Tokuyama Improves Productivity by Migrating from MicroXL to CENTUM CS 3000

Background of This Project

TOKUYAMA Improves Productivity by Migrating
from MicroXL to CENTUM CS 3000

Tokuyama Electronic Chemicals Pte. Ltd. (TOKUYAMA) is located on the Jurong Industrial Estate in west Singapore. TOKUYAMA manufactures specialty chemicals for the electronics industry. Their Singapore plant had relied on Yokogawa's medium-scale MicroXL process control system for more than 10 years without experiencing a single failure. Due to the discontinuance of MicroXL support and the desire to improve operations with the latest technology, TOKUYAMA decided to undertake a system migration and modify its plant processes. The installation of the CENTUM CS 3000 system was successfully handled by Yokogawa Engineering Asia.

The Challenges and the Solutions

The search for Production Excellence
To improve quality and efficiency, TOKUYAMA was looking to improve the effectiveness of its operation control and monitoring functions. Another consideration was the desire to improve global competitiveness by cutting costs. With its powerful functions, improved operability, and simplified engineering procedures, the CENTUM CS 3000 process control system offered clear advantages to its predecessor.

To ensure high product quality, an existing Yokogawa gaschromatograph was integrated with a CENTUM CS 3000 field control station (FCS). This made it possible for operators of the CENTUM system to monitor data from the gaschromatograph in real time on a graphic display, allowing them to determine whether the product was of sufficient quality to proceed to the next step in the production process.

Good customer support
Engineers from TOKUYAMA and Yokogawa Engineering Asia worked together very closely to complete all the engineering work for this legacy system migration in just six months. The factory acceptance test (FAT) was completed within one week and the plant needed to be shut down for only one day. The plant was started up on schedule in early 2006 and the system has operated trouble-free since then. TOKUYAMA appreciates the high reliability of this Yokogawa system and the fact that Yokogawa Engineering Asia is situated nearby and can offer immediate support should any problem occur.

Customer Satisfaction

Mohamed Kasim Bin Daud, Manufacturing Manager:
"We are always looking for Operational Excellence. After installing the CENTUM CS 3000, we have not had a single failure of the control system. So we are now operating the plant efficiently and the productivity is very high. We appreciate Yokogawa's reliable system."

Shunkitchi Omae, Managing Director:
"We are looking to make further improvements to our operations to achieve sustainable manufacturing. So we need further advice and will work together with Yokogawa Engineering Asia."

Central control room

System Configuration