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.
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