Announcement of the Construction of a People and Eco-Friendly Smart Factory Utilizing Digital Twin Technology and Geothermal Energy
Jan 21, 2020
ROHTO Pharmaceutical Co., Ltd. (Head Office: Osaka City; President: Masashi Sugimoto) is pleased to announce the expansion of a smart factory with a focus on people and the environment at the Ueno Techno Center in Mie Prefecture, which serves as ROHTO Pharmaceutical's mother factory (scheduled for completion in 2022). The new factory aims to realize a "smart factory" that is "friendly to both people and the environment" by fully utilizing IoT (Internet of Things) and AI (Artificial Intelligence) to create a digital twin environment※１ and harness renewable energy sources such as geothermal energy and the latest energy-efficient facilities.
※１It is a system that utilizes technologies such as IoT to transmit real-world information to a virtual space in near real-time, replicating the environment of the real world within this virtual space. By harnessing the dual spaces of reality and virtuality in the Digital Twin environment, it enables not only real-world monitoring but also simulations. This allows for efficiency, optimization, and even the prediction of future equipment failures in the real world, facilitating early maintenance.
(Photo left: Current Ueno Techno Center, Photo right: Conceptual drawing of the new factory building)
Background of Expansion
In response to the growing trend of self-medication and increased demand for high-quality over-the-counter pharmaceuticals and high-performance skincare products in the beauty segment, ROHTO Pharmaceutical has decided to construct a new factory building to meet these expanding needs. The new factory, compared to the existing facilities, will enable a 1.5-fold increase in production capacity. The new factory will utilize IoT and AI technologies, advancing the initiatives ROHTO Pharmaceutical has undertaken for workstyle reform and environmentally-friendly practices. It aims to be a "smart factory" that aligns with both the concept of being "friendly to both people and the environment."
Key Features of the Smart Factory Building
People-Friendly Factory
Ensuring the safety and efficiency of workers through collaboration between robots and humans
Establishment of a centralized management system that utilizes IoT devices such as omnidirectional cameras and sensors to detect abnormal behavior, unauthorized entry into hazardous areas, and proximity to manufacturing equipment, notifying not only the workers themselves but also management in real-time to prevent workplace accidents.Introduction of collaborative robots to create production lines that leverage the strengths of both humans and robots, aiming to eliminate waste and streamline work processes.
Enhancing Productivity Through IoT and AI
Achieving increased productivity through digitalization using IoT and AI technologies that visualize people, equipment, and processes, ensuring stable product quality and process efficiency.
Data collection on human activities, movement patterns, and physical strain using sensing technology based on quality, cost, and delivery requirements. This data will be further enhanced in the virtual space using AI and deep learning, allowing for simulations of work, movement patterns, line configurations, and strain. This will lead to standardized work processes, enabling the production of high-quality products consistently.
Environmentally-Friendly Factory
(Photograph: Mechanism of geothermal utilization)
Reducing energy consumption by 20% compared to the existing factory through the utilization of renewable energy sources such as geothermal energy※２, solar power, and the introduction of energy-efficient equipment. The transition to eco-friendly materials will also be carried out progressively.
※2: Geothermal energy utilization is a system that uses this temperature difference to enable efficient air conditioning operation (heating and cooling), since the ground temperature is lower than the outside air temperature in summer and higher than the outside air temperature in winter.
Domestic and International Production Base
The new factory building will serve as a production base not only for domestic production but also for overseas markets. It will establish a quality assurance system compliant with PIC/S GMP (Pharmaceutical Inspection Convention and Pharmaceutical Inspection Co-operation Scheme) in both the existing and new factory buildings.
About Ueno Techno Center
The Ueno Techno Center, which began operations in 1999 and has now been in operation for 20 years, produces ROHTO Pharmaceutical's flagship products, including V ROHTO Premium eye drops, and skincare products such as Hada-Labo Gokujyun Lotion. It serves as a mother factory, responsible for quality control and logistics.
Address: 7-3 Yumegaoka, Iga City, Mie Prefecture, 518-0131
Phone :0595-26-2111