Food & Beverage

Smart Factory/IIoT

Smart factory as envisioned by YOKOGAWA

Smart factory as envisioned by YOKOGAWA is a factory in which various data on 4Ms (Machine, Man, Material, and Method) in a food factory are centrally managed, factory automation and labor saving are promoted, and the following three points are realized.

1. Improvement of quality and productivity
2. Cost reduction by reducing losses incurred in manufacturing and indirect operations
3. To create an environment in which more value-added work can be concentrated

Instead of partially introducing automated equipment, the entire factory can be optimized by connecting equipment and data through IIoT utilization within the factory and constructing a foundation.

In the food manufacturing industry, in addition to the conventional challenges of achieving both "quality improvement" and "cost reduction," flexibility is required to respond appropriately to the following new challenges.

• Shift to low-volume production of multiple products due to diversified consumer needs
• Decline in working population and the succession of skills
• Adaptation to the New Normal Era (breaking out of manufacturing sites' crowded situation/manpower-based production)

To achieve the above objectives, YOKOGAWA is advocating the IA2IA (Industrial Automation to Industrial Autonomy) initiatives.
IA2IA means a shift to a manufacturing system that realizes "autonomy of operation" where the system is responsible from startup to shutdown by breaking away from processes that require constant human monitoring and interventions and where facilities learn and adapt by themselves.
For details, see the following link.
⇒ Industrial Automation to Industrial Autonomy

YOKOGAWA's consulting services

YOKOGAWA provides comprehensive consulting services by combining a variety of products based on its experience and expertise over many years and helps customers realize their smart factories.
For details, see the following link.
⇒Consulting

Effects:

(1) Automatic planning of production plans reduces the number of planning processes and eliminates dependence on individual skills
(2) Achieve unification and visualization of cost data, and clarify points that require cost reduction measures
(3) Reduce inventory loss through accurate raw material management in response to multi-product production
(4) Establishment of sign monitoring/preventive maintenance infrastructure reduces equipment downtime, number of failures, equipment restoration time, and production opportunity loss
(5) Prevention of incorrect input and reduction of incorrect work loss in multi-product production by double-checking by personnel and the system
(6) Achieve rapid traceability by integrating production results
(7) Reduce analysis time and implement quick quality stabilization measures by integrating inspection results
(8) Production process automation/labor saving for workers and reduction of on-site personnel achieved through control of production processes, equipment, and robots
(9) Identify and improve wasted energy by unifying energy consumption and facility operation results for each facility
(10) Collection/analysis of operation data achieves debottlenecking and quality stabilization

Major Package Products for Smart Factory Construction and Effects

Solutions Map

※Some of the products introduced may differ between the Japanese version HP and the English version HP.

Cost Reduction

Cost reduction is achieved through the following five points: (1)production planning support; (2)production management and cost management; (3)equipment maintenance; (4)manufacturing management; and (5)automated control and quality-stabilization

(1) Production Planning Support

Challenge

• Production planning by manual work takes time and labor

Solutions

• Automatic planning of the production plan considering people, equipment, and contamination is possible
• Highly visible user interfaces facilitate progress management of planned plans

Effects

• Realize sharp reduction of planning man-hours, shortening of planning time, and elimination of dependence on individual skills
• Realize reductions in production costs, opportunity losses, and in-process inventory through efficient planning in line with operations

(2) Production management and Cost management

Challenges

• Difficulty in calculating costs such as profit analysis and cost variance analysis
• Difficult to grasp accurate costs, results, and losses
• Manufacturing is unable to follow changes in sales plans due to demand fluctuations

Solutions

• Accurate performance data collection from manufacturing sites and cost accounting enable grasping of costs and losses
• Achieve response to fluctuations in supply and demand through collaboration between manufacturing, sales, and inventory information, as well as high-speed MRP
• Planning that reflects production conditions enables smooth reflection of plan revision to manufacturing sites

Effects

• Realize cost reductions by setting standard costs, grasping actual costs, and simplifying cost variance analysis
  In addition, realize reduction in man-hours required for the above-mentioned work
• Reduce production opportunity losses by promptly responding to changes in supply and demand
• Reduce inventory losses through appropriate inventory management

(3) Equipment Maintenance

Challenges

• A sudden facility failure has resulted in line shutdown, time for restoration required, and loss of opportunity
• Maintenance parts management cannot be performed correctly, resulting in excessive parts inventory
• Regular inspections to prevent sudden breakdowns lose touch with the actual state of breakdowns and lead to excessive inspections, resulting in a shortage of man-hours
• It takes time to plan and review the inspection plan

Solutions

• Integrated management of information related to equipment maintenance, such as past failure data, and prompt formulation of inspection plans
• Cooperation between centrally managed information and facility operation data enables CBM and eliminates surplus inspections
• Continuous monitoring of equipment vibrations and temperatures enables detection of equipment malfunctions and precautions against failures without periodic inspections
  ※CBM：Condition Based Maintenance

