SOUTHERN MANUFACTURING & ELECTRONICS 2026

TALKING DATA: HOW MITSUBISHI ELECTRIC AUTOMOTIVE CZECH TRANSITIONED TO DATA-DRIVE DECISION MAKING

In modern production environments, competitive advantage is increasingly determined by how effectively a manufacturer can capture, connect and act on data. At Mitsubishi Electric Automotive Czech (MEAC), located in Slaný, data has become a strategic asset.

The facility, which supplies electrical automotive components including integrated starter generators to manufacturers across Europe, first opened in 2001. It now employs over 500 people and has evolved from a traditional production environment into a highly connected factory where millions of data points are transformed into real-time operational insight, as it looks to support the automotive industry’s transition towards electrification and smart manufacturing.

Crucially, rather than pursuing digitalisation through wholesale equipment replacement, MEAC has adopted a pragmatic approach that combines proven production assets with connected automation technologies, facilitated by its long-term automation equipment supplier, Mitsubishi Electric Factory Automation. The result is a factory that has made significant improvements to its output, quality, uptime, environmental impact and employee wellbeing.

One of the most striking aspects of MEAC’s digital transformation is its approach to existing infrastructure. While many manufacturers would have pursued a strategy of replacing existing machinery and control systems, for MEAC, the focus has been on extracting greater value from equipment that continues to perform.

“On the production side, we keep what works,” explains Jan Kabát, manufacturing engineering manager. “Our Q-Series control units have been operating reliably for more than 10 years, while modernisation is achieved through a data layer using MES interfaces to connect machines and generate operational insights without disrupting output.”

He continues: “We do not modernise machines simply for the sake of it. The stable Q-Series control remains in place, while connectivity and data capabilities are added where they deliver measurable gains: less downtime, better visibility and faster troubleshooting.”

Such an approach has enabled MEAC to connect more than 100 machines through Mitsubishi Electric’s e-F@ctory architecture. This has created a digital layer that provides visibility into plant performance without incurring significant CapEx costs.

The data generated now forms the basis of day-to-day decision making throughout the factory. It enables engineers to create custom reports and deploy additional sensors where greater process visibility is required.

However, for MEAC, the real value of connectivity lies in the ability to continuously improve manufacturing performance. Digital tools and analytics provide detailed visibility into processes, allowing teams to quickly identify issues and implement corrective actions before they affect production quality or customer deliveries.

For Dalimil Bartoň, general manager, data has become central to the company’s continuous improvement strategy: “We use data to drive continuous improvement in both process and product quality. By analysing detailed manufacturing data, we can identify defect patterns, optimize processes and reduce scrap. The result is more consistent quality for customers and lower manufacturing costs for the business.

“The point isn’t about using technology for technology’s sake. It’s knowing how to deploy systems so they genuinely support production within a true PDCA cycle. By using Mitsubishi Electric FA’s portfolio in a pragmatic way, the team continues to raise automation levels, protect quality, and deliver measurable results on the shop floor.”

While digital transformation is often associated with plant equipment, MEAC has also applied data-driven techniques to improve working conditions for employees. The company uses RFID technology and workstation data to understand how work is performed across the facility and identify opportunities to reduce physical strain.

Petr Soukup, manufacturing senior manager, explains: “We use RFID technology to identify operators and understand where they are working, combining this information with muscle-load and workstation-level data. This helps us plan job rotations and organize work more effectively to reduce ergonomic strain. As a result, we’ve achieved more consistent performance across shifts.”

With MEAC also understanding the impact of environmental conditions on production performance, the facility represents a comprehensive software-defined building based on Mitsubishi Electric iQ‑R PLCs and ICONICS GENESIS64 software.

According to Milan Koňarik, facility manager, the system provides a single view of critical facility infrastructure. “Our software-defined building is built on ICONICS and GENESIS64, with Mitsubishi Electric iQ-R PLCs. This allows us to actively manage the plant environment and its impact on production.”

