Otsuka Chemical Co., Ltd.
■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.
Solution 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.
In addition, there are approximately 320 types and 4600
units of equipment at the three factories, and the
number of parts used ranged from 30 to 2000 items. As
such, maintenance and management of equipment to
keep proper operation was one of the important
management issues.
To resolve this issue, the company established a
department called the Production Innovation O��ce,
which thoroughly reviewed and examined operations
under the slogan of "building a world-class facility
maintenance system."
The key of these efforts was what indicators to use for
facility management.
Therefore, as new indicators of production capacity we
focused on
"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.
The "loss of production opportunities" was summarized
monthly to confirm the content, and information was
shared on the causes of loss of production
opportunities, problems related to equipment, and how
to deal with them. We also examined what kinds of
facility maintenance systems are required.
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.
Otsuka Chemical Co., Ltd.
Founded 1950
Established 1950
Head Office Chuo-ku, Osaka
Capital 5 billion yen
Net sales 60.841 billion yen (March 2011)
Number of Employees 620 (as of March 2011)
Business Description
Hydrazine, inorganic materials, composites,
pharmaceutical intermediates, etc.
Development and production of chemicals and soft
drinks such as ORONAMIN C
Solution Overview
As an OTSUKA Group company, the company operates
three chemical and soft drink businesses:
Hydrazine-related, Materials, and Fine. The three
Tokushima, Matsushige, and Naruto plants in Tokushima
Prefecture are production bases that provide products
globally in the areas of "Automobiles," "Electric and
Electronics,"
"Residential" and "Medical."
We aim to create products that bring "healthy and rich
life" to the world through the development of valued
and original unique and world-class products by
practicing the company philosophy "Trusted by
individuals, Trusted by the company, Trust is the dream
of our society. Building trust with technology and
commitment. Spreading trust with the people around
the world."
Company Outline
Introduction of the cloud-based facility maintenance system eServ
Otsuka Chemical Domestic Factories
Work plan Work history
Information sharing
with Chatter!
Inspect thoroughly by looking at
photographs and drawings with iPad!
Otsuka Chemical Co., Ltd.
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.
At the monthly maintenance report meeting, it became
possible to share and discuss problems based on the
input information, and it also helped to make efforts to
increase the equipment skill of all members.
In addition, by sharing real-time follow-up information
on troubles with the simple blog function Chatter, older
employees taught young employees how to maintain
equipment and facilities, and young employees taught
older employees how to use eServ and iPad, which was
unexpectedly effective in enhancing communication.
In the future, eServ will be used to centralize
information and share components across the entire
company, including its abroad factories. "We will expand
our perspective to obtain optimal equipment in
accordance with domestic, foreign, and local locations.
In some cases, even at Japanese factories, we will
procure equipment manufactured abroad. In order to do
this, it is crucial that the facility information is shared
and thoroughly analyzed by eServ. I would like to take
on various challenges while considering
countermeasures for the disadvantages of equipment
in-house.
Our company has just begun to move from individual
optimization to overall optimization, but we are strongly
determined that we can do so, " the company's project
leader, Mr. Nanjo, commented.
Future developmentIntroduction effect
System Overview
Introduction of the cloud-based facility maintenance system eServ
Master information
Failure
information
Work history
• Equipment
• Manufacturer
• Model
• Failure information
• Inspection and control
(Annual, Monthly)
• Modification plan
• Repair plan
• Registration of
work contents
• Equipment and
parts linkage
• Sharing
• FRegistration of
response measures
Confirm with
image information
using photographs!
Maintenance
standard
Inspection set
Components
Parts storage/
retrieval
Inspection
results
Schedule
management
with eServ!
Using QR code
enter results
with ease and
certainty!
Inspection
items
Tokushima
Factory
Equipment
320 types 4600 units
Parts
30 types 2000 items
Deploy eServ to overseas factories
as well as the three domestic factories
Matsushige
Factory
Naruto
Factory
Printed in Japan, 104(HT) [Ed:01/d]
Yokogawa Electric Corporation
2-9-32 Nakacho, Musashino-shi, Tokyo 180-8750 Japan
Mail：pharm@cs.jp.yokogawa.com
URL：https://www.yokogawa.co.jp/solutions/solutions/life-innovation/