Smartening up maintenance operations for factories and plants. Supporting the visualization of equipment maintenance and the efficiency of maintenance tasks.
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.
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basic information
■What is the Comprehensive Maintenance Service? Fujielectric's "Comprehensive Smart Safety Service" is an O&M (Operation & Maintenance) service that utilizes IoT and AI technologies. It addresses issues arising from traditional, person-dependent maintenance operations and supports highly efficient business operations. It optimizes equipment maintenance from planning maintenance schedules to monitoring equipment and proposing maintenance management strategies. The various data and information collected, integrated, and analyzed through IoT and AI technologies are stored in a server system, allowing for centralized management and sharing among headquarters, branches, and various departments on-site. Additionally, it can be accessed within Fujielectric's service department, enabling the sharing of various data related to investigations, diagnostics, and support with customers. Under robust security, seamless sharing of information, data, and insights is achieved both within and outside the department. ■Providing Equipment Maintenance and Diagnostic Expertise Unique to Equipment Manufacturers, Supporting Customers with Comprehensive Assistance Fujielectric offers comprehensive support as an equipment manufacturer, providing expertise in equipment diagnostics and maintenance, conducting training sessions on product knowledge and deterioration diagnosis techniques, and collaborating with customers to develop maintenance plans regarding parts procurement, inspections, and renewal timing.
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Applications/Examples of results
■Reading meter data for patrol inspections with IoT cameras - By utilizing IoT cameras, the meter reading tasks for patrol inspections can be automated without human intervention. Remote operation is expected to reduce labor hours by up to 95%. ■Utilizing tablets for equipment maintenance and inspections; centralized management of maintenance information - The use of tablets enables a paperless environment. It allows for the standardization of maintenance tasks and centralized management of maintenance information and data. This is expected to achieve a cost reduction of up to 50% in maintenance expenses. ■Analysis and centralized management of operational information for multiple equipment - Centralized management of multiple equipment allows for early detection of equipment issues. By linking the failure status of multiple equipment to future countermeasures, a reduction in failure rates of up to 50% is expected. ■Utilization and visualization of operational data and maintenance data for equipment - By using BI tools, it is possible to reassess inspection and parts replacement timings and evaluate deterioration conditions, enabling failure and anomaly detection. This is expected to achieve a reduction in failure rates of up to 80%.
Detailed information
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■Efficiency through Operational Management Function (Cloud Remote Monitoring System) Information about the target equipment is accumulated in the cloud server system via the network from the edge controller. This enables remote monitoring, allowing for the understanding of equipment operational information and deterioration status, diagnosis of abnormal signs, and the acceleration and labor-saving of maintenance and security tasks such as patrol inspections. The online monitoring data includes alarm records, time-series measurement data as operational records, event data, and deterioration status monitoring data. This data can be collected using edge controllers and IoT cameras. The offline maintenance data includes maintenance plans such as regular inspections and work instructions, inspection records, and work performance data related to troubles. In field operations, the results are input via a tablet, which accumulates the data in the server system.
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Visualization through maintenance management functions (maintenance management support system) From managing parts information associated with equipment to planning maintenance work, recording and inspection, failure information, accumulation of related technical documents, and even schedule management among members, we realize the visualization of various tasks. We support the efficiency of equipment management operations.
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■Utilization of Data through Analysis Management Functions (BI Tools) Integrate and analyze online operational information collected from target devices and offline maintenance information related to human activities. Conduct comprehensive evaluations and health assessments based on the correlation between equipment status, environmental impact, and maintenance history. Based on these results, review and revise maintenance plans and optimize equipment operation and management.
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Company information
Providing solutions for various plants and factories such as food, chemicals, oil and gas pipelines, paper and pulp, and cleaning facilities. Our measurement and control systems have over 40 years of history since the launch of the first distributed control system in 1975. Based on our track record, we propose systems and solutions to support the latest technologies, IoT utilization, and the development of smart factories. - Steam generation heat pumps / waste heat utilization / visualization of thermal energy - Clamp-on steam flow meters / flow meters / flow sensors / thermal balance analysis - Industrial furnaces / electric furnaces / high-frequency induction furnaces / IGBT power supplies - Gas analyzers / gas measurement devices / gas analysis sensors - Predictive maintenance / anomaly detection maintenance / preventive maintenance / maintenance and prevention systems / smart security - Smart factory - MES / DCS / SCADA / edge controllers - EMS / energy management systems / visualization of energy - Smart glasses / remote work support systems - Multivariate analysis / MSPC - Engineering tools