Drones fly the skies over the plant. Image data is accumulated, collected from high above and inside facilities, where visual inspection is difficult. Sensors installed on some equipment regularly collect and monitor information such as temperature and vibration. AI systems analyze this data for inspection and trouble detection purposes.

A new service of detecting anomalies in pipelines from noise or the speed of corrosion, as well as new concepts, such as the “digital twin” where the data of an actual plant and those of a virtual plant on a computer are linked, have been created. This is the new high-tech normal of equipment maintenance.

The tide of digitalization is sweeping over traditional facilities. This comes at a time when it has become more difficult to ensure the safety of plants while at the same time improving their productivity.

As equipment ages, man hours required for maintenance and inspection work increase, but the number of workers operating plants or ensuring their safety are decreasing. Operating a plant for longer without interruption helps enhance profitability because companies can avoid missing manufacturing opportunities. However, if this situation continues, it becomes difficult to not only maintain or improve productivity, but also ensure safety.

Structural changes surrounding plants and innovations in digital technology have driven moves to look at equipment maintenance from a fresh angle and the ongoing shift to the digital transformation strategy, which adds new value to existing businesses.

Responding to new needs

There are now plant operators who have adopted top-down management strategies, instead of simply leaving operational improvement to plant staff. More prominent these days, however, are moves where the growth of new types of equipment maintenance needs is regarded as a business opportunity.

For instance, an increasing number of companies in other industries, not just conventional equipment makers and engineering companies, are entering this area. There is also growing moves for companies to collaborate in projects involving internet of things technology at their plants.

Startups with unique know-how in areas such as sensors and big data analytics are emerging as key players in the field of smart maintenance and are increasingly making their presence felt.

There are many companies in Japan that have developed such technology for the automobile and electronics industries, though they have not yet entered the aviation field. Electrification could bring a paradigm shift to the aviation industry. Partnerships and alliances to be established based on technical innovation for electrification could potentially create business opportunities for Japanese companies.

Reduction of CO2

Boeing Co. Chief Technology Officer Greg Hyslop visited the Ministry of Economy, Trade and Industry in Tokyo on Jan. 15 and met top executives from 10 companies and research institutes including GS Yuasa Corp., Toray Industries Inc. and Mitsubishi Heavy Industries Ltd.

“Japan is a perfect place to look for business partners. I’d like to exchange opinions on a technology plan that would form the future of the aviation industry,” he enthusiastically told the executives.

On the same day, Boeing reached an agreement with METI on technical cooperation for the future aircraft industry. The agreed points cover a wide range of areas, including composite production and manufacturing automation. Among them, the electrification of airplanes is especially anticipated.

Just as with automobiles, airplanes are not completely unrelated to the trend of carbon dioxide emissions reduction. While the air transport passenger demand is expected to grow — centering around Asia — 2.4 times by 2037, parties including the International Air Transport Association aim to halve the CO2 emissions in 2050 to below 2005 levels. Airplane manufacturers have advanced development of lesser fuel consumption airframes, but that alone won’t provide a complete solution.

Efficiency, weight reduction

Realizing fuel consumption reduction through electrification requires solving issues that are classified broadly into improved energy efficiency and weight reduction.

To that end, it’s important to mobilize high-performance motors, lithium ion batteries, magnetic materials and superconductive transmission technology. Additionally, an innovative change from the stages of material development and fundamental technology would be a key.

Component makers have already embarked on research and development in anticipation of electrification. For instance, Tamagawa Seiki Co., a developer of motors and sensors for airplanes, expects growing demand for motors to be used around engines. Mitsubishi Electric Corp. seeks to utilize its power electronics technology such as power semiconductors in this area. Nabtesco Corp., manufacturer of flight control actuation systems, anticipates its devices would be used more if hydraulic drive systems go electric. But for these to be realized, it’s essential to implement downsizing and weight reduction, and improve reliability.

Local municipalities have high expectations for next-generation mobility such as electric vertical takeoff and landing aircraft (eVTOLs) and drones as they could provide solutions to regional issues, stimulate regional economies and promote tourism.

These vehicles are expected to play a wide variety of important roles in different situations. For instance, they could be utilized for students and workers to commute to avoid traffic congestion in urban areas, while they could become familiar and convenient means of transport on remote islands and mountainous areas, as shown in the METI video. Additionally, they could be used for logistics and emergencies in the event of a disaster.

Future urban transportation

With demonstration flights of flying vehicles expected to begin in fiscal 2019, many local governments are working to host them.

At a 2018 briefing session by U.S. major car dispatch company Uber Technologies Inc. on its flying taxi project, Tokyo Gov. Yuriko Koike said, “I’m looking forward to the new initiative opening up a future of urban transportation.”

Under the governor, who is very much in tune with innovative technology and who has had a wide range of exchanges with global management executives, the level of commitment of the metropolitan government can be observed from the amount of support it provides to makers that develop relevant technology.

The Tokyo Metropolitan Government decided to provide SkyDrive Inc., the first company in Japan to develop an eVTOL, with up to ¥500 million in subsidies over three years and three months. The company was founded mainly by members of Cartivator, an organization established by volunteers to realize a demonstration of a flying vehicle in 2020 when the Tokyo Olympic and Paralympic Games are held.

SkyDrive President Tomohiro Fukuzawa, who also serves as a co-representative of Cartivator, said, “We are hoping for our vehicles to be used at the times of disasters, for sightseeing, as well as transportation purposes in Tokyo, where more and more foreign tourists visit and an increasing number of people come to live.”

The Office of the Governor for Policy Planning at the Tokyo Metropolitan Government has expectations for the early realization of flying vehicles.
“The social implementation of flying vehicles would not only help them become transportation means for the elderly, but also lead to reduced travel time in urban areas,” it said.