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PRODUCTIVITY IMPROVEMENT A bigger leap towards Smart Manufacturing

Dec 18, 2018

We see the manufacturing industry in India turn towards a more responsive and unified manufacturing process, combining technology. With this, the 4th edition of the CII Smart Manufacturing Summit, which was recently held in New Delhi, provided an opportunity for companies to understand the implementation of Industry 4.0 and how to make smart manufacturing a success. A post-event report...

Manufacturing is shifting from automated to autonomous systems. The global manufacturing scene is being converted by digital technologies, such as, Industry 4.0. To help smart manufacturing leaders implement and take forward their smart manufacturing journey, the fourth CII Smart Manufacturing Summit was recently held in Delhi that brought together international and national experts from the industry, government, multi-lateral agencies and academia. This provided them an opportunity to deliberate on various aspects pertaining to adoption of smart manufacturing in India. Besides, the summit witnessed the launch of the CII online portal, www.ciismart.in, which brings forward case studies of more than 25 companies from across the country that have experienced an effective increase of 20-30% in their productivity, by deploying smart manufacturing. An MoU between CII and ZonesCorp UAE towards future collaborations on manufacturing was also signed.

Industry must become cognizant

At the summit, Prof Ashutosh Sharma, Secretary, Department of Science and Technology, highlighted that conventional ways of doing incremental business will no longer suffice and India will need to push its people to adopt disruptive ways of doing business, while Dr Martin Ney, Ambassador of Federal Republic of Germany, cited that digitalisation in manufacturing means modelling products with software rather than hardware, manufacturing more variants on the same assembly line, embracing new business models and creating jobs that were unheard of earlier.

Furthermore, Dr Vandana Kumar, Joint Secretary, Department of Industrial Policy and Promotion (DIPP), mentioned that the industry must become cognizant of ongoing mega trends, which are in the form of new technologies, business models and threats. Talking about NITI Aayog’s initiatives, Anna Roy, Advisor, NITI Aayog, proposed for a sector-wise approach for smart manufacturing and mentioned that the GoI is looking to develop plug and play infrastructure, where companies could benefit from already established facilities, testing labs and access to new technologies.

Government & industry need to come together

Moving on, Dr Nobert Gaus, Executive VP and Head - R&D in Digitalisation and Automation, Siemens AG and Representative, Platform Industrie 4.0, Germany, showcased how digitalisation is changing everything, from products to value chains to society. Moreover, Chandrajit Banerjee, Director General, CII, emphasised the need for the government and industry to come together and adopt the P E T formula–People, Enablement and Technology. He further added that up-skilling and re-skilling of labour will be critical in ensuring that smart manufacturing will become a success.

Using 3D printing

Throwing light upon Hero MotoCorp’s efforts in bringing out the highest efficiency, Vijay Sethi, CIO, Hero MotoCorp, shared that Hero MotoCorp had created a digital replica of its factories to stimulate possible optimisations at the assembly line to better efficiency. This prevents Hero’s day-to-day operation from getting affected. Another key takeaway of the summit came from Chandrashekhar Shetty, GM, Triveni Turbines, who explained how the implementation of Industry 4.0 data analytical solution helped them identify and address top 5 reasons for downtime. The implementation of Industry 4.0 resulted in productivity increase by 30% at Triveni.

Plus, Mukesh Manocha, AGM, Honda Cars India, mentioned that the use of 3D printing for quality checks at Honda’s headlamp assembly plant enabled the company to create a product that is 70% lighter and 60% cheaper. Sameer Gandhi, MD, Omron Industrial Automation India, added by recommending starting with the big picture, choosing a reliable partner and following a step-by-step approach towards implementation.

AI: Key to the future of manufacturing

Withal, Scott Hunter, Regional Business Leader (APAC)–Manufacturing, Microsoft–Singapore, talked about how technology is enabling the fourth industrial revolution and how Microsoft itself has delivered excellence in digital manufacturing by implementing Industry 4.0 design principles of connected, predictive and cognitive systems. Additionally, Dr Ganesh Natarajan, Executive Chairman and Founder, 5F World, emphasised on Artificial Intelligence and how it holds the key to the future growth in manufacturing.

Customer-supplier relationship

The summit also had Bipin Jirge, MD, IFM Electronic India, talk about built-in sensors and actuators, which form the basis of Industry 4.0. He mentioned that the IO link technology allows process transparency from the machine to ERP to optimise existing automation to achieve maximum efficiency and cost saving. Rama Shankar Pandey, MD, Hella India Lighting, further spoke about the new world of co-creation of innovation, where supplier & customer relationships are getting re-defined in terms of risk sharing, uncertain & evolving deliverables, focusing on solutions than fixed specifications, ‘speed & skilling of human interfaces’ becoming the key to success. Kumar Virani, Manager– Manufacturing, SKF India, added by explaining about SKF’s smart spindle, which resulted into zero surprise failure through the use of real-time data analytics, diagnostics and predictive maintenance supported by data validations and live reporting.

Furthermore, Sunil Mathur, Chairman, CII Smart Manufacturing Council and CEO & MD, Siemens India, spoke about Industry 4.0 being an enabler for SMEs in broadening their offerings using already available resources. The summit came to an end with Sunjay J Kapur, Co-Chairman, CII Smart Manufacturing Council and CEO, Sona BLW, stressing that change is no longer the only constant, disruption is.

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