富士電機 List of Products and Services

MainGATE/PPA for EMS (Energy Management System) is an energy management and analysis tool based on a manufacturing management and performance analysis package. As a Factory Energy Management System (FEMS), it integrates not only energy measurement data but also manufacturing data such as operational information of production equipment and product shipment volumes, enabling detailed energy analysis. Additionally, for Building Energy Management Systems (BEMS) in office buildings, it can be easily constructed using templates based on extensive experience. It analyzes energy consumption from various facilities such as heat sources, air conditioning, and lighting, achieving optimal energy management. By utilizing energy measurement technology from EMS (Energy Management System) and leveraging analytics, AI, and IoT, it enables advanced energy management through detailed analysis of energy data. *PPA: Process Performance Analysis

• Business Intelligence and Data Analysis

A Computerized Maintenance Management System (CMMS) is a system designed to streamline equipment management in chemical plants and improve productivity. By implementing a CMMS, it becomes possible to centralize inspection histories, repair records, and parts inventory related to equipment maintenance management, as well as to formulate optimal maintenance plans based on historical data. This can lead to various benefits, including cost reduction in equipment maintenance management, improved work efficiency, and enhanced safety. The equipment management system "Maintenance Station" is a CMMS that is simply structured with only the necessary functions, based on a wealth of experience in supporting equipment maintenance management in the industrial sector. The digitalization of equipment management enables the sharing of equipment management data, the efficiency of equipment management operations, and the reduction of maintenance costs. *CMMS: Computerized Maintenance Management System

• Database

An Energy Management System (EMS) visualizes the energy consumption of factories, enabling efficient energy management. By utilizing EMS, it becomes easier to understand the energy consumption of factories and equipment, allowing for the quantification of energy-saving effects and the reduction of unnecessary energy losses. For example, in the food sector, implementing an EMS allows for energy savings from both electricity and heat. This contributes not only to cost reduction but also to the reduction of environmental impact. In the EMS solutions for the food sector, energy management and energy savings in factories are achieved through the visualization and understanding of electricity and heat with the EMS. Based on the know-how gained from realizing smart factories, we propose EMS and MES integration solutions, as well as EMS for utilizing on-site data.

• Demand Monitoring

The equipment management support system is a system that streamlines equipment management and maintenance in factories, enabling the centralization of equipment management information. In food factories, there is a demand for the implementation of planned maintenance and rapid response in the event of failures. On the other hand, equipment management tasks are diverse, leading to challenges such as labor shortages and insufficient information sharing. The equipment management support system addresses these issues. The equipment management support system "Maintenance Station" streamlines the management of equipment ledgers and maintenance records, reducing maintenance costs. It realizes the digitalization of equipment management from a paper-based system, enabling the sharing of equipment management data and the efficiency and speed of equipment management tasks and operations.

• Document and Data Management

Application examples of soft sensor technology in the manufacturing process of chemical products. Conventional sampling analysis made it difficult to detect frequent measurements and sudden concentration changes, leading to concerns about line blockage and increased operator workload. This time, a system was established to estimate the concentration of the can liquid in real-time using soft sensor technology, enabling operational control aimed at maintaining the can liquid concentration, thereby achieving a reduction in manufacturing losses and waste.

• Other measurement, recording and measuring instruments

Application examples of soft sensor technology in the chemical manufacturing industry. In the manufacturing process of chemical products, the catalyst regeneration operation for hydrogenation reactions was carried out according to a schedule, but there were challenges related to increased workload and the costs of switching catalyst towers. Therefore, by using soft sensor technology, a predictive model for future selectivity values was constructed, enabling the estimation of catalyst performance indicators, and optimizing the regeneration frequency, which resulted in improved productivity.

• Other process controls

Case study of the introduction of an equipment diagnosis system utilizing AI technology from Company A in the chemical manufacturing industry. The company had previously conducted equipment diagnosis through numerical management and remote operation, but faced challenges due to the speed of human judgment and the increased burden from the growing number of monitoring targets. Therefore, they implemented MainGATE/MSPC equipped with Fujielectric's AI technology, achieving automation of abnormal signal detection. This enabled rapid detection of abnormal signals and advanced failure prediction.

