Mitsubishi claims plant-to-ERP control breakthrough

Hatfield, UK - Top-to-bottom plant and enterprise control that is affordable, even for SMEs, and easy to use was the promise from Mitsubishi officials at the UK launch of the company's iQ Platform. The product, they said, will empower process engineers to access and analyse all plant information and communicate reports right up to the boardroom – as well as enabling senior managers to view how their operations are running at the touch of a PC or laptop button.

The iQ Platform, which is based on Mitsubishi’s existing Qn series programmable automation controller (PAC), features a range of control modules that interface directly with business information systems. The Japanese company originally developed the “flattened architecture” technology for a flagship servo motor plant in Nagoya, but then launched it as a commercial product in late 2006.

“The iQ Platform will make a significant difference to the way we do automation,” claimed Jeff Whiting, marketing manager, Mitsubishi Electric UK. “We see this as a phenomenal move forward in the way information comes available across a whole operation, right up to the boardroom to make improvements to the business.”

The iQ Platform uses common systems, protocols and networks and is scalable to meet the requirements of all of MES systems; from simple work-in-progress reporting to full end-to-end manufacturing control and monitoring. The MES connectivity is designed to make it easy to track, measure and control production data in areas such as traceability, productivity and quality.

The product, said Whiting, allows integration of plant and business functions, from the shop floor to corporate commercial systems to increase operational efficiency, for example by reducing waste, rework, maintenance and spares holdings.

According to Mitsubishi, the costs of the controller have been significantly reduced by removing an entire layer of the hardware so that control engineers can integrate data directly into and from the management databases. The system includes an MES module and is designed to remove the need for specialist IT database skills in the integration process.

This technology is not new, said Whiting, but the capabilities it offers were previously exclusive to major players able to invest at the SAP level. “We are bringing this right back to mainland manufacturing to companies that could only afford to look at it up to now,” he commented.

“Previously you needed IT specialists, which was expensive and involved long development times. Now all that is gone as the process engineer can get data from the darkest parts of his plant right up to the boardroom,” the Mitsubishi Electric UK manager added.

At the launch, Mitsubishi officials cited the use of the technology on a project in the automotive industry at automotive engine manufacturer Global Engine Manufacturing. This client, they said, had saved $100 million across operations, which produces 840, 000 units/year.