Kaizen rethought

With its "Smart Manufacturing Kaizen Level" (SMKL) concept, Mitsubishi Electric is introducing a solution that enables companies to digitize their production facilities in a targeted and gradual manner. The concept is based on the Kaizen philosophy of continuous improvement and is designed to advance digital transformation in manageable, efficient steps. With the support of state-of-the-art technologies and software solutions, companies can increase their productivity, quality, and plant availability in the long term and work toward fully networked manufacturing.

The concept is designed to support companies in digitizing in targeted steps. The approach is based on the Kaizen philosophy, or continuous improvement, applied to digital transformation.

The basic idea is the ability to scale from small to large: from data collection, through visualization and analysis, to process optimization. This applies from the individual machine to the entire supply chain. The concept helps companies analyze their existing infrastructure and specifically identify processes that can be digitized efficiently. It enables them to advance their digitalization gradually and in line with their needs. In each phase, we jointly examine which technologies or automation solutions are most suitable for achieving efficiency gains.

The SMKL concept thus structures the digitalization process into different phases, enabling companies to seamlessly integrate existing production facilities into the digitalization process and gradually adapt them to modern requirements.

The Necessary Tools

Mitsubishi Electric offers a range of innovative tools that enable companies to take a holistic approach. One example is the MELSOFT Gemini 3D simulator, which enables the digital pre-verification of entire production lines and systems. This shortens development times and reduces costs during the planning phase. Another example is the AI-based solution MELSOFT VIXIO, which performs real-time visual inspections and detects errors or anomalies at an early stage. These technologies are essential for making the use of digital tools practical and measurable.

In addition to these simulation and inspection technologies, Mitsubishi Electric also offers SCADA and IoT solutions through Iconics – a Mitsubishi Electric Group company – that ensure the seamless integration and use of production data. These solutions enable comprehensive real-time monitoring, effective alarm management, and targeted measures for production optimization. Thanks to this IoT-based infrastructure, companies can improve their plant availability, reduce downtime, and achieve greater efficiency.

Data-Driven Optimization

Another key element of the SMKL concept is data-driven process optimization. Through clear visualization and detailed analysis of production data, companies are able to make targeted adjustments that improve both quality and productivity. From local HMI solutions to complex IoT platforms, Mitsubishi Electric offers the necessary technological foundation to effectively utilize data and achieve the greatest possible benefit for production.

By combining automation, control, and robotics systems with advanced software solutions, Mitsubishi Electric demonstrates how companies can secure the long-term efficiency and competitiveness of their production facilities.