en.Wedoany.com Reported - Mitsubishi Electric Automotive Czech (MEAC) has transformed its factory into a highly interconnected manufacturing base through a data-driven strategy, without replacing mature equipment. Located in Slaný, the factory first began production in 2001 and now employs over 500 people, primarily manufacturing automotive electrical components such as integrated starter generators. By connecting over 100 machines and generating real-time operational insights, the plant has achieved improvements in output, quality, uptime, environmental impact, and employee well-being.
MEAC's digital transformation strategy emphasizes extracting greater value from existing equipment rather than large-scale machine replacement. Manufacturing Engineering Manager Jan Kabát stated that the company retained Q-series control units that have been reliably operating for over a decade, achieving machine connectivity and operational insights through a data layer based on the MES interface without disrupting output. This approach leverages Mitsubishi Electric's e-F@ctory architecture to add connectivity and data capabilities, avoiding significant capital expenditure, and the resulting digital layer has become the foundation for daily decision-making at the factory.
Digital tools and analytical capabilities enable the team to monitor the manufacturing process in detail, quickly identify issues, and take corrective actions before they impact quality or delivery. General Manager Dalimil Bartoň noted that data is used to drive continuous improvement in process and product quality: by analyzing detailed manufacturing data to identify defect patterns, optimize processes, and reduce waste, the factory provides customers with more consistent quality while lowering manufacturing costs. The team pragmatically uses Mitsubishi Electric's FA product portfolio to support production within the PDCA cycle, enhancing automation levels and protecting quality.
In personnel management, MEAC applies data-driven technologies to improve employee working conditions. Senior Manufacturing Manager Petr Soukup explained that the company uses RFID technology to identify operator locations, combined with muscle load and workstation data to plan job rotations, effectively organizing work to reduce ergonomic strain and achieving more consistent performance across shifts.
The factory also manages environmental conditions through an integrated software-defined building management system, based on Mitsubishi Electric's iQ-R PLC and ICONICS GENESIS64 software. Facility Manager Milan Koňarik stated that the system monitors HVAC, data centers, pre-cooling systems, UPS, and other technical utilities, aggregating over 3,000 measurement points into a single data view to accelerate decision-making. The system can trigger SMS and email alerts, support energy procurement decisions, and help the energy-saving team act quickly to maintain carbon neutrality goals.
MEAC's practice demonstrates a path to effective digital transformation without disrupting established production processes. By improving visibility of key data points, reducing downtime, enhancing product quality, lowering energy consumption, and creating a more sustainable work environment, the factory has truly made data speak for itself.