• Business Intelligence and Data Analysis

Case study of the implementation of a power visualization system aimed at carbon neutrality. Company B in the chemical manufacturing industry has introduced an EMS to achieve its carbon neutrality declaration, starting with understanding the current situation and promoting energy conservation. The system enables real-time aggregation and monitoring of electricity usage across approximately 50 locations nationwide, facilitating efforts towards carbon neutrality and enabling data-driven efficient energy-saving measures.

• Demand Monitoring

A case study of visualizing parts inventory through a maintenance management system in a chemical plant. The company experienced equipment downtime due to a shortage of parts inventory during repairs, which halted operations until the equipment was restored. To align the equipment inspection plan with actual failures, they implemented a maintenance management system that achieved visibility of the inventory of repair parts. This resolved the parts inventory shortage and significantly reduced the impact of breakdowns on planning and production.

• Other information systems

Proposal case of a heat balance analysis system. In the food manufacturing industry, improving the efficiency of steam utilization equipment is effective for energy-saving measures. On the other hand, energy management of heat requires specialized knowledge, which has resulted in a lag in energy-saving measures compared to electricity. By implementing this system, it becomes possible to quantitatively grasp the heat balance of steam utilization equipment, conduct factor analysis, reduce unnecessary heat consumption, promote energy savings in factories, and reduce energy costs.

• Other energy equipment

Case study of the introduction of an energy-saving analysis support system. Company A in the food manufacturing industry implemented an Energy Management System (EMS) and worked on visualizing energy consumption. However, the burden of energy-saving tasks, such as data analysis, was significant, leading to a stagnation of energy-saving activities. By introducing the energy-saving support system, they achieved a reduction in the workload of data analysis, prioritization of cost-effectiveness initiatives, and reporting tasks, enabling the implementation of a PDCA cycle for energy savings across the entire factory.

• Demand Monitoring

Case study of database integration for manufacturing information management systems and production orders/actual performance information. Company A in the food manufacturing industry had systematized production information management, but faced challenges in the efficiency of integrating production data and utilizing data due to the need for individual management for each piece of equipment and machinery. With the introduction of MainGATE/PPA, they established an environment for integrated management of production information and online collection of actual performance, enabling efficient data utilization.

• Other production management systems

Case study of the introduction of a power visualization system in a factory. Company A in the food manufacturing industry needed to quantitatively understand the electricity consumption of its factory to promote CO2 emission reduction and energy-saving measures. This time, an energy visualization system was implemented targeting four substations. As a result, it enabled the visualization of electricity consumption, information sharing, and feedback on energy-saving activities, making it possible to promote energy savings and reduce CO2 emissions in the factory.

• Demand Monitoring

Proposal case of steam generation heat pump. Company A in the food manufacturing industry faced challenges in the efficient use of hot water used in the production process, necessitating an understanding of the reusable amount through heat exchange, as well as the running costs of the equipment and cost-effectiveness. A proposal was made for the high-efficiency utilization of heat using a steam generation heat pump, and the calculations showed that utilizing the waste hot water could reduce energy costs by 60% and CO2 emissions by 55%.

• Other energy equipment

Related: FLEXLOGI (Inventory Management System) It visualizes on-site data from factories and logistics centers, enabling real-time understanding of productivity. Over 200 systems have been implemented. It can integrate with material handling equipment, existing facilities, and existing systems, and offers functionalities such as raw material receiving, storage, work-in-progress management, picking, product shipping, inventory management, traceability, and appearance inspection for the chemical and pharmaceutical sectors.

• Other production management systems

Proposal for the Renewal of Power Supply Equipment for Industrial Electric Dust Collectors Fuji Electric has over 60 years of manufacturing experience as a manufacturer of electrical equipment (power supply equipment) for electric dust collectors, having delivered more than 3,500 units to domestic thermal power plants, chemical plants, glass factories, and more. We collaborate with machinery manufacturers to support not only our own products but also the renewal of products from other companies. Please feel free to contact us.

