Process Data Analytics software and Yokogawa's analytical services are quality stabilization solutions that can help companies stabilize and continuously improve the quality of their products. Process Data Analytics enable you to understand the situation of your plant more deeply by analyzing process data from the view point of 4M (Material, Machine, Method, huMan).
Operational Excellence Transformation is Yokogawa and KBC’s co-innovated portfolio of solutions and services.We provides comprehensive solutions for business automation in all four areas using consulting and digital technology.
Asset Operation and Optimization deals with realizing the potential of physical assets by pushing throughput and maximizing the production of the highest-value products, while minimizing variable costs, such as energy. It ensures small and large capital expenditure projects are delivered on time and on budget, to achieve growth and meet environment requirements. Through these competencies, it will be possible for companies to take full advantage of their physical assets. Yokogawa’s Asset Operation and Optimization solution leverages industry-leading technology to generate precise operating information to increase operator insight, ultimately leading to improved performance and profitability.
With our track record of providing project execution and thorough lifecycle services and KBC consulting, our customers can obtain practical and deep insights on maximizing their physical assets. Together, we aim to contribute and actualize improvements not only for profitability, but also for overall safety, operability and reliability.
·Supply Chain Optimization
- Optimize management of supply, whether oil in the ground or feedstocks for a refinery or chemical asset, in light of product market demands. This provides operators with the agility to take full advantage of market conditions.
·Operational Risk Management
- Reliably control safety, health and environmental risk at a personal and process level. This assures the robustness required to avoid catastrophic losses.
·Asset Management and Integrity
- Confidently ensure asset reliability and availability, whilst controlling maintenance costs. This assures the asset always meets expectations and is always available to capitalize on short term market opportunities.
A new success story has been released for a consulting service with Yokogawa Data Analytics solution
Featured Reference: Stabilization of Process and Improvement of Operation through Process Data Analysis
Process Data Analysis aims at creating value from process historian Big Data by classifying, organizing and interpreting process data accumulated in a plant (big data) according to 4M* conditions. Recently, in the theme of AI and IIoT, more and more companies have introduced process data analysis for quality improvement, yield improvement, and production stabilization.
* 4 M: Method, Material, Machine, huMan
However, even if you actually try to analyze the process data on site, it will not work soon. This is because, for example, the following issues prevent the utilization of process data.
Analyzing process Big Data is time-consuming because it is necessary to consider the process design concept and 4M* condition when extracting and preprocessing data.
Process Data Analytics is Yokogawa proprietary and field-proven data analysis software which is designed and developed from the broad know-how of more than 100 consulting projects to customers in the process industry, and it allows process engineers to analyze and create valuable insights from their plant Big Data in quick and efficient manner.
Process Data Analytics has powerful and user-friendly functions for quick analysis of process data. These functions can be tailored out to allow customers not only conduct analytical tasks on their plant Big Data, but also plan and implement countermeasures efficiently. Below is a list of some of these functions:
* Customers with little experience of data analysis can order the service of analysis consulting done by YOKOGAWA specialized consultants.
All trend graphs are displayed instantly at the time when process data is imported. In addition, other chart types that are useful for data evaluation such as histograms, scatter plots and overlay graphs can be created and displayed easily.
Based on the manufacturing site 4M conditions, which is included in the process data, data can be partitioned, labelled, stratified and compared to discover and highlight useful insights about process changes.
Examples of 4M change: Change of raw material lot, switch of MAN / AUT mode, facility stop, sensor failure, etc.
Process Data Analytics has a function to adjust the phase difference and the time difference between data of relevant process tags. Performing such adjustment makes is essential to make comparison meaningful; because there is often a time shift/difference between process tags which relate to each other physically or chemically.
Process Data Analytics has a preprocessing function to eliminate periodic fluctuation and measurement error contained in process data. This function makes it possible to extract the characteristics of the data, display the trend on the software and confirm it.
Process Data Analytics has discriminant analysis function for quality engineering called Mahalanobis-Taguchi method (MT method). By using the correlation analysis of such method, the relationship between normal data points against abnormal data points can be verified quantitively.
Process Data Analytics has other functions for database linkage, such as linkage with Exaquantum, OSI soft's PI System, and MathWorks' MATLAB.
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* Company names and product names described on this page are trademarks or registered trademarks of their respective companies.
MGC Mizushima Plant selected Yokogawa's PDA to achieve one of its improvement activities.
MGC has successfully stabilized the process and reduced the operator work load.
Yokogawa has a long history of co-innovation in process control and safety. Combined with recent strategic know-how and IP-rich acquisitions, the company can now apply its deep domain expertise to create a differentiated offering in the industrial automation space. From analog or manual data being digitized to the complete digitalization and improvement of work process, with recently-acquired KBC, Yokogawa is helping industrial organizations transform their businesses to help meet both current and future challenges.
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