Effects

• Stable operation of facilities realizes production as planned and reduces losses due to waste loss
• Realization of CBM reduces equipment shutdown time, number of failures, and equipment restoration time
• Reduce maintenance management man-hours, such as paper management and transcription, by centralized management of information
• Efficient facility inspection and reduction of inspection man-hours by sign monitoring

(4) Manufacturing Management

Challenges

• First-in, first-out management of raw materials is not properly implemented, and waste loss is generated
• Disposal loss due to work errors such as incorrect weighing and incorrect input
• Tracing in the event of quality abnormalities, facility troubles, or work errors takes a long time, and prompt response is not possible
• The automation facility has been introduced, but man-hours of workers can not be reduced

Solutions

• Achieve appropriate reserve management and accurate inventory management from receipt to use-up
• Realize computerization of information such as on-site results manually managed by paper etc.
• Manage standard operation procedures by the system, and realize guidance of procedures and double-checking by the system and personnel

Effects

• Reduce raw material inventory by improving inventory control accuracy and reducing expired materials
• Electronization of site performance information realizes tracing time reduction and prevention of inconsistency with inventory information due to transcription errors
• Reduce work errors by workers and reduce waste loss
• The system supports instructions to automation equipment and achieves overall manufacturing site optimization

(5) Automated Control and Quality-Stabilization

Challenges

• Automated equipment has been introduced, but it takes time to adjust for each manufacturing item
• The quality is not stabilized, and the cause is not known
• Inefficient production due to line shutdowns and deviated supply timing of materials etc. caused by equipment abnormalities

Solutions

• Realize automatic control based on recipes that have reached manufacturing items through the introduction of DCS
• Stabilization of quality by the measure of visualizing 4Ms fluctuation factors
• Monitoring the signs of equipment malfunctions and realizing JustinTime manufacturing through the cooperation of automated equipment and materials supplies

Effects

• Shorten downtime when changing manufacturing items
• Achieve optimal operation by ensuring stable quality while following changes in manufacturing sites
• Reducing production line shutdowns and achieving stable plant operations

　　　　　　　　　　　
An example of how a production/cost management system can be used for cost reduction

You can get greater effects of cost reduction by implementing a production management and cost management system,
enabling cost visualization and cost variance analysis, and implementing targeting activities for cost reduction

Major Package Products for Cost Reduction and Challenges

※Some of the products introduced may differ between the Japanese version HP and the English version HP.

Traceability

In the food manufacturing industry, everyone may probably be working to establish a food chain that provides even "safer" and more "secure" products.
With established traceability, YOKOGAWA supports food manufacturers by immediately tracing back the production results to determine the causes of any inquiries about the products after shipment and to enable prompt responses to such inquiries.

Environment surrounding food production

Due to heightened health awareness, the introduction of risk-management systems such as HACCP, and the need for food diversity, interest in food "safety" is rising, and "quality" requirements are becoming more stringent not only for the food manufacturing industry, but also for companies involved in food products.

Allergen issues

• What are the contained allergens?
• Is the allergen content of raw materials/production materials acceptable?
• Is there a possibility of allergen contamination?

Halal certification

• Are they compliant with Halal certification?

Challenges in the Food Manufacturing Industry

• Rapid response to inquiries from the market
  （establishment of a system for responding to inquiries and indicated items)
• Quick response to quality problems caused by abnormalities in raw materials and manufacturing processes
  　Integrated management of information from development to manufacturing and from manufacturing to supply
  （Establishment of a Trace Forward/Traceback System)
• Shortened life cycle of products:
  A large amount of information needs to be managed due to the small-scale production of a wide variety of products

YOKOGAWA's traceability solutions

Traceability systems are classified into production traceability systems and distribution traceability systems.
YOKOGAWA provides solutions primarily related to traceability in production.
Using production management systems and manufacturing management systems, we realize integrated management of information about manufacturing and support a range of operations from procurement to manufacturing and shipment.
In addition to responding to inquiries from consumers, we provide quality management and quality assurance solutions aimed at creating quality that supports food "safety" and "security."

(1) Production Management:
　　Managing production plans and raw material procurement plans, such as what to make and when, and to what extent
(2) Manufacturing Management:
　　Assisting to prevent work errors such as incorrect input, and managing production results such as what was made and how it was made
(3) Quality Management:
　　Management of quality data such as analytical values and cleaning records in the inspection of raw materials and products
(4) Equipment Maintenance:
　　Management of equipment conditions such as temperature in the manufacturing process

Major Package Products and Solutions for Building Traceability Systems

※Some of the products introduced may differ between the Japanese version HP and the English version HP.