• Dust collector

Related Products: MainGATE/PO・EM ・MainGATE/PO (Manufacturing Instruction Deployment): Based on the factory's conditions and the production plan from the upper system, it automatically issues manufacturing and work instructions. ・MainGATE/EM (Event Integration Management): Based on the process information and process transition rules received from the manufacturing instruction system (PO), it monitors the manufacturing/work execution status within and between processes and manages progress.

• Other production management systems

Related Products: MainGATE/PPA MainGATE/PPA enables real-time understanding and management of operational information related to product manufacturing, achieving "visualization" of manufacturing information across various levels from the shop floor to the factory, and from managers to executives. Additionally, it can be used to analyze the causal relationship between manufacturing parameters and actual data on a lot-by-lot basis. In the facility maintenance department, it allows for monitoring energy usage at the factory, line, and equipment levels, and can also be utilized as integrated energy management.

• Business Intelligence and Data Analysis

Related products: MainGATE/PPA MainGATE/PPA enables real-time understanding and management of operational information related to product manufacturing, achieving "visualization" of manufacturing information across various levels from the shop floor to the factory, and from managers to executives. Additionally, it can be used to analyze the causal relationship between manufacturing parameters and actual data on a lot-by-lot basis. In the facility maintenance department, it allows for monitoring energy usage at the factory, line, and equipment levels, and can also be utilized as integrated energy management.

• Business Intelligence and Data Analysis

Related Products: MainGATE/PPA MainGATE/PPA (Process Performance Analysis) is an energy management and analysis tool based on a manufacturing execution system. It analyzes and visualizes factors that hinder operational efficiency from integrated data on energy and manufacturing management, achieving energy savings improvements of 3-5% (with a maximum recorded improvement of 27%).

• EMS

Related products: MainGATE/MSPC With over 550 implementations primarily in the manufacturing industry, it is used for improving processing accuracy through diagnosis and analysis of manufacturing processes, enhancing quality yield through diagnosis and analysis of manufacturing processes, ensuring process quality through application in equipment abnormality diagnosis for medical devices, stabilizing production volume, and detecting abnormal signs through monitoring of refrigeration systems.

• Other production management systems

■About the Maintenance Management System (Maintenance Station) An equipment management solution that integrates and optimizes facilities and operations. By utilizing data such as equipment information, work information, and failure information, it helps to create better work plans by determining what, when, and how maintenance should be performed, thereby optimizing operations. It improves operational efficiency and safety, reduces costs, extends the lifespan of equipment, and provides a "safe and secure" environment.

• Document and Data Management

Related products: Maintenance Management System (Maintenance Station) An equipment management solution that integrates and optimizes facilities and operations. By utilizing data such as equipment information, work information, and failure information, it helps to create better work plans by determining what, when, and how maintenance should be performed, thereby optimizing operations. It improves operational efficiency and safety, reduces costs, extends the lifespan of equipment, and provides a "safe and secure" environment.

• Document and Data Management

■Energy Management System for Food Factories Are there any issues or challenges regarding energy conservation and energy efficiency improvement in your food factory? Fujielectric's EMS promotes energy conservation through "visualization," "understanding," and "optimization" of energy use, and by leveraging the know-how gained from realizing smart factories, we propose an optimal energy environment for your factory.

• EMS

■About FLEXLOGI (Inventory Management System) It visualizes on-site data from factories and logistics centers, enabling real-time understanding of productivity. With over 200 systems implemented, it can integrate with material handling equipment, existing facilities, and existing systems. For food factories, it offers functionalities for receiving, sorting, product shipping, inventory management, expiration date management, traceability, and appearance inspection.

• Other production management systems

■Remote monitoring system using IoT technology By grasping operational data of key points and aggregating it through a network, analysis can be conducted on-site or in the office. It not only "visualizes" operational conditions but can also be utilized for anomaly monitoring, preventive maintenance, and analysis of optimal operating patterns.

