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The OpreX Profit-driven Operation solution is focused on solving plant performance issues in real-time.

Japan: Yokogawa Electric Corporation has received the Global Customer Value Leadership Award for Integrated Performance Management from global market research and consulting company Frost & Sullivan as part of their 2019 Best Practices Awards. Announced on July 29, the award recognizes how Yokogawa’s OpreXTM Profit-driven Operation solution helps customers in the process industries deliver more profitable operations through real-time production performance improvements that are aligned from the management level to the plant floor.

Frost & Sullivan presents Best Practice Awards to companies that have demonstrated outstanding leadership in technology innovation and the strategic development of products and services for regional and global markets. To decide these awards, Frost & Sullivan analysts independently conduct interviews, analyze data, and carry out research in many different fields. For the Global Customer Value Leadership Award, Frost & Sullivan evaluates companies based on several factors that concern the two key aspects of customer and business impact.

The OpreX Profit-driven Operation solution that earned this recognition takes the production performance indicators that are conventionally monitored by plant management on a weekly or monthly basis and breaks them down to the technical and operations levels using industrial best practices. It then calculates and displays them in real time by utilizing the big data from the distributed control system (DCS). By providing performance alarms, guidance messages, and a performance balance score, the solution helps operators and engineers stay aligned and promptly improve production performance. In addition, consulting services are provided to uncover more fundamental production performance improvements by referring to the historical production performance indicators recorded over time.

By merging Yokogawa’s expertise in Operational Technology (OT) and Industrial Internet of Things (IIoT) technology with the process industry best practices of its subsidiary KBC, Yokogawa enables production performance optimization over the lifecycle of a customers’ plant.

In the award write-up, Frost & Sullivan’s Industry Director for Automation and IIoT, Muthuraman “Ram” Ramasamy states, “In a market with several solutions that help customers make more sense of big data, Yokogawa chose to take an uncharted path and create a market category of its own. The innovative category is Integrated Performance Management. The OpreX Profit-driven Operation solution pulls in real-time data from distributed control systems to structure a KPI dashboard that outlines the performance of plant management objectives. Yokogawa’s ingenuity in leveraging this real-time big data from the DCS differentiates it from its peers. The OpreX Profit-driven Operation solution is expected to become the standard for global plant operations because it balances the tradeoffs between KPIs and provides one solid operational health score.”

Yasunori Kobayashi, General Manager of the Solution Development Department in Yokogawa’s Digital Enterprise Business Headquarters, commented, “Yokogawa is supporting its customers’ Digital Transformation journey by integrating OT, IIoT technology, and industry best practices. OpreX Profit-driven Operation is a leading example of that, so we are delighted that this unique value has been so highly evaluated by Frost & Sullivan. The response from our customers has also been very positive and we look forward to helping them deliver profit improvement across their entire plant.”

Yokogawa has structured the following SPIs to help customers measure, monitor, and manage:

Production:

  • Feed and products complying with the plan
  • Capacity utilization
  • Minimization of off-spec products or reprocessing of slopped products

Profit:

  • Maximization of higher value product yields
  • Minimization of quality give away
  • Supplemental materials than energy for manufacturing of products
  • Loss and flaring

Energy:

  • Energy consumption (Fuel, Steam, Electricity)
  • Energy performance (Furnace, Heat Exchanger, Distillation column, Pipe)
  • Utility network (Fuel gas, Hydrogen, Steam, Electricity)
  • Carbon emission

Reliability:

  • Plant availability
  • Equipment availability and efficiency
  • Critical operating points of each equipment

Safety:

  • Safety risk factor of critical equipment
  • Violation of environmental regulations
  • Loss of containment
  • Flammable and toxic gas content
  • Lost time injury frequency rate
  • First aid injury frequency rate

Each year, Frost & Sullivan presents this award to the company that has demonstrated excellence in implementing strategies that proactively create value for its customers with a focus on improving the return on the investment that customers make in its services or products. The award recognizes the company’s unique focus on augmenting the value that its customers receive, beyond simply good customer service, leading to improved customer retention and customer base expansion.

Frost & Sullivan Best Practices awards recognize companies in a variety of regional and global markets for demonstrating outstanding achievement and superior performance in areas such as leadership, technological innovation, customer service, and strategic product development. Industry analysts compare market participants and measure performance through in-depth interviews, analysis, and extensive secondary research to identify best practices in the industry.

Founded in 1915, Yokogawa engages in broad-ranging activities in the areas of measurement, control, and information. The industrial automation business provides vital products, services, and solutions to a diverse range of process industries including oil, chemicals, natural gas, power, iron and steel, and pulp and paper. With the life innovation business, the company aims to radically improve productivity across the pharmaceutical and food industry value chains. The test & measurement, aviation, and other businesses continue to provide essential instruments and equipment with industry-leading precision and reliability. Yokogawa co-innovates with its customers through a global network of 113 companies spanning 60 countries, generating USD 3.6 billion in sales in FY2018.

For over five decades, Frost & Sullivan has become world-renowned for its role in helping investors, corporate leaders and governments navigate economic changes and identify disruptive technologies, Mega Trends, new business models and companies to action, resulting in a continuous flow of growth opportunities to drive future success.

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