Food Defense

Total food defense to strengthen security on food factory premises and in factories

Contamination in the factory is one of the major causes that undermine confidence in the company.
In order to protect against deliberate contamination of food products, YOKOGAWA is developing mechanisms to prevent food products from becoming contaminated before something happens and to track food products after it happens, and supports food production sites to protect food safety.

• Access control　　　　　　 :Entrance to the premises only by the parties concerned
• Entrance and Exit control　: Entry into the factory and entry into the manufacturing process by only related persons.
• In-process monitoring　　  : Control of traceability of raw materials/products and video recording of in-process operations

In order to strengthen food safety and security, we also support food safety perspectives such as appropriate temperature and hygiene control.
For details, see the following links.
Traceability / HACCP

COVID-19 countermeasures

In recent years, the outbreak of COVID-19 has forced the food manufacturing industry to take various measures, such as controlling the physical condition of field workers and avoiding the three Cs (Closed spaces, Crowded places, and Close-contact settings) at factories.
We provide a temperature measurement solution that can detect the temperature of many people at a time safely and speedily and can track individuals.
This solution can identify individuals early who have developed a fever and support measures to prevent disease clusters from occurring at factories.

Supporting the acquisition of Food Safety Systems Certification Standard FSSC22000

Following recent social trends, there is an increasing number of cases where suppliers are requested to obtain certification for food safety and hygiene management standards.
We assist in addressing the requirements of Food Defense, Biovigilance and Bioterrorism, described in Chapter 18 of Prerequisites Program ISO/TS22002-1: 2009 for Food Safety Systems for Food Manufacturing FSSC 22000.

Defense in the manufacturing process

|Access control | Recording of work videos | In-process zoning control | Ingredient/Chemical storage linking |

Access control

Card/fingerprint authentication system prevents outsiders from entering.
Surveillance cameras also monitor intrusion from outside.

Recording of work videos

Using the Manufacturing management system , the operation of inputting raw materials is recorded with the direction of web cameras changed to the input port timely.

In-process zoning control

Establish a system to detect entering and exiting in the production process and not allow anyone other than those concerned to enter the room.

• Management of staying hours：If staying time exceeds the preset time, it is judged to be abnormal
• Anti-pass back：This function prevents entry and exit without card operation
  If you do not follow the procedures of "Entry" and "Exit," it is judged unauthorized use of the card

Ingredient/Chemical storage linking

Image detection technology detects the removal of goods from the raw material and chemical warehouses and records the images.

Major Package Products for Food Defense

• Manufacturing Management Package CIMVisionLIBRA
• Operation Efficiency Improvement Package Exapilot
• Monitoring camera FIELDEYE

※Some of the products introduced may differ between the Japanese version HP and the English version HP.

HACCP / FSSC22000

This section introduces hygiene management solutions at food factories, such as those for HACCP, for FSSC22000*, for food quality management, and for sanitary equipment, as well as efforts to reduce food loss.
*FSSC22000: International Standard for Food Safety Management Systems

Complying with HACCP Requirements

The introduction of HACCP is expanding year by year in many countries worldwide.
As imports and exports of food become increasingly active in the future, HACCP, a method of managing international standards, is crucial for maintaining food safety.
In accordance with the Guideline of 7 principles and 12 steps stipulated by the Codex Alimentarius Commission, it is required to monitor and control the process from stocking raw materials to supplying products.
YOKOGAWA supports HACCP compliance from the standpoint of Step 6: Conducting a hazard analysis, Step 7: Determining Critical Control Points, Step 9:Establishing monitoring system, Step 10:Establishing corrective actions, Step 11:Establishing verification procedures, and Step 12: Establishing documentations ＆ record keeping.

Efforts to Reduce Food Loss

As food loss reduction has become an issue worldwide, food-related businesses are required to take measures to reduce food loss, such as using raw materials without waste and extending the shelf life of products.
YOKOGAWA supports efforts to reduce food loss from the perspectives of "quality-risk reduction" and "appropriate inventory control".

Sanitary Sensor and Analyzer

YOKOGAWA provides sanitary sensors and analyzers to meet stringent hygiene requirements for the food manufacturing industry.

• Hygienic Pressure Transmitter
• Process Analyzers

Major Package Products for Ensuring Food Safety

• Manufacturing Management Package CIMVisionLIBRA  
• Operation Efficiency Improvement Package Exapilot
• Laboratory Information Management System LIMS
• Realtime Operational Information Management Package PI System
• Plant Information Management System Exaquantum
• Panel Mount Recorders Touch Screen GX10/GX20

※Some of the products introduced may differ between the Japanese version HP and the English version HP.

Equipment Maintenance

YOKOGAWA provides solutions to preventing failures, factory stability, safe operation, and reducing production opportunity loss, including an equipment maintenance system that supports facility ledger management and maintenance planning, as well as a machine learning-based abnormal prediction detection system.

