from terminals, and data leaks, but Yokogawa protects against these.
Centralized Engineering is realized using web-based technology, allowing the distributed the Collaborative Information Server databases to be configured and synchronized from a central location, drastically reducing engineering time associated with managing distributed architectures.
Multi-user functionality is incorporated by design, allowing local or geographically distributed personnel to operate and engineer the system online without disturbing the operational system.
The Collaborative Information Server makes it possible to integrate the plant floor horizontally bringing in critical process information from industrial equipment and sensors simultaneously.
This information is seamlessly transported vertically to upper-layer systems for visualization and analytics purposes, using built in industry standard communication standards such as OPC UA, MQTT & ODBC.
The Collaborative Information Server delivers highly reliable system integrated management because in addition to incorporating the process data acquired and monitored at plants by DCS, production and geographically distributed production systems, and other integrated control systems, it can acquire data from devices and systems that manage various equipment and installations, store this huge amount of data long-term, and provide server redundancy.
It also supports the IEC 61850 communication standard, and achieves measurement field (continuous control, DCS) and electric field (sequence control, PLC) integration. Through such EI (electric-instrument) integration, both electronics and measurement can be centrally run and operated simultaneously at all manufacturing sites, which advances the integration and construction of a comprehensive system for running and operating facilities and equipment.
It’s not just a matter of managing individual operations and manufacturing at a plant.
To increase production efficiency and implement continuous improvement company wide requires acquisition and storage of diverse operational data (OT data) including quality information related to the plant’s production.
To realize the benefits of the captured information, data informatization is required. The Collaborative Information Server fuses the operational and informational data (IT/OT convergence) and seamlessly links it to sophisticated algorithms AI that transform it into actionable feedback for production plants.
Each plant runs a variety of equipment, systems, and devices, which involves an extremely large amount of raw data that is difficult to use for increasing production efficiency and continuous improvement activities.
By mutually associating data on manufacturing, quality, equipment operating rates, and other processes, and then organizing those associations, for the first time you can see the big picture of your plants and analyze it for future improvements.
With the Collaborative Information Server, not only can you operate plants and manage production, but you can also transform the large variety of data related to those activities into a form that adds value: you can “informatize” that data.
Beyond simply acquiring and storing data, the Collaborative Information Server provides these as a data model for wider use in optimizing your overall plant production and improving operations. And when you link up integrated production control and safety systems, your data and models are always updated with information that is continuously acquired on operational changes and external phenomena. While ensuring plant operation fundamentals such as safety and stability, you can also start focusing more on operational profitability, revenues, and flexibility.
The Collaborative Information Server acquires and stores process (OT) data from the manufacturing sites, and also enables you to process that “big data” into a state suitable for your purposes and applications.
By linking with AI you can derive algorithms for optimal control logic and procedures, and then use a digital twin to verify whether those algorithms function effectively. By feeding back verified algorithms to manufacturing sites through the Collaborative Information Server, the system can continuously optimize itself throughout the plant lifecycle.
Repeating this cycle improves plant operation and overall efficiency, and improves corporate profitability. It optimizes general production and achieves even better operations throughout.
The data and information that people need can differ depending on their roles, authority, and fields of responsibility in the company.
The Collaborative Information Server contextualizes and presents information in real time to suit the individual user profile, such as of an operator and technician.
You can ascertain the conditions at plants within each site and the data that affects those conditions in real time, and this enables flexible responsiveness and decision-making. By taking timely and targeted action in each situation, you will realize integrated operations with optimization throughout.
Looking for more information on our people, technology and solutions?