1. Background for introducing a solution

    ‘Human operation error’ accounts for a significant portion of losses due to unexpected accidents during process operation.

    The solution integrates the operation know-how of experienced operators and implements it into a operation automation system.

    A solution that harmoniously connects the infinite potential of humans and automation technology to increase productivity.

2.PSP system is

   Know-how of experienced operators.

     - Significant loss is cause by operational error.

   Operation automation system

     - implementing operator’s know-how into a operation automation system.

   All I have to worry about is the alarm...

   No worries about mistakes...

   I can check how it's running.

   It’s convenient to operate with SOP…Wouldn’t it be nice to apply the SOP to other processes?

3.Features

   PSP system provides powerful & convenient built-in functions & tools.

   1) Drag & Drop : Drag & drop pre-created icons to place them on the flowchart.

   2) No programming : No special programming knowledge required. (Visual Basic, C++, etc. not required)

   3) Connecting with arrows : Automatic operation is possible by connecting with arrows and executing according to the execution order.

4. Strong Points

   1) The best tool for depositing industrial knowledge and experience : A convenient tool for training and learning new operators

   2) Visualize the production process : Graphical operation flow chart interface, Color, sound and other prompt modes., Supporting multi-layer nesting

   3) The programming is easy and the operator can modify the procedure. : • Step by Step, • Graphical programming

   4) Flexible, open and convenient : • Use template, • Same procedure, different tag, can use alias to associate

5. Expected Benefit

   By introducing the PSP system : Users can achieve the following benefits.

   1) Increased safety : Prevent incorrect operation procedures in advance, Pre-detection of process abnormalities.

   2) Improved product quality : Increased product quality, Improved production by dramatically reducing operating time, Off-Spec. of the product.

   3) Cost Reduction : Saving of raw materials (steam, fuel gas, electricity, instrumentation air), Inventory management savings, Reduce operator work load, Reduce engineering work load

   4) Decrease operator load : Significantly reduced number of operator’s operation actions.

6. Success Story

    Improved product quality : Achieved the goal of uniform quality by reducing operation deviation.

7. Success Story

    Batch operation time is minimized

    1) Achieved the goal of uniform quality by reducing operation deviation

    2) Minimized batch time of production. (Average operation time 12.0 hours => 9.0 hours, 12.3% decreased.)

8. Success Story

    Decrease operator load : Reduced number of human operations by more than 95%. (144 times => 5 times)