Client Overview

Mitsubishi Electric is a global leader in electrical and electronic equipment, automation, and industrial solutions, providing high-quality technologies across manufacturing, energy, transportation, and building systems.

Electric motors play a crucial role in Mitsubishi Electric’s operations, powering industrial machinery, automation systems, HVAC equipment, and energy management devices. These motors require high efficiency, precision control, reliability, and seamless integration with complex automation platforms.

To address these operational requirements, Mitsubishi Electric partnered with Simo Motors to implement customized motor solutions designed to enhance energy efficiency, reliability, and automation integration, while supporting Mitsubishi Electric’s high standards for industrial performance and sustainability.

3. Project Challenge / Problem

Despite Mitsubishi Electric’s advanced engineering capabilities, several challenges existed:

1. Energy Optimization

• Certain motors in Mitsubishi Electric’s systems were not operating at peak efficiency, resulting in higher electricity consumption.

• Reducing energy usage was essential to align with the company’s sustainability and green manufacturing objectives.

2. Operational Reliability

• Continuous operation of motors in demanding industrial and automation environments posed a risk of unplanned downtime.

• Failures could disrupt production, affect quality, and delay schedules.

3. Precision Control Requirements

• Automated systems required motors capable of precise speed, torque, and position control.

• Standard motors lacked the required precision for high-end industrial applications.

4. Maintenance Complexity

• Diverse motor types across multiple production lines led to complex maintenance planning.

• Simplified maintenance procedures and improved reliability were necessary to streamline operations.

5. Harsh Operating Environments

• Motors needed to withstand continuous operation, temperature fluctuations, vibration, and industrial contaminants, while maintaining performance and longevity.

These challenges highlighted the need for customized, high-performance, energy-efficient motors capable of operating reliably under Mitsubishi Electric’s demanding industrial conditions. Simo Motors was tasked with delivering solutions that improved energy efficiency, reliability, and automation integration.

Solution Provided by Simo Motor

To address Mitsubishi Electric’s operational challenges, Simo Motors provided a comprehensive, customized motor solution that combined high efficiency, reliability, and seamless integration with advanced automation systems:

1. High-Efficiency Custom Motors

• Simo supplied energy-optimized AC and DC motors tailored for Mitsubishi Electric’s industrial machinery, automation equipment, and energy management systems.

• Advanced winding techniques and high-grade insulation minimized energy losses and enhanced overall operational efficiency.

• Motors were engineered to perform efficiently under variable loads and speeds, meeting Mitsubishi Electric’s diverse operational needs.

2. Durable and Reliable Construction

• Motors were designed for continuous heavy-duty operation, capable of withstanding high temperatures, vibration, and industrial contaminants.

• Reinforced bearings, precision-engineered rotors, and robust stators ensured long service life and minimal unplanned downtime.

• Protective coatings and sealed housings improved resistance to harsh environments, maintaining consistent performance.

3. Seamless Automation Integration

• Motors were fully compatible with Mitsubishi Electric’s VFDs, PLCs, and control platforms, enabling precise speed, torque, and position control.

• Real-time monitoring interfaces allowed predictive maintenance, diagnostics, and performance tracking.

• Integration improved process consistency, production efficiency, and product quality across all lines.

4. On-Site Assessment and Installation

• Simo Motors conducted detailed site assessments to evaluate operational requirements and environmental conditions.

• Installation was meticulously planned to minimize production disruption, including alignment, calibration, and system testing.

5. Training and Documentation

• Mitsubishi Electric maintenance and engineering teams received hands-on training on motor operation, preventive maintenance, and troubleshooting.

• Detailed documentation, including performance logs, maintenance schedules, and operational manuals, ensured long-term operational success.

6. Ongoing Support and Performance Optimization

• Simo Motors provided continuous technical support, monitoring motor performance and fine-tuning parameters to maintain maximum efficiency, reliability, and operational output.

By delivering custom-engineered, high-performance motors, Simo Motors enabled Mitsubishi Electric to improve energy efficiency, enhance reliability, and seamlessly integrate with advanced automation systems, supporting both operational excellence and sustainability goals.

 Implementation Process

The deployment of Simo Motors’ solutions at Mitsubishi Electric followed a structured and meticulous process to ensure optimal performance and minimal disruption:

1. Initial Assessment and Planning

• Simo Motors’ engineers conducted a comprehensive site survey, evaluating existing motor performance, load requirements, and automation integration needs.

• Detailed project planning included motor selection, customization specifications, installation schedules, and integration strategies.

• Risk assessments minimized disruption to Mitsubishi Electric’s ongoing operations.

2. Custom Motor Engineering and Factory Testing

• Motors were custom-engineered to meet Mitsubishi Electric’s operational demands, including torque, speed, insulation class, and durability for harsh industrial conditions.

• Each motor underwent rigorous factory testing, including load, thermal, and vibration assessments, ensuring efficiency, reliability, and compliance with Mitsubishi Electric’s standards.

