Mitsubishi Chemical Corporation uses the PI System™ to build OT data platform growing operational intelligence
- ChallengeData collection and analysis siloed, site applications and functions duplicated at each site
- SolutionsBuild an OT data platform that links the systems of 16 manufacturing sites
- BenefitsOptimized return on investment (ROI) for digital transformation
With 16 production sites in Japan, Mitsubishi Chemical Corporation (MCC) is one of the largest chemical companies in the country, and it’s one of the top five chemical companies in the world. Formed in 2017 through the merger of Mitsubishi Chemical Corporation, Mitsubishi Plastics, and Mitsubishi Rayon, MCC provides a wide range of products from petrochemicals to high-performance plastic materials and information electronics materials. But because MCC was born from the integration of three companies with long histories, each production site had a unique approach to operations data use and management. At some production sites, it took a long time to collect and organize data, and it was a challenge to integrate operations data between sites for analysis. When MCC discussed its data silos with various vendors, many suggested the PI System was the best data management platform for the job. The PI System easily links to existing systems and the latest equipment and can be used comfortably – “KAITEKI” – by everyone, from maintenance teams to management.
A custom OT data platform to break down data silos
The Mitsubishi Chemical Corporation embarked upon a digital transformation journey to gain enterprise- wide operational intelligence. The company needed to standardize data access and use, even across production sites with unique operations and equipment, so MCC built a company-wide OT data platform with the PI System at its core.
Using PI Server features – Data Archive, Asset Framework, and High Availability – as well as PI Interfaces to connect to other control systems like SCADA, MCC custom built its platform to meet its needs. The OT platform serves as a “common historian” to unify the siloed data – not only improving the efficiency of operations at production sites but also optimizing processes across the company.
MCC first deployed its new OT data platform at three production sites: Ibaraki, Mie, and Okayama, and at these sites, MCC used Asset Framework (AF) to consolidate and contextualize the manufacturing data for each facility. Since deployment, the company has seen faster abnormality detection and shortened problem resolution times at the plants.
MCC expects the successful launch of the OT platform at these sites will serve as a guide for subsequent OT platform deployments at other sites. MCC intends to extend its platform to all sites across Japan and overseas.
To support enterprise-wide deployment, MCC signed an Enterprise Agreement with AVEVA to provide support for the introduction, operation, and deployment of its OT data platform. Since MCC’s smaller sites are not in the habit of collecting data and often store data in CSV files instead of using Historian, MCC is looking forward to learning from AVEVA’s extensive experience implementing OT data platforms.
As part of its digitalization journey, MCC not only seeks to improve efficiency at production sites but also to improve worker safety and reduce workloads. Digital transformation is at the core of the Mitsubishi Chemical Holdings Corporation’s mid-to-long-term management policy, “KAITEKI Vision 30.” KAITEKI, based on a vision for 2050 and outlines goals to be achieved by 2030, the midpoint of the vision, It is a plan that seeks to balance the well-being of people, society, and planet earth. KAITEKI envisions sustainable operations that contribute to society and address environmental issues.
MCC foresees embracing more PI System components as it prepares its plants for the future. Currently, MCC is collaborating with AVEVA’s dedicated team on Event Frames (EF) utilization in a business impact workshop at the Ibaraki office.