MIE, May 01, 2025 (News On Japan) - Across Japan, labor shortages driven by an aging and shrinking population have become a pressing challenge. In response, companies are increasingly turning to artificial intelligence to fill the gaps. One such future-oriented development is unfolding at a state-of-the-art synthetic rubber plant in Yokkaichi City, Mie Prefecture.
At this facility operated by ENEOS Materials, an unprecedented milestone has been achieved: full plant operation without human monitoring, made possible by AI-based control systems.
"This is the control room that manages the entire plant," explained Ryota Tate from the production division. Remarkably, the room is completely unmanned.
Thanks to the newly implemented AI system, the plant runs autonomously. Previously, workers were required to monitor the plant around the clock and manually adjust valves related to waste heat recovery every 15 minutes. The task involved reading roughly 20 data points and instantly deciding the optimal valve position—an act that once demanded the instincts of experienced technicians.
Now, AI replicates these skills, making real-time adjustments with no human involvement. This breakthrough marks the first time globally that a plant of this kind has achieved autonomous operation using AI alone.
"The AI keeps operations running at an optimal level, allowing us to shift our time toward other process improvements," said Tate.
In addition to boosting efficiency, the system has also cut energy use and CO2 emissions by about 40%. The driving force behind this leap? Japan’s advanced AI robotics technology.
At Nara Institute of Science and Technology, researchers have developed AI robots capable of learning through trial and error. One experiment involves teaching a robot to flip a handkerchief from its green side to its red side. At first clumsy, the robot gradually expands the red area and begins to "reward" itself—encouraging continued learning. Within four hours, it masters the task entirely on its own.
"This mechanism is very similar to how humans and animals learn through praise," said Professor Takamitsu Matsubara. "Our goal is to build AI robots that can genuinely work in place of humans."
Bridging the gap between lab and industrial site is Yokogawa Electric. Executive Officer Hiroaki Kanokogi realized that the way AI robots experiment and learn from outcomes parallels how plant workers rely on experience to operate valves. This insight inspired the application of such AI systems to real-world manufacturing.
"AI today is often flashy in virtual environments, but I wanted to see it move something real—to apply it to actual industrial plants," said Kanokogi.
By bringing together academic research and factory experience, the team made it possible to introduce AI into plant operations. The unmanned, AI-controlled factory now stands as a model for the future.
"With declining birthrates and fewer successors in skilled trades, AI could serve as an apprentice—running plants temporarily until the next generation is ready," Kanokogi added.
AI is no longer just a support tool—it’s becoming a reliable partner in the workplace. The transformation of work through AI has only just begun.
Source: TBS