(1)Equipment maintenance system that supports maintenance operation

Challenges

• The optimal replacement cycle of equipment parts is unknown, and the inspection cycle is unknown
• It takes time to respond to restoration by a sudden drop in performance of production equipment or stoppage

Solutions

• Visualization of fault history enables to determine the replacement cycle of equipment parts and create an optimal maintenance plan
• Integrated management of equipment-related data ensures proper equipment spare parts inventory control

Effects

• Reduction in man-hours through review of periodic inspection work
• Reduce sudden equipment failures and reduce production opportunities loss
• Unified management of equipment and maintenance information reduces indirect operations such as paper management and transcription
• Reduction in the time required to respond to equipment problems

(2)Equipment maintenance by detecting signs of abnormal conditions

Challenges

• Major opportunity loss was caused by a sudden failure or line stoppage of production equipment
• Detection of abnormalities in production equipment was delayed, forcing product disposal and recall

Solutions

• Detecting minor abnormalities in equipment and raising the alarm before a failure occurs enables prevention of failure
• Continuous monitoring of equipment vibration and temperature to detect signs of equipment malfunction
• Analysis of collected data enables quick identification of the cause of failure

Effects

• Reduce sudden equipment failures and reduce production opportunities loss
• Reduce quality risks caused by equipment and process abnormalities
• Reduction in the time required to respond to equipment problems

Major Package Products for Equipment Maintenance and Challenges

※Some of the products introduced may differ between the Japanese version HP and the English version HP.

Energy Management

Visualization of energy consumption not only realizes energy savings, but also helps improve operations by discovering waste and dispersion.

Challenges:

• difficulty in identifying improvement points for energy management
• Energy management is being promoted, but we don't know what to do next
• In addition to saving energy in utilities, we want to link with production processes to reduce overall production costs

Solutions:

• Support for discovering waste and setting the optimal KPI
• Energy consumption rate per product and lot realizes clarification
• Realize support for energy conservation activities throughout the entire production process by integrating energy information and production information

Effects:

• Visualization of energy consumption throughout the plant enables monthly comparison and identification of improvement points
• Investigation of energy-saving measures and measurement of effects can be made easier by grasping the trends of each line
• Linking with production information enables analysis of the causes of energy efficiency deterioration in the manufacturing process.
• Comparison of the same manufacturing item with other factories enables optimal production planning from a utility cost perspective

YOKOGAWA's Kofu factory, located in Japan, has achieved significant results in energy-oriented improvements, focusing on the IT-based visualization system and the systematic operation, and has attracted attention as a model plant for energy management.
For details, see the following link
⇒Kofu factory

Major Package Products for Energy Management

• Production Scheduler FLEXSCHE
• Factory Energy Operation Supporting System Enerize E3
• Energy Management
• Data Logging Software GA10

※Some of the products introduced may differ between the Japanese version HP and the English version HP.

Sensors for Food Factories

Major sensor products for food factories

■Sanitary sensor

• Hygienic Pressure Transmitter

■Other sensors

• Distributed Temperature Sensor
• Tunable Diode Laser Spectrometers
• Sushi Sensor
• Level Meters
• Magnetic Flowmeters
• Vortex Flowmeters
• Coriolis Mass Flowmeters

Application example of Coriolis mass flowmeter

We change the common sense that "foam" in the mass flowmeter is not good.

Challenge

• If air bubbles enter the existing mass flow meter it becomes over range

Solution

• Measurement is possible even for fluids containing 10% or more bubbles

Effect

• Continuous measurement is possible, which reduces the loss of products discarded due to unknown blending volume due to bubble contamination

※Some of the products introduced may differ between the Japanese version HP and the English version HP.
※Please note that the mounting port differs depending on the area and the standard.

Through extensive experience built on long-term relationships with IA industry leaders, Yokogawa offers the advanced products and custom solutions that food and beverage manufacturers need to create a quality product. Brewery operations and sugar manufacturing serve as two examples.

| Brewing Applications | Sugar Production Applications |

Brewing Applications

Malt Silo

• Raw Material Handling

Brew House

• Raw Material Handling
• Mashing
• Batch Management
• CIP (Cleaning In Place)

Fermentation/Lager

• Fermentation/Lager
• Racking
• Fermentation Management
• Yeast Management
• CIP (Cleaning In Place)

Filtering

• Filteration
• Beer Movement
• CIP (Cleaning In Place)

Bottling/Canning

• Packaging
• Warehousing

Inspection/Shipping

• Quality Control

Affiniated Sugar Melt

• Weighing Control
• Affination

Purification

• Carbonation
• Filter Machine Control
• Ionic Exchange Resin Control
• Decolourization

Concentrate and Crystallization

• Concentration
• Vacuum Pan Control
• Centrifuge Control

Centrifugal

• Drying Control

Packaging

• Packaging Management