December 4, 2020Management

AGC Develops Integrated Operation Management System for Chemical Plants

Aims to digitize plant operation know-how

AGC Inc.(AGC), a world-leading manufacturer of glass, chemicals and high-tech materials, has announced that it has developed an integrated operation and quality management system for chemical plants called “CHOPIN.” The full-scale deployment of the system will begin in 2021, and by 2023, the system will be expanded to all chemical plant facilities at the Chiba and Kashima plants, with the aim of fully digitizing operation know-how.

Plant employees using CHOPIN Plant employees using CHOPIN
Chemical plants use a combination of multiple management systems, including plant control systems, plant information management systems for recording and managing operational conditions, and systems for managing product quality. Conventionally, plant operators use handwritten notes to share information and to give instructions on operations, which has been a major drawback as it requires a great deal of time and effort.
CHOPIN is a system that enables integrated management by digitizing all information related to plant operation that was previously conducted on multiple systems, as well as operator task instructions, task logs, and workflow information. AGC has developed this system for the centralized management of all data related to plant operation. In 2019, AGC started test runs at a high-performance fluorinated resin manufacturing plant at the Chiba Plant, which has reduced working hours by more than 11 hours per day. Furthermore, the introduction of this system has enabled the plant to operate stably, resulting in an annual cost savings of more than 100 million yen.

In the future, AGC plans to promote the use of real-time data using mobile handsets so that inspection data of plant floor work can be input into the operation management system sequentially.

Under its AGC plus management policy, the AGC Group is committed to promoting Smart AGC, which aims to reform business processes through digital technology. By utilizing big data from every aspect of operations including manufacturing, R&D, and sales, AGC continues to pursue the goals of achieving even more efficient operations and providing its customers with new added value.

Reference Information

An outline of this system is as follows.
・A hybrid of cloud and in-plant systems enables continuous operation even in the event of a cloud or public network failure
・Workflow dashboard: Sharing progress on the plant floor in real time
・Operation dashboard: Centralized management of each plant’s KPIs
・Yellow cards (operational near misses): Sharing operational near-miss incidents and using the information to pass on technologies and skills

Workflow dashboard Workflow dashboard
Kazumi Tamaki, General Manager, Corporate Communications & Investor Relations Division
AGC Inc.
Contact: Yuki Kitano
TEL: +81-3-3218-5603