Smart Manufacturing Kaizen Level: Systematic Digitalization

At SPS 2025 in Nuremberg, Mitsubishi Electric and its partners presented a practical approach to advancing automation, data analysis, and energy efficiency with the Smart Manufacturing Kaizen Level (SMKL) concept.

SMKL describes how companies can transition from traditional plant operations to networked, data-driven manufacturing in clearly defined steps. This process extends from the management to the production level.

Top Floor – Data Analysis and Visualization with Genesis V11

Mitsubishi Electric presents an open system that bundles, visualizes, and analyzes data from a wide variety of sources in real time with the IIoT platform Genesis V11 (ICONICS). Dashboards and KPIs can be viewed in a browser or on mobile devices. This provides the perfect basis for data-driven decisions, energy optimization, and preventive maintenance.

The open system architecture allows production and business data to be seamlessly connected without media breaks or proprietary interfaces.

Edge – Intelligent Control and Operation

At the edge level, the new MX controllers combine control, motion control, and communication in a single platform. Thanks to time-sensitive networking (TSN), they synchronize machines and systems precisely in the microsecond range.
Integrated IT functions enable direct data exchange with cloud and MES systems – without additional gateways. Cybersecurity mechanisms protect data and processes at the control level.

For human-machine interaction, Mitsubishi Electric presents the GOT 3000 HMI series. The panels visualize process data, support remote maintenance, and simplify commissioning and service. New diagnostic and remote functions ensure that operators can detect anomalies at an early stage and avoid downtime.

Shop floor – Energy-efficient Drive Technology

At the field level, Mitsubishi Electric is showcasing the next generation of compact drive solutions with the new FR-D800 inverter.

The FR-D800 controls both asynchronous and permanent magnet motors, achieving high energy efficiency of up to IE5, especially when used with EM-A motors. The FR-D800 offers advanced protection functions, an integrated emergency stop function, and a clear LED display with a digital dial. Its compact design, spring-loaded terminals, and simplified parameterization significantly reduce installation and maintenance time.

Simulation and virtual commissioning

Another building block for efficient project planning is the MELSOFT Gemini 3D Simulator. It allows for the digital pre-verification of systems, robot cells, and production lines. This allows control programs, motion sequences, and energy flows to be tested virtually before real components are installed, saving significant time and costs in the engineering phase.