Application example: Real-time analysis of manufacturing processes using soft sensor technology.
Enables real-time analysis of manufacturing processes with soft sensors. Achieves reduction in CO2 emissions through cost reduction and waste reduction by stabilizing equipment operation.
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.
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Related: Soft Sensor Technology (Estimation Model Construction/Calculation Tool) Estimation model construction/calculation tool for soft sensors. It automatically and continuously estimates target values that are difficult to measure in short time intervals or at regular intervals, such as sampling in manufacturing sites, and enables visualization of data and other information.
Applications/Examples of results
[Challenges Before Implementation] - The concentration of the can liquid was measured through sampling analysis, but it was difficult to detect rapid concentration changes due to non-steady operations, raising concerns that deviations from the appropriate concentration range could lead to line blockages due to crystallization. - In the continuous concentration crystallization process, over-concentration occurred without the ability to frequently measure the can liquid concentration through sampling analysis, forcing equipment shutdowns and cleaning, temporary storage and recovery of solvent recycling liquid, or disposal each time. The operator's workload also increased. [Effects of Implementation] Real-time prediction of can liquid concentration enabled detailed operational adjustments to maintain the concentration within an appropriate range, reducing the risk of line blockages and allowing for stable operations. - By establishing management values and methods for can liquid concentration and implementing monitoring controls, the occurrence of troubles was significantly suppressed. - This contributed to stabilizing equipment operations and achieved significant cost reductions through reduced loss costs from troubles and improved solvent recycling amounts. - By reducing waste, it became possible to cut carbon dioxide emissions by over approximately 100 tons annually.
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Application example: Real-time analysis of manufacturing processes using soft sensor technology.
Current Status and Challenges of DX in Manufacturing Management in the Chemical Industry
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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