Kaizen rethought Step by step to the smart factory

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Mitsubishi Electric's SMKL concept provides a structured approach to digitalizing production facilities. Built on the Kaizen principle of continuous improvement, it enables companies to implement digital transformation in manageable steps.

With the “Smart Manufacturing Kaizen Level” (SMKL) concept, Mitsubishi Electric presents a solution that enables companies to digitise their production facilities in a targeted and step-by-step manner. The concept is based on the Kaizen philosophy of continuous improvement and is designed to drive digital transformation in manageable, efficient steps. With the support of state-of-the-art technologies and software solutions, companies can sustainably increase their productivity, quality and plant availability and work towards a fully networked production.

The concept is designed to help companies digitise in targeted steps. The approach is based on the Kaizen philosophy of continuous improvement applied to digital transformation.

The basic idea is the ability to scale from small to large: from data collection, visualisation and analysis to process optimisation. And from the individual machine to the entire supply chain. The concept helps companies analyse their existing infrastructure and identify specific processes that can be efficiently digitised. It enables them to move forward with digitisation in a step-by-step, needs-driven manner. At each stage, the company works together with its clients to determine which technologies or automation solutions make sense to achieve efficiency gains.

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

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 digital pre-verification of entire production lines and systems. This shortens development times and reduces costs in the planning phase. Another example is the AI-based solution Melsoft Vixio, which performs visual inspections in real time and detects defects or anomalies at an early stage. These technologies are essential to make the use of digital tools practical and measurable.

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

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

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