• Remote Control

■IGBT Power Supply We have adopted a newly developed high-capacity, high-efficiency IGBT (Insulated Gate Bipolar Transistor) stack and digital control system. By enhancing the stack's high capacity and high voltage, re-evaluating the internal structure, and digitizing the control, we have realized a next-generation power supply. This provides new value such as improved efficiency, enhanced maintainability, and quicker recovery.

• power supply

■High-frequency induction furnace that realizes energy saving for electric furnaces The high-frequency induction furnace F-MELT100G, which consolidates energy-saving and power supply technologies into a high-efficiency induction furnace, contributes to the energy saving of electric furnaces and the carbon neutrality of industrial furnaces. Additionally, utilizing IoT-based data analysis technology makes the induction furnace user-friendly, smartly analyzes data, feeds it back to the equipment, enables optimization of operations, reduces costs, and contributes to improved production efficiency.

• Electric furnace

Case study of the introduction of electric furnaces (high-frequency induction furnaces) and furnace operation monitoring systems. The challenges prior to implementation included building a manufacturing system aimed at decarbonization and green growth strategies, as well as achieving energy conservation and CO2 reduction. The transition from a cupola, which uses coke as a heat source, to an electric furnace, which uses electricity as a heat source, has led to reduced environmental impact, improved quality and safety, and stabilized the supply of maintenance parts.

• Electric furnace

Flow meters/flow sensors are useful for the maintenance of equipment in casting factories, abnormal detection, and energy-saving measures. For example, they can be used for monitoring flow rates and velocities, restricting the use of water supply and drainage based on data, and optimizing the number of operating pumps for energy savings. On the other hand, the equipment and manufacturing processes in casting factories are complex, which may limit the locations where flow meters can be installed, necessitate modifications or processing of existing piping, or require halting the production line. For such issues, we recommend considering clamp-on ultrasonic flow meters. Clamp-on types do not require modifications or processing of piping and can accurately measure flow rates and velocities from the outside of the piping using flow sensors (ultrasonic). Fujielectric's liquid flow meters/flow sensors are clamp-on ultrasonic flow meters. They can be easily installed on the outside of the piping and allow for non-contact measurement. The lineup includes fixed types (wall/pipe-mounted) and portable types that can be handheld. They are ideal for measuring the flow of cooling water, hot water, pure water, and oil in casting factories.

• Flow Meter

Foundries need to comply with laws and regulations regarding environmental protection (air pollution) by accurately understanding the types and concentrations of harmful substances contained in exhaust gases and implementing appropriate measures. By measuring and analyzing exhaust gases, it becomes possible to optimize manufacturing processes based on measurement and analysis data, implement appropriate measures, evaluate and improve environmental impacts, and ensure compliance with legal regulations. Engaging in these initiatives contributes to the sustainability of the company, enhances the corporate brand image, and increases reliability. Fujielectric's exhaust gas analysis equipment is equipped with infrared gas analyzers that excel in long-term stability, capable of simultaneously measuring up to seven gas components necessary for environmental monitoring, including NOx, CO2, HCl, and particulate matter. It is ideal for measuring exhaust gases from factories and electric furnaces.

• Other environmental analysis equipment

In foundries, there is an active movement to promote energy conservation and carbon neutrality. These are important management issues that lead to reduced environmental impact, cost savings, and enhanced corporate value, and it is believed that efforts to address environmental issues will continue across various industries in the future. On the other hand, energy-saving activities at the operational level in foundries have been undertaken for some time. To aim for further energy savings and reductions in CO2 emissions from the current situation, more in-depth initiatives and capital investments, such as restructuring production and business processes, are necessary. When promoting energy conservation and carbon neutrality in foundries, there are methods such as converting the heat source of industrial furnaces and switching to high-efficiency electric furnaces/induction furnaces. This is expected to improve energy unit consumption and reduce CO2 emissions/environmental impact. The product that addresses this challenge is the high-frequency induction furnace F-MELT100G, which consolidates Fuji Electric's energy-saving and power supply technologies. It achieves high efficiency, energy conservation, and safe and secure operations, contributing to energy conservation in foundries and the promotion of carbon neutrality in industrial furnaces.

