From Robotics to IIoT: How Manufacturing is Getting ‘Smarter’

Indian manufacturing companies are increasingly harnessing the power of advanced technology trends to become globally competitive & address their current challenges

Every industry today is witnessing dramatic changes in processes and functioning with the rapid proliferation of technology, and manufacturing is no different. In fact, with disruptive technologies like IoT, advanced automation and machine-to-machine communication making headway into manufacturing, the sector is undergoing profound transformation.

“The manufacturing sector has seen a steady growth in the recent past. This renaissance is due to the inclusion of technology, automation and robotics which is revolutionizing towards advanced manufacturing. The change has enabled a faster and better production, optimization of the resources, better quality, accuracy and precision along with savings on cost,” asserts Marc Jarrault, MD, Lapp India.

Marc Jarrault, MD, Lapp India
The Indian manufacturing sector is on the path of the major renovation. We are on the edge of Industry 4.0 where technologies such as big data, improved data analytics, machine-to-machine communication, advanced robotics and 3-D printing are transforming the fundamentals of manufacturing. Following the growing trend of the fourth industrial revolution, futuristic factories are emerging in the Indian market…

The drivers for technology adoption are similar to any other sector: meeting user requirements and remaining competitive. “In order to meet customer needs and have a strong market hold, the manufacturing industries need to reduce errors and wastage. They also have to be more careful about the quality and precision which can only be achieved with automated tools and smart setup. Product durability and reliability have become immensely necessary which again requires manufacturers to use upgraded techniques,” elaborates Kalidas Bhangare, MD, Testo India.

Indian manufacturing warming up to advanced technologies

In line with the government’s vision to develop India into a global manufacturing powerhouse, the Indian manufacturing industry has also started evaluating advanced technologies to become globally competitive. “The Indian manufacturing sector is on the path of the major renovation. We are on the edge of Industry 4.0 where technologies such as big data, improved data analytics, machine-to-machine communication, advanced robotics and 3-D printing are transforming the fundamentals of manufacturing. Following the growing trend of the fourth industrial revolution, futuristic factories are emerging in the Indian market,” agrees Jarrault.

Kalidas Bhangare, MD, Testo India
Digitization and smart solutions have become the need of the hour and is very rapidly influencing the Indian market. It has promoted the usage of smart and networked equipment that reduces downtime of any manufacturing facility, require lesser human involvement, and imply automatic operation of devices that can communicate, interpret and adjust on its own seamlessly.

The increasing focus on technology is substantiated by a report from Tata Strategic Management Group, which found that a number of Indian manufacturing companies are considering leapfrogging towards the advanced manufacturing trends, including additive manufacturing, advanced robotics, Industrial Internet of Things (IIOT) and augmented reality. As per the report, 80% of the Indian manufacturing industry plans to adopt the advanced trends by 2020. The industry perceives productivity improvement and quality consistency as the most critical advantages of adopting technology.

The PwC report, ‘Industry 4.0 – Building the Digital Enterprise,’ also reveals similar intent of Indian manufacturers to invest in advanced technologies. The report reveals that about 39% of the Indian companies surveyed plan to invest more than 8% of their annual revenues in digital programs in the next five years considering both top line and bottom line gains which can be achieved. The report further goes on to state that more than 80% of the respondents in India expect a greater than 10% gains in efficiency; more than 60% expect over 10% reduction in costs from operations and an over 10% improvement in additional revenue in the next five years.

“Digitization and smart solutions have become the need of the hour and is very rapidly influencing the Indian market. It has promoted the usage of smart and networked equipment that reduces downtime of any manufacturing facility, require lesser human involvement, and imply automatic operation of devices that can communicate, interpret and adjust on its own seamlessly,” states Bhangare.

Pankaj Gauba, Head Digital Manufacturing Group – India & Middle East, Autodesk
The key advantage of 3-D printing is that it enables single-step manufacturing, while eliminating the need for several processes like welding, painting and grinding. 3-D printing drives product innovation by making previously impossible designs possible. Further, it makes manufacturing more sustainable by reducing waste.

Elaborating on how technology usage has helped Testo India, a leading player in the test and measurement segment, Bhangare says, “Our share of business has increased considerably with the technology acceptance. In fact, it has enabled us to make much better and high-tech instruments to fulfil the need. For example, the cloud technology with testo Saveris 2 – Wifi Data Loggers help to monitor indoor climate – temperature & humidity of production houses, warehouses, R&D labs, etc., anytime, anywhere. All the measurement data is at your fingertips and with ability to give SMS alarms when limit values are violated. Further, simply integrating a smartphone into your routine parameter measurements has changed the measurement world totally. Reports are now available in a PDF format readily on any device—smartphone, laptop or tablet.”

