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Mitsubishi Electric introduces MELSOFT VIXIO, an innovative AI-powered inspection software designed to enhance quality control, minimize waste, and improve production efficiency. This solution leverages image analysis to ensure only products meeting strict quality standards move forward in the production process, addressing key challenges such as labour shortages and manual inspection bottlenecks.

To explore the impact of MELSOFT VIXIO, we spoke with Daniel Sperlich, Strategic Product Manager for Controllers in the EMEA region. With over eight years at Mitsubishi Electric, Daniel has extensive experience in automation, having worked as an Automation Specialist and Product Manager for the German market. His three-year assignment in Japan, where he collaborated with the Servo & Motion development team, further strengthened his expertise and global perspective. Now, he is dedicated to supporting manufacturers on their digital transformation journey, helping them leverage advanced technologies to optimize operations and drive efficiency.

A: Let’s start with a simple question: What exactly is MELSOFT VIXIO, and what makes it stand out among other production management solutions?

D: MELSOFT Vixio is an AI-powered inspection software designed to be accessible to anyone. By analysing images from the production line, the system ensures that only products meeting predefined quality standards are delivered to customers. At the same time, it helps address critical challenges such as labour shortages and bottlenecks in manual inspection processes.

A: From your experience, what are the most common production challenges that MELSOFT VIXIO helps companies overcome?

D: One of the biggest challenges is material waste and inefficiencies in the production process. Without quality control at key checkpoints, defective products often continue through various production stages, consuming additional resources before ultimately failing the final inspection. Another major issue is the time-consuming nature of manual inspections. Every product, whether defective or not, requires thorough checking, which slows down production and creates bottlenecks. Additionally, manual inspections can be inconsistent, as they rely on human attention and expertise, which naturally fluctuate over an eight-hour shift. The longer someone works, the higher the risk that a defect might slip through unnoticed, potentially reaching the customer.

A: Modularity is one of the key features of the system. Which modules provide the quickest benefits for manufacturers?

D: The system’s scalability is a major advantage. It allows manufacturers to start with a basic setup and expand based on their needs. Depending on the production environment, some companies benefit immediately from automated defect detection, while others see quick wins in optimizing rework processes.

A: Could you explain how MELSOFT VIXIO’s real-time monitoring capabilities enhance production efficiency?

D: Let’s take a traditional manual inspection process as an example. A worker might take 10 seconds to inspect each product, whether it’s defective or not. With MELSOFT VIXIO, manufacturers can opt for a fully automated process, where defective products are automatically removed, or a semi-automated approach, where only non-conforming products require manual review.

Additionally, real-time data visualization—such as heatmaps highlighting defect locations—enables quicker rework. Monitoring quality trends also helps teams proactively address production issues before they escalate, further boosting efficiency.

A: How does MELSOFT VIXIO support quality control processes in manufacturing?

D: The system automatically detects defects, allowing manufacturers to make instant decisions—whether to proceed with the next production step or divert a product for rework. Since the AI model requires minimal setup time, companies can implement high-precision quality control with low deployment costs.

A: Data analytics is crucial in modern manufacturing. How does MELSOFT VIXIO transform raw production data into actionable insights?

D: MELSOFT VIXIO itself does not perform deep analytics, but it does generate historical quality data that can be used for further analysis. For example, the system logs quality scores for each inspected product, allowing manufacturers to track trends over time. This data could potentially be integrated with MELSOFT MAILAB to gain deeper insights into production quality and create a closed loop to the process, meaning MELSOFT MAILAB can advise or control the process to stabilize the product quality.

A: The system offers integration possibilities with various devices and systems. How flexible is this integration in practice?

D: MELSOFT VIXIO supports GigE Vision / GenICam industrial cameras, which are widely used in manufacturing. It can also work with any camera capable of saving images to a Windows folder, though this may affect processing speed.

As for installation, the system is highly flexible. It runs on standard hardware equipped with an NVIDIA GPU (Ampere architecture or newer) and an Intel CPU—components that are easily available and cost-effective.

A: Could you share some insights about the typical implementation process and what companies should prepare for?

D: Implementation is straightforward. We can assess feasibility remotely—companies simply provide sample images (both good and defective products), which they likely already have. We then analyse these images and discuss AI results and optimization strategies.

Since MELSOFT VIXIO monitors rather than interferes with the production process, a camera can be installed above the production line without disrupting operations. This allows companies to gain valuable insights almost immediately.

A: We often hear about Industry 4.0. What specific features of MELSOFT VIXIO help companies embrace this trend?

D: MELSOFT VIXIO aligns perfectly with Industry 4.0 principles by enhancing quality control, boosting productivity, and leveraging data for process optimization. By implementing the system, manufacturers are already stepping into the Industrial IoT (IIoT) era, where automation and smart decision-making drive efficiency.

A: Customers often ask about data security. What security mechanisms does MELSOFT VIXIO offer?

D: Data security is a top priority. MELSOFT VIXIO operates entirely within the customer’s environment, eliminating the need to send data to the cloud. Additionally, communication between the user and the inspection system is secured using certificates and browser-based security / authentication mechanisms.

A: Could you explain how the system helps in production planning and scheduling optimization?

D: While production planning is not MELSOFT VIXIO’s primary function, its quality trend analysis can provide valuable insights. If quality starts declining despite parameter adjustments, it could indicate the need for planned maintenance to restore machine performance and prevent defects before they occur.

A: What role does MELSOFT VIXIO play in reducing production waste and improving sustainability?

D: During production, it’s common for good products to be mistakenly rejected, leading to unnecessary waste. MELSOFT VIXIO helps minimize such misclassifications, reducing waste and improving overall efficiency. Additionally, by implementing quality inspections at various production stages, manufacturers can prevent defective products from undergoing further processing, saving energy, materials, and additional costs associated with unnecessary production steps.

A: Looking at your experience with different manufacturing environments, what types of companies benefit most from MELSOFT VIXIO?

D: MELSOFT VIXIO is designed to be adaptable across industries. Any company that relies on manual inspection can see immediate improvements. Industries like automotive, luxury goods, electronics (e.g., PCB inspection), and general manufacturing benefit significantly, especially if they currently lack an inspection system.

A: How does the system handle unexpected production events or breakdowns?

D: While MELSOFT VIXIO does not manage machine breakdowns, it does detect anomalies in production quality. If an unexpected issue causes a series of defective products, the AI flags this immediately, allowing operators to react before large-scale defects accumulate.

A: Finally, what do you think are the most exciting features that users discover when working with MELSOFT VIXIO?

D: One of the biggest surprises for users is how fast and intuitive the system is. The AI model is trained and ready in minutes, making implementation seamless. Additionally, the system’s ease of use means that even those without prior AI experience can quickly navigate it. Most importantly, the accuracy of defect detection often exceeds expectations, reinforcing confidence in automated quality control.