• Electric furnace

■Remote Work Support Package for Maintenance Operations FWOSP-Glass The feature of FWOSP-Glass is its ability to grasp the on-site situation in real-time from a remote location. By wearing smart glasses, workers can receive work instructions while viewing video from a distance. It is utilized across various industries as a package that supports the digitization of security and maintenance work records and assists in maintenance operations.

• Surveillance Camera System

■About the Wiserot Rotating Machinery Fault Prediction Monitoring System The Wiserot Rotating Machinery Fault Prediction Monitoring System is a system that enables preventive maintenance for rotating machinery and motor-related equipment. By regularly measuring the vibrations of rotating machinery operating on production lines and as critical equipment, it contributes to the early detection of abnormal signs through trend monitoring, facilitating the planning of appropriate preventive maintenance and reducing production loss costs.

• Vibration Monitoring

■About the Comprehensive Smart Security Service The Comprehensive Smart Security Service is an O&M (Operation & Maintenance) service that utilizes IoT and AI technologies. By leveraging IoT and AI technologies, it supports the optimization of equipment maintenance from planning maintenance strategies to monitoring equipment and proposing maintenance management measures.

• Power Monitoring Equipment

■About the Whole Smart Security Service The Whole Smart Security Service is an O&M (Operation & Maintenance) service that utilizes IoT and AI technologies. By leveraging IoT and AI technologies, it supports the optimization of equipment maintenance, from planning maintenance strategies to monitoring equipment and proposing maintenance management measures.

• Surveillance Camera System

■Case Overview A case study on energy-saving measures using heat pumps. Before implementation, steam was generated by a boiler and supplied to the clean room, but now the waste heat from the cooling water of a diesel engine is utilized. Heat recovery is achieved using a steam generation heat pump to supply steam, reducing the use of the boiler. As a result, energy costs associated with steam generation were reduced by approximately 55%, and CO2 emissions were reduced by about 40%.

• Heat exchanger

■Case Summary A case study on the thermal balance analysis of steam in sterilization equipment. The analysis of steam and thermal balance revealed an increase in product outlet temperature, the generation of flash steam from the discharged hot water, and heat input from steam during shutdown. Through the analysis, it was found that the waste hot water could be utilized for heat recovery, enabling energy-saving initiatives in the factory.

• Flow Meter

■Case Overview A visualization case of energy using a clamp-on ultrasonic flow meter. The purpose was to plan energy-saving measures for boiler equipment by measuring steam flow. After approximately two weeks of measurement, it was found that steam was flowing even during nighttime and holidays, and there was a significant consumption of steam during specific time periods on holidays, allowing for a review of the operating conditions of the boiler.

• Other measurement, recording and measuring instruments

As part of energy-saving measures in factories, the utilization of unused thermal energy and the optimization of thermal use are gaining attention as further energy-saving strategies. Factories have numerous facilities that utilize steam, and improving thermal efficiency and promoting energy conservation can lead to reductions in energy costs and CO2 emissions in food factories. To achieve this, it is necessary to quantitatively grasp the thermal balance, such as steam usage and waste heat amounts. However, measurement and calculation are not straightforward, and there are challenges such as the lack of personnel who can analyze thermal energy, including thermal efficiency. The thermal balance analysis system addresses these challenges. It enables the automatic visualization of the thermal balance of saturated steam utilization equipment, the determination of abnormal data, and factor analysis to improve thermal efficiency, thereby facilitating energy-saving measures in factories and reducing CO2 emissions.