He adds: “We monitor HVAC, the data centre, pre-cooling systems, UPS and other technical utilities, with over 3000 measurement points feeding a single data view for faster decision-making. The system can trigger SMS and email alarms, support smarter energy purchasing and help our energy-saving team act quickly. We see it as a practical tool for reducing energy costs and operational risk while keeping our carbon neutrality ambitions on track.”

Ultimately, as automotive manufacturers continue to face pressure to improve efficiency, quality and sustainability, MEAC shows how effective digital transformation can be achieved without disrupting established production processes.

With improved visibility of key data points, reduced downtime, enhanced product quality, lower energy consumption and a more sustainable working environment, MEAC has truly managed to get its data talking.

More information https://emea-fa.mitsubishielectric.com/fa/

A CHANGE OF MACHINE STYLE BRINGS BENEFITS TO COMBINED ENGINEERING SERVICES WITH INVESTMENT IN XYZ TMC

Combined Engineering Services (CES) was born following the 2018 merger of Brecon Designs (formed in 2007) with another local engineering company, Infinite Engineering Design. Since then, managing director Steve Willams and his team have seen continued growth.

From humble beginnings with a facility housing little more than a turret mill, manual lathe and wire eroder, CES now has substantial CNC machining capability. This allows the company to manufacture tooling, jigs and fixtures, along with the design and build of special-purpose machines. The aim of CES is to build lasting customer relationships by working with integrity to provide cost effective solutions, providing mutual security for both parties.

CES made its first step into CNC milling by investing in an XYZ VM 4000 bed mill, with Willams outlining that it was the ProtoTRAK control that made the company gravitate towards XYZ.

“As with many companies, our first step into CNC was made with great trepidation but we gelled with ProtoTRAK control,” he confirms. “Since that first machine, we now have seven more XYZ bed mills with different capacities and generations of controls, along with a flat-bed lathe that also has the ProtoTRAK CNC.”

This progressive and forward-thinking business located just off the ‘Heads of the Valleys’ in South Wales has now made further investment to enhance its capability and help to improve productivity.

Chris Bow, design director at CES, explains: “The bed mills have served us well and continue to do so, but it became apparent that we needed to try something different on our next machine tool purchase to remain competitive. When we’re not successful in winning work following a quote, we always look at why didn’t we win the job. These investigations led us to look at our machining capability.”

He continues: “We arranged a visit to the XYZ head office in Devon to look at several options. On our return we concluded – following the advice provided by the XYZ sales team – that the 750 TMC with its enclosed layout would be a good fit for our business.

“We knew the TMC would allow us to improve material removal rates and reduce cycle times due to its 11 kW BT40 spindle. In addition, the travels of 743 mm in the X axis and 425 mm in Y, mated with the 20 station BT40 tool changing carousel, would open up the opportunity to load a number of parts on the bed at the same time. In turn, this would push us towards lights-out machining and subsequently help us achieve the goal of lowering our manufacturing cost per part.”

Chris continues with the justification of the purchase by adding: “Another improvement for the business was better staff utilisation due to less operator input during component manufacture. The potential to walk away from the machine for the whole of the process brings its own increase in efficiency, creating more capacity within the workshop and helping to reduce takt time when we build one of our special-purpose machines”.

Now the new machining centre is up running, CES is benefitting from the flexibility that the XYZ TMC range offers. Having taken advantage of the optional front-mounted electronic handwheels, all the programmers and operators at CES can jump on the machine and use it in a manual capacity for simple machining operations if required.

The transition to the XYZ TMC from existing bed mills at CES was easy due to the resident conversational programming in the control. Having made an investment in CADCAM software, CES is now in a position to use all of today’s latest technology, both on the ProtoTRAK 15” touchscreen RMX control or through CADCAM to manufacture parts quickly and cost effectively.

