Smart AGC: Transforming Business Processes through Digital Technology
The AGC Group provides application solutions for architectural, automotive, and display glass as well as chemicals and other high-performance materials to customers around the world. Under its AGC plus 2.0 management policy, the AGC Group is committed to promoting Smart AGC, which aims to transform business processes through digital technology. AGC has been improving the efficiency of its business processes by introducing digital technology not only in manufacturing and R&D but also in such back-office operations as purchasing and logistics departments.
Glass factories procure silica sand and other raw materials needed to produce glass, as well as caustic soda and hydrochloric acid used to treat wastewater, on a daily basis. To cope with complex production plans, workers must check inventory levels, review procurement plans, and adjust for storage and usage plan changes every day, which can be very time-consuming.
AGC developed a new system—the Smart Inventory System—for automatically managing raw materials. This system became fully deployed as of April 2021 at the Group’s Kansai Plant, Takasago Factory (in Takasago City, Hyogo Prefecture), and the Amagasaki Factory (in Amagasaki City, Hyogo Prefecture). By introducing DX (digital transformation) into procurement operations such as inventory checking, procurement planning, and ordering—previously all done manually—the Group will promote technology and skill sharing among workers and expects to reduce labor by 1,000 hours per year. Going forward, AGC will look to introduce this system to other plants with a focus on its glass business in Japan.
Raw Materials Inventory Management System
Tank Inventory Management System
The Smart Inventory System is AGC’s new system for automatically managing raw materials. All raw material containers include RFID tags linked to the raw material data. Sensors installed at warehouse entrances and exits collect the tag information to monitor raw material storage and usage history data in real time.
AGC has also developed a system for remotely monitoring tanks containing caustic soda and other raw materials that require visual management by workers. The system digitizes the data from measuring devices installed on the tanks and uses this data to place orders automatically.
Dashboard (Japanese) Click to enlarge Real-time Remaining Amount Display of Raw Material Tank
System Configuration Click to enlarge
The Smart Inventory System raw material automated ordering system includes two systems: a raw materials inventory management system and a tank inventory management system. AGC jointly developed the tank system’s cloud-based inventory management system for procurement operations DX with Contec. The IoT system developed for the Smart Inventory System includes a dashboard for viewing remaining amounts and automatically updates inventory tables for automatic ordering from suppliers. Sensors and gateway devices installed on the tanks also enable real-time remote monitoring of remaining tank amounts through mobile connections. Contec’s CONPROSYS™ TM (Telemeter) Series is used on these gateway devices.
By introducing DX (digital transformation) into procurement operations such as inventory checking, procurement planning, and ordering—previously all done manually—the Group will promote technology and skill sharing among workers and expects to reduce labor by 1,000 hours per year. Going forward, AGC will look to introduce this system to other plants with a focus on its glass business in Japan.
Complete IoT System Creation Environment CONPROSYS provides one-stop IoT services for operation monitoring and visualization of existing factory equipment in various industries.
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