DI Markus Gruber
A Differentiation: Selmo & AI in PLC Programming
An interview with Sabine Reisinger and Selmo CEO Markus Gruber
As part of our participation in EXPO 2025 in Osaka, we take a closer look at Japanese manufacturing culture, which is renowned worldwide as a model of efficiency, quality, and innovation. Values such as continuous improvement (Kaizen), error prevention (Poka-Yoke), and lean production define the way work is done in Japan – and at Selmo. But what makes these principles so unique? And how do we implement them through our technology?
Key characteristics of Japanese manufacturing culture
1. Poka-Yoke (Error Prevention)
This is a method for preventing errors in production processes. Systems, devices, and processes are designed in such a way that errors are either prevented from occurring in the first place or immediately detected and corrected.
How Selmo integrates Poka-Yoke:
Poka-Yoke is a cornerstone of our technology. Using our patented Sequence Logic Modelling approach, machine processes are modeled during the engineering phase, and all states are precisely defined.
The decisive advantage: After modeling, our technology algorithmically translates this process model into an error-free and seamless PLC code. The result is 100% error-free PLC code without any undefined states in the programming. This level of precision is nearly impossible to achieve manually, as defining every single state of a machine through manual programming is not viable.
Additionally, our technology ensures comprehensive machine monitoring: Deviations are detected immediately and precisely localized, allowing for quick and efficient resolution of issues.
2. Lean Production (Elimination of Waste)
Lean production is a concept for designing production processes efficiently by consistently avoiding all types of waste (Japanese: Muda). The goal is to achieve maximum value creation with minimal resource use. The key principles include optimizing workflows and standardizing processes.
How Selmo supports lean production:
Our approach optimizes production by precisely coordinating processes to reduce downtime, material waste, and unnecessary energy loss. With clear and stable process control, we don’t address waste after it occurs— we prevent it entirely during the planning phase.
Additionally, our technology enables sustainable improvements across the entire production chain through standardized yet adaptable control strategies. This combination of precision and efficiency helps companies achieve maximum value creation with minimal resource input.
3. Quality Management (e.g., Total Quality Management, TQM)
This approach focuses on achieving high quality in both products and processes. Tools include statistical process control, error prevention strategies, and regular quality checks.
How Selmo supports Total Quality Management:
By eliminating undefined states in PLC programming and enabling real-time monitoring, we ensure consistent production quality. Our technology emphasizes stability and precision: Machine processes run without surprises or failures.
Through precise control, deviations and potential quality issues are addressed at their source, preventing them from impacting the final product. This approach not only ensures high product quality but also drives sustainable improvements in production workflows. Companies can maintain their quality standards at the highest level – fully aligned with the principles of comprehensive quality management.
4. Kaizen (Continuous Improvement)
Kaizen means "change for the better" and describes a philosophy focused on continuous, incremental improvements. In practice, all employees, regardless of their position, are encouraged to contribute suggestions for improving processes, products, and working conditions.
How Selmo fulfills Kaizen:
Selmo promotes continuous improvement within companies by transforming existing machines into modern, flexible production systems through a retrofit approach. These upgraded systems are data-driven, allowing businesses to continuously adapt their production processes without the need for new machinery.
Additionally, our technology is designed to be exceptionally user-friendly, enabling even employees without advanced programming knowledge to independently implement improvements. This reduces the barriers to optimization and ensures flexible adaptation to evolving requirements.
5. Gemba (The Place Where It Happens)
The focus here is on solving problems directly where they occur – at "the place of action."
How Selmo supports Gemba:
As described earlier, Selmo’s real-time monitoring immediately detects errors and displays them directly on the HMI. The system not only alerts users to the problem but also pinpoints the exact location with bit-level accuracy. This significantly accelerates the resolution process and minimizes downtime.
Another key advantage: Selmo’s intuitive and user-friendly design allows employees to resolve issues independently, reducing reliance on programmers or machine builders.
Conclusion
Japanese values like Kaizen and Poka-Yoke have had a lasting impact on the world of production. At Selmo, we embody these principles, making automation safer, more efficient, and more transparent. Our participation in EXPO 2025 offers the perfect platform to share these values with the world and shape the future of production together.
Read more about our participation at EXPO 2025 in Osaka here.
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