XYZ’s TMC (Toolroom Machining Centre) brings the added versatility of a tool-change system, while maintaining the familiarity of the latest version of the ProtoTRAK control system. The use of the RMX ProtoTRAK CNC provides a high level of familiarity for exiting users of XYZ bed mills. For those not familiar, its touchscreen interface and easy-to-use programming tools make the control suitable for low-to-medium production batch sizes. Combining that with a fully enclosed machining envelope and either a 12- or 20-station automatic tool changer, make the XYZ TMC a great choice machine for any business looking to step up productivity.

“The one thing that we didn’t see coming when the machine was installed was the enthusiasm from the team of machinists here at CES,” reports Chris. “They all have a desire to use the machine and help the business reap the benefits of this new technology. Due to software enhancements – such as the ‘defaults’ setting where operators can set the control features to their own liking, the TRAKing feature to put them in control by winding handwheels to execute the program, and the fact the machine has been fitted with a swarf conveyor to cut down on machine cleaning time – all the team have shown willingness to get involved.

“This is helping the company move forward and be more competitive when it comes to quoting for work as the enthusiasm from the team means they’re now looking at manufacturing parts in a different way and employing production methods that were not possible on our older machines. It’s not just the machine that’s making a difference here at CES but the staff too.”

Today, the workshop team at CES is able to offer a complete range of services from CNC milling and turning, through EDM to metal finishing and machine building. The company’s acquisition of the adjoining unit in 2021 allowed it to expand into clearly defined work areas, giving a more controlled production flow from workshop through build and inspection.

More information www.xyzmachinetools.com

BEMA INVESTS IN HIGH-QUALITY MANUAL MACHINES FROM MACH MACHINE TOOLS

For more than a decade, BEMA (British Engineering Manufacturers’ Association) has been investing in manual machine tools from MACH Machine Tools to ensure its engineering apprentices develop the practical machining skills that employers across the southwest of England continue to demand.

The latest investments form part of an ongoing commitment by BEMA to provide apprentices with relevant, transferable workshop experience before they return to their employers to complete the remainder of their training. To date, the organisation has purchased 11 manual machines from the Bristol-based supplier, including six MACH L-1340 centre lathes and five MACH VS-1 vertical milling machines.

The machines are installed at BEMA’s dedicated engineering training centre in Yate, South Gloucestershire. Operated in partnership with Swatpro Academy, the purpose-built facility delivers practical training for Level 2 and Level 3 engineering apprentices in machining, fitting and maintenance. The centre serves employers across the region, helping develop the skilled workforce required by the area’s diverse manufacturing and engineering industries.

Engineering apprenticeships supported by BEMA and delivered through Swatpro typically span four years. During the first year, apprentices spend ten months at the training centre, attending full-time from September through to July before returning to their respective employers to complete the remaining three years of their apprenticeship.

Following an initial induction period, apprentices undertake a structured programme divided into six-week training blocks. Each block comprises two weeks of turning, two weeks of milling and two weeks of fitting, providing a balanced introduction to the core engineering disciplines while allowing instructors to monitor progress through regular assessments and practical inspections.

“Our turning, milling and fitting modules are very much practical, skills-based programmes,” explains Andrew Dunster, lead workshop and commercial training instructor and assessor.

“By the time apprentices complete their first year, they have developed a solid level of technical competence across all three disciplines. Those skills provide the foundation they need when they return to their employers, where they continue developing throughout the remainder of their apprenticeship.”

Throughout their training, apprentices use the MACH lathes and milling machines to manufacture a wide variety of precision components from materials including mild steel, alloy steel, aluminium, brass and engineering plastics.

Rather than producing simple practice pieces, the machining projects are deliberately designed around functional workshop equipment that apprentices can use during subsequent training. These include thread vices, go/no-go gauges, location plates, V-blocks, toolmakers’ clamps and precision vices.

