Manufacturer Significantly Reduces Downtime with Mitsubishi Electric PLCs

The company upgraded its process control system without any interference to planned production across three plants in three cities.

Verona, WI - October 13, 2021

A new customer case study from Mitsubishi Electric is now available, highlighting the experience of a leading semi-trailer manufacturer that wanted to replace a PC-based control system with a programmable logic controller (PLC) system.

The manufacturer’s legacy control system had begun to fail too often, leading to costly downtime and the need for a number of manual repair tasks and paperwork. In addition, the person who had developed the PC-based system was no longer with the company and no one else knew how to maintain it.

Ready to upgrade to a more modern PLC system, the manufacturer relied on its longtime Mitsubishi Electric distributor, Tri-Phase Automation. The distributor brought in ACS, a “hands-on to hand-over” systems integrator, who engineered the main Mitsubishi Electric PLC systems, as well as the Manufacturing Execution System (MES) PLC system, to the manufacturer’s unique needs.

The new Mitsubishi Electric PLC systems not only delivered more advanced automation, but also resulted in a faster, more powerful and user-friendly database; ensured HMI functionality identical to the previous system to make the transition as seamless as possible; and integrated controls with existing instrumentation and mechanical systems.

With Mitsubishi Electric PLCs, the manufacturer greatly reduced unexpected downtime and eliminated many manual tasks and paperwork, which were vulnerable to human error. The system also automated data capture with a built-in barcode scanner to boost productivity.

ACS reports, "The new control systems have been problem-free and doing exactly what they wanted it to do. Their top-of-the-line Mitsubishi Electric PLCs are known for industry-leading reliability and uptime and have performed as expected, delivering consistent product quality and data capture across all three plants."

More Information

- About Mitsubishi Electric Automation, Inc.

Headquartered in Vernon Hills, Ill., Mitsubishi Electric Automation, Inc. is a U.S. affiliate company of Mitsubishi Electric Corporation. It offers a broad product portfolio including programmable automation controllers (PAC), programmable logic controllers (PLC), human machine interfaces (HMI), variable frequency drives (VFD), servo amplifiers and motors, control software, computerized numerical controllers (CNC), motion controllers, robots and low-voltage power distribution products. Additional information about Mitsubishi Electric Automation is available at us.mitsubishielectric.com/fa/en/.

- About Mitsubishi Electric Corporation

Guided by its corporate philosophy, Mitsubishi Electric Corporation (TOKYO: 6503) places sustainability at the core of its operations and values stakeholder trust—encompassing society, customers, shareholders and employees. In pursuing profitability, capital efficiency and growth, Mitsubishi Electric works closely alongside customers to develop value-added solutions that address today's complex challenges while enhancing the company's sustainable corporate value. Founded in 1921, Mitsubishi Electric has over a century of experience in delivering reliable, high-quality products and solutions. With over 200 group companies and approximately 150,000 employees worldwide, the company is a recognized global leader in manufacturing, marketing and selling electrical and electronic equipment and systems across a broad range of sectors, including public utility systems, energy systems, defense and space systems, factory automation systems, automotive equipment, building systems, air conditioning systems & home products, digital innovations, and semiconductor & devices. Mitsubishi Electric recorded consolidated revenue of 5,521.7 billion yen (U.S.$ 36.8 billion*) in the fiscal year that ended on March 31, 2025. For more information, please visit www.MitsubishiElectric.com.

*JPY 150=USD 1, the approximate rate on the Tokyo Foreign Exchange Market on March 31, 2025

- About Mitsubishi Electric Factory Automation Business Group

Offering a vast range of automation and processing technologies, including controllers, drive products, power distribution and control products, electrical discharge machines, laser processing machines, computerized numerical controllers, and industrial robots, Mitsubishi Electric helps bring higher productivity – and quality – to the factory floor. In addition, our extensive networks around the globe provide direct communication and comprehensive support to customers. The global slogan "Automating the World" shows the company's approach to leverage automation for the betterment of society, through the application of advanced technology, sharing know-how and supporting customers as a trusted partner. For more about the story behind "Automating the World" please visit: us.mitsubishielectric.com/fa/en/about-us/news-center/automating-the-world/

- About e-F@ctory

e-F@ctory is Mitsubishi Electric's integrated concept to build reliable and flexible manufacturing systems that enable users to achieve many of their high speed, information driven manufacturing aspirations. Through its partner solution activity, the e-F@ctory Alliance, and its work with open network associations such as The CC-Link Partners Association (CLPA), users can build comprehensive solutions based on a wide ranging "best in class" principle.
In summary, e-F@ctory and the e-F@ctory Alliance enable customers to achieve integrated manufacturing but still retain the ability to choose the most optimal suppliers and solutions.

*e-F@ctory, iQ Platform are trademarks of Mitsubishi Electric Corporation in Japan and other countries.
*Other names and brands may be claimed as the property of others.
*All other trademarks are acknowledged

- Media Contact

Pam Summers
Marketing Communications Manager
Mitsubishi Electric Automation
Pam.Summers@meau.com
+1 (847) 478-2415

Return to News Center