• Other energy equipment

Heat is recovered from hot wastewater (60-80°C) discharged from factories and supplied as saturated steam (100-120°C). It supports remote monitoring and operation. By combining it with an energy management system, it enables energy conservation and optimization of energy use throughout the factory. [Main Features] - Heat is recovered from hot wastewater (60-80°C) discharged from factories and supplied as saturated steam (100-120°C). - By reusing waste heat, the load for high-temperature reheating in boilers can be reduced. - Depending on the amount of steam used, multiple units can be operated in connection (up to 10 units). - It is not subject to the High-Pressure Gas Safety Act, requires no special construction, and is easy to install and implement. [Energy Cost Reduction and CO2 Emission Reduction Effects] - By reusing waste heat, the load for high-temperature reheating in boilers can be reduced. - When generating the same amount of steam using a steam boiler fueled by city gas and a steam generation heat pump, the steam generation heat pump can produce steam with about 50% of the energy consumption of the steam boiler. - This allows for a reduction in boiler fuel costs, enabling energy conservation and CO2 emission reduction in factories.

• Other energy equipment

In food factories, steam energy is utilized in large quantities. While efforts to promote energy-saving measures and visualize energy consumption are progressing for electricity, energy-saving measures utilizing steam and heat have not advanced as much. One reason for the slow progress in energy-saving measures is that, compared to electricity, measuring steam is difficult, making it hard to grasp the energy-saving effects. The steam used in factories incurs losses due to heat dissipation from pipes and steam leaks after being produced in boilers. Ultrasonic flow meters for steam can be easily installed without construction, allowing for the visualization of steam flow in factories and equipment where installation has previously been difficult, without the need for equipment shutdown during flow meter installation. Furthermore, by establishing an energy management system, it enables energy savings and optimization of energy use throughout the entire food factory.

• Ultrasonic Flow Meter

In chemical plants and factories, efforts to save energy and visualize electric energy usage have already progressed, making it difficult to achieve further reductions. On the other hand, when it comes to steam energy, visualization and measurement are more challenging compared to electricity, leading to delays in energy-saving initiatives. The thermal energy from steam is utilized in various aspects of the factory, and optimizing the use of thermal energy is crucial for reducing energy loss and implementing further energy-saving measures. By introducing clamp-on ultrasonic flow meters for steam, measuring the thermal energy of steam becomes easier, enabling visualization and energy management for energy-saving initiatives. Moreover, by establishing an energy management system, it becomes possible to optimize energy use across the entire chemical plant or factory, facilitating further energy-saving measures and efforts towards carbon neutrality.

• Flow Meter

In industrial infrastructure such as factories and plants, there are challenges such as the aging of plant equipment, the aging and shortage of safety personnel, and the transmission of skills and technology. As a means to address these challenges, IoT and AI technologies are gaining attention for ensuring the safe and stable operation of plants and safety operations. The Ministry of Economy, Trade and Industry is promoting regulatory reforms to encourage the demonstration of new technologies and their utilization, aiming to enhance industrial safety and productivity. At Fuji Electric, we utilize IoT and AI technologies to support the optimization of equipment maintenance, from planning maintenance strategies to monitoring equipment and proposing maintenance management measures, through our "Comprehensive Smart Safety Service." By enabling remote monitoring of factory and plant equipment, supporting maintenance management, early detection of abnormal signs, and reviewing management plans through data analysis, we facilitate the stable operation of chemical plant equipment and reduction of maintenance costs.

• Integrated operation management

The multivariate analysis tool (quality simulation) is an analytics and AI technology (analysis and optimization technology) with a wealth of achievements in manufacturing quality improvement and abnormal detection of equipment at the customer's site. It detects anomalies arising from multiple factors in the manufacturing process, determines the relationship between product quality and factors, and enables quality simulation, thereby achieving product quality improvement and yield enhancement. One of the features of this analysis tool is the ability to verify the effects of implementation early on. If existing data is available, a simple diagnosis can be performed in as little as one day through offline analysis. Even if there is no existing data, data collection can be easily facilitated by retrofitting an edge controller to the existing system, allowing for the creation of diagnostic models. We will propose a deep dive into the analysis content, the construction of an online analysis system, system operation, maintenance, and expansion while confirming the effects of implementation together with the customer.

• Business Intelligence and Data Analysis