3. Logistics and Pre-Installation Preparation

• Motors and components were carefully packaged and shipped with pre-configuration for installation, ensuring timely deployment.

• Coordination with Mitsubishi Electric minimized production downtime during installation.

4. On-Site Installation and Integration

• Simo’s technical team performed precise installation, ensuring correct alignment, secure mounting, and integration with VFDs, PLCs, and control systems.

• Calibration and testing ensured motors operated within exact parameters, supporting precise speed, torque, and position control.

• Integration with monitoring systems enabled real-time diagnostics and predictive maintenance, enhancing operational reliability.

5. Training and Documentation

• Mitsubishi Electric’s maintenance and engineering teams received hands-on training covering motor operation, preventive maintenance, and troubleshooting.

• Comprehensive documentation, including manuals, maintenance schedules, and performance logs, ensured smooth long-term operations.

6. Ongoing Support and Optimization

• After installation, Simo Motors provided continuous technical support, monitoring motor performance and optimizing parameters for maximum efficiency and reliability.

• Regular performance audits ensured motors consistently delivered energy savings, operational reliability, and productivity improvements.

This structured implementation process allowed Mitsubishi Electric to achieve improved energy efficiency, reduced downtime, and enhanced operational performance, while maintaining continuous production and high-quality output.

Results / Outcomes

The collaboration between Mitsubishi Electric and Simo Motors delivered measurable improvements in energy efficiency, reliability, and operational performance:

1. Energy Efficiency and Cost Savings

• High-efficiency, custom-engineered motors reduced energy consumption by approximately 16–20%, resulting in substantial electricity cost savings.

• Optimized motor performance improved load management and minimized energy waste across automation systems and industrial equipment.

2. Enhanced Reliability and Reduced Downtime

• Reinforced and durable motor designs reduced unplanned downtime by 28%, ensuring smoother production schedules and minimal operational disruptions.

• Longer motor lifespans and predictable maintenance schedules decreased labor costs and operational interruptions.

3. Seamless Integration with Automation Systems

• Motors were fully compatible with Mitsubishi Electric’s VFDs, PLCs, and automation control systems, enabling precise speed, torque, and position control.

• Consistent motor performance enhanced process reliability, product quality, and overall operational efficiency.

4. Sustainability and Operational Benefits

• Energy-efficient motors contributed to Mitsubishi Electric’s sustainability initiatives and green manufacturing objectives.

• Reduced energy consumption and optimized operations supported lower carbon emissions and improved environmental performance.

5. Improved Maintenance and Monitoring

• Maintenance teams reported simplified procedures, faster troubleshooting, and enhanced performance oversight.

• Predictive maintenance capabilities enabled proactive interventions, reducing the risk of unexpected failures.

6. Client Satisfaction

• Mitsubishi Electric praised Simo Motors for their technical expertise, professional support, and customized solutions, which met stringent industrial and automation standards.

• The successful implementation reinforced Simo Motors as a trusted long-term partner for high-performance motor solutions.

Key Takeaways / Lessons Learned

The Mitsubishi Electric case study highlights several key insights and demonstrates Simo Motors’ expertise in delivering high-performance motor solutions for demanding industrial environments:

1. Customized Solutions Ensure Maximum Efficiency

• Tailored motor designs are essential to meet the specific operational and automation requirements of industrial clients like Mitsubishi Electric.

• Simo Motors’ engineered solutions guarantee optimal energy efficiency, precise control, and operational reliability.

2. Energy Efficiency Supports Sustainability and Cost Reduction

• High-efficiency motors reduce energy consumption while supporting corporate sustainability and green manufacturing objectives.

• Implementing energy-optimized motors provides long-term cost benefits for industrial operations.

3. Reliability Reduces Operational Risk

• Durable motor construction minimizes unplanned downtime and extends service life.

• Predictable maintenance schedules improve workflow consistency and reduce labor and operational costs.

4. Integration with Automation Systems Enhances Productivity

• Motors compatible with VFDs, PLCs, and advanced automation platforms enable precise speed, torque, and positioning control.

• Real-time monitoring and predictive maintenance capabilities improve process efficiency, product quality, and operational stability.

5. Technical Support Strengthens Long-Term Partnerships

• Comprehensive support, on-site training, and responsive service foster strong, long-term client relationships.

• Clients benefit from both high-quality products and operational expertise, ensuring sustained collaboration.

Overall, the Mitsubishi Electric project illustrates that Simo Motors is a trusted, innovative, and client-focused partner, capable of delivering measurable improvements in energy efficiency, reliability, and industrial performance for complex automation and industrial applications.

Client Testimonial / Quote

“Simo Motors delivered highly customized, high-performance electric motors that perfectly aligned with our automation systems and operational requirements. Their expertise and professional support significantly enhanced our energy efficiency, operational reliability, and overall productivity. We are extremely satisfied with the results and look forward to continuing our collaboration with Simo Motors.”
— Mitsubishi Electric Industrial Operations Manager