“Our apprentices are machining practical tools that have a genuine purpose, rather than simply producing parts with abstract features,” says Dunster. “It gives greater meaning to the work while reinforcing the importance of accuracy and good machining practice.”

Producing these components requires considerably more than simply operating a machine tool. Apprentices must learn to read and interpret engineering drawings, select appropriate tooling, safely set up each machine and consistently achieve the specified dimensional tolerances and surface finishes.

On the lathes, this includes operations such as external and internal turning, facing, parting-off, grooving, drilling and thread cutting. Milling exercises include face milling, end milling, drilling and boring, helping apprentices build a broad understanding of conventional machining processes before progressing to more advanced manufacturing technologies.

According to Dunster, the reliability and usability of the MACH machines make them particularly well suited to an educational environment.

“The MACH lathes and milling machines are accurate, reliable and straightforward to use,” he says. “That consistency is important when you’re teaching apprentices because it allows them to concentrate on developing sound machining techniques and good workshop practices.”

Value for money has also been an important factor in BEMA’s purchasing decisions.

“The machines are competitively priced and supplied with a comprehensive range of standard equipment, including tooling packages, chucks, steadies and digital readouts, rather than these being optional extras,” he adds. “That makes them an attractive proposition whenever we evaluate new equipment.”

This combination of technical capability, competitive pricing and educational support proved decisive when BEMA invited tenders in 2019 for a further six manual machine tools comprising three MACH L-1340 lathes and three MACH VS-1 milling machines.

For Martin Wear, BEMA’s centre manager, the decision extended beyond the machines themselves.

“MACH Machine Tools presented a strong technical proposal, but what also impressed us was the company’s understanding of the education and training sector,” he explains. “Its experience of working with training providers, together with the additional support and sponsorship it offers educational organisations, helped distinguish its submission.”

Today, the MACH machines play a central role in the day-to-day operation of the training centre.

The MACH VS-1 manual milling machines feature rigid construction, generous table capacities, variable-speed 5,000rpm spindles and two-axis digital readouts, while the MACH L-1340 centre lathes combine compact footprints with features including quick-change tool posts, precision tailstocks, stress-relieved beds and two-axis digital readouts. Together they provide apprentices with the robust, accurate and dependable platform needed to develop fundamental machining skills.

As engineering employers continue to seek apprentices with strong practical capabilities alongside theoretical knowledge, BEMA believes that investment in high-quality workshop equipment remains essential.

“We currently have 11 MACH machine tools in our training centre,” concludes Wear. “They continue to perform reliably year after year and play an important role in helping us develop the turning and milling skills our apprentices need before they progress into industry. Ultimately, that’s what this investment is all about: giving employers apprentices who are confident, capable and ready to contribute from day one.”

More information www.machinetoolsalesonline.com

Programming made simple

Hurco (Stand G200)is demonstrating the latest software developments on its Max5 control. They include a solid model import option, which enables the creation of conversational programs directly from an STP file. Similarly, 3D DXF files may be imported and worked on seamlessly.The 19-inch colour touchscreen control supports the easyprogramming ofa first-off part, withsimple conversational prompts guiding the user through program stages, taking the load off CAM stations. Offline-generated NC code can be added into the program using an NC Merge function. Live on-line help is available at the control.More information www.hurco.com

Head for the cutting edge

On Stand D200, Guhring is showing its extensive portfolio of cutting tool solutions spanning drilling, milling, threading, reaming and deburring, with the company’s RF 100 AL milling line among the headline attractions. The RF 100 AL series of solid-carbide end mills is available in diameters from 0.5 to 25 mm and suitable for use on aluminium, other non-ferrous metals and plastic. The smaller RF 100 AL Micro achieves cycle time reductions of up to 76% compared to conventional small end mills, while the standard RF 100 AL delivers a 30% increase in machining performance with real-world data demonstrating 59% faster machining times and 54% longer tool life.

More information www.guhring.co.uk