Automation: The need of the hour

Technology is also being used by Indian manufacturers to address their current challenges. For example, automation is being widely used to address the shortage of skilled manpower and reduce the cost of operation.

“Automation is being used extensively mainly in the production of large quantities, repetitive parts. Major advantage with automation is that the productivity is far greater than manual methods. Also, uniformity is maintained in the produced parts. Since the past few years, demand for automation has gone up significantly due to the lack of skilled manpower. Especially, for smaller companies automation is making a lot of sense as they are always plagued by the challenge of retaining good workmen,” elucidates Shrinivas Shirgurkar, MD, Ace Designers, which is a leading manufacturer of CNC lathe machines in India.

Shrinivas Shirgurkar, MD, Ace Designers
The data generated with IoT can be analyzed to monitor what is happening on the machine. It allows for real-time analysis, which increases traceability leading to improved productivity. One can exactly pin-point finger on the faulty component and take corrective measures. Another advantage is that the sensors embedded in machines provide data which can provide predictive capabilities about life of certain components.

Automation is also being increasingly used by manufacturers to increase productivity, standardize the product portfolio and shorten development cycles. “Advanced automation is the way forward for industries to achieve the desired growth and higher productivity. Robot technology has now become one of the most dynamic areas for development. Following this trend, Lapp India is focusing on robotic cables and system solutions like Servo Motors that are needed for robot applications,” says Jarrault.

Sharing details about automation plays a vital role in test and measurement segment, Bhangare says, “Automation gives our products a whole new identity and makes them unique in the market. Intuitive and self-governed nature of the products makes them the choice of the end users. Automation definitely helps to bring out the world-class products.”

IIoT making manufacturing smarter

Whether you call it IIoT (Industrial Internet of Things), Industrial 4.0 or Smart Manufacturing, the concept has taken the manufacturing world by storm. It is often being termed as the next industrial revolution, and rightly so, as it has the potential to fundamentally reconfigure the industry. The key advantage for manufacturers implementing Industrial IoT solutions lies in improved decision making ability. Manufacturing equipment connected to a web-based network generates data, which upon analysis can aid manufacturers in making timely and effective choices.

“Software and computer networks make it possible to gather data and turn into actionable information to make better decisions about manufacturing processes, such as optimizing machine uptime, scheduling maintenance, etc. All of this put together means improved productivity, which in turn leads to maximizing profits,” agrees Shirgurkar. IoT solutions provide better visibility into faulty machine tool and help with predictive analytics capabilities for machine maintenance.

Shedding more light on the benefits of using IoT features in machining Shirgurkar says, “The data generated with IoT can be analyzed to monitor what is happening on the machine. It allows for real-time analysis, which increases traceability leading to improved productivity. One can exactly pin-point finger on the faulty component and take corrective measures. Another advantage is that the sensors embedded in machines provide data which can provide predictive capabilities about life of certain components. The next level in IoT is autonomous machines, which have the ability to correct themselves.”

The 3-D printing revolution

According to a study by the market research firm Technavio, some of the factors responsible for the huge shift from traditional manufacturing techniques to 3-D printing is the reduction in capital costs, raw material costs, and costs incurred during the reuse of scrap materials. As per estimates, 3D printing technology reduces material usage by nearly 30% to 70% as compared to traditional techniques. This results in faster speed to market for new products and a reduction in development costs.

“The key advantage of 3-D printing is that it enables single-step manufacturing, while eliminating the need for several processes like welding, painting and grinding. 3-D printing drives product innovation by making previously impossible designs possible. Further, it makes manufacturing more sustainable by reducing waste,” says Pankaj Gauba, Head Digital Manufacturing Group – India & Middle East, Autodesk.

While 3D printing is definitely revolutionary, it is currently at an evolving stage. At present, it is not very practical for regular applications as it can prove beneficial only in small batch production. That said, a lot of R&D efforts dedicated towards 3D printing, mainly on the material side, definitely makes it a technology to watch out for. Looking ahead, the industry stands at a tipping point of complete shift as the fully allocated costs associated with 3D printing are expected to fall well below the traditional manufacturing process — even with the upfront investment in the printers themselves.

In the coming years, in a bid to accelerate the ‘Make in India’ vision outlined by the government, Indian companies will step up the adoption of advanced technologies. While the adoption of IIoT is expected to be broad-based at various levels, 3D printing is also expected to find favor, particularly in small batch production.