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SMART MANUFACTURING Recognising excellence in the manufacturing sector

Apr 16, 2019

With the fourth generation of the industrial revolution gripping the nation, the recently-held CII conference on the ‘Future of Manufacturing’ and ‘Pinnacle Awards for Excellence in Manufacturing’ provided an overview of the new era of manufacturing, driven by upcoming transformative technologies and the prospective future of upcoming developments. A post event report…

The manufacturing industry in India has achieved great heights with the oncoming wave of globalisation paired with Industry 4.0. In this context, to felicitate the remarkable contribution of companies across the sector, the two-day CII Conference on ‘Future of Manufacturing’ and ‘Pinnacle Awards for Excellence in Manufacturing’ was held recently in Mumbai. The objective of the conference was to aid sharing of knowledge, industrial practices and to inspire innovation.

CII Pinnacle Awards for Excellence in Manufacturing

CII had launched the Pinnacle Awards for ‘Excellence in Manufacturing’ in September 2018. This is one of the leading awards that CII has initiated with an objective to recognise and reward excellence in manufacturing, to facilitate sharing of knowledge and implementation of best practices among the industry and to inculcate the culture and spirit of manufacturing innovation so as to make the sector globally competitive. The finale of the CII Pinnacle Awards 2019 for Excellence in Manufacturing was held in Mumbai in February, 2019. Around 135 applications were received from companies across the country for the various categories, of which 16 applications were shortlisted by the jury for 6 categories, for both large scale enterprises as well as SMEs for final presentations.

The jury/expert group comprised of the following members—Shailesh Sheth, Corporate Strategy Adviser, Management & Manufacturing Technology; Satish Jamdar, Former MD, Blue Star; Suresh Tanwar, Former Chief – Group Safety & Health, Tata Sons; Ravi Damodaran, Chief Technology Officer, Greaves Cotton; Shalini Kamath, Founder & CEO, Shalini Kamath & Associates and Kiran Nataraj, Co-Founder & CEO, Entrib Analytics Technology.

In association with the awards finale, a conference on ‘Future of Manufacturing’ was also organised that highlighted how manufacturing across the world is undergoing the greatest changes and how digitisation is changing the way one lives, as smart and connected systems are increasingly pervading all types of applications. The keynote sessions were held on topics, such as, ‘Towards a $1 Trillion Manufacturing Economy’, ‘Weld 4.0: Future of Intelligent Manufacturing’, ‘Intelligent Manufacturing: Is Technology a Disruptor or Enabler?’, ‘Industry 4.0 – Growth Engine for Indian Economy’ and ‘Making Digital Manufacturing Happen’.

CII Pinnacle Awards 2019 Winners

  • Operational Excellence

    Large Scale Enterprises - Fiat India Automobiles, Pune

    Small and Medium Enterprises - Takshi Auto Components, Pune

  • Environment, Safety and Health

    Large Scale Enterprises - BASF India, Mumbai

  • Gender Diversity and Inclusion

    Large Scale Enterprises - Cummins India, Pune

  • Organised and Impactful R&D Efforts

    Large Scale Enterprises - Bharat Forge, Pune

    Small and Medium Enterprises - Grind Master Machines, Aurangabad

  • Future Ready Manufacturing

    Large Scale Enterprises - Godrej & Boyce, Mohali

  • Young/Emerging Manufacturing Leaders of Tomorrow

    Large Scale Enterprises - Sidheswar Kumbhar, Senior Manager, Godrej & Boyce, Shirwal

    Small and Medium Enterprises - Sameer Kelkar, CEO and R&D Head, Grind Master Machines, Aurangabad

Conference on ‘Future of Manufacturing’

The conference commenced with the inaugural session titled, ‘Towards $1 Trillion Manufacturing Economy’. The speakers for the session were K Nandakumar, CMD, Chemtrols Industries and Member of CII National Council and Rahul Jain, Senior Partner & MD, BCG India. Nandakumar spoke on the global economy and how it necessitated contracts to help sustain it. He also spoke about the internal trade and addressed the initiatives taken by the government. He cited, “The government has recognised that the internal trade needs to be deeply integrated,” and suggested that doing so from the district level could prove beneficial.

Moving on, Jain addressed the emergence of new businesses and how Industry 4.0 would facilitate them. He conferred that a concerted effort is needed to be undertaken by the government and the people in order to emphasise on ease of doing business, rigorously focus on skill building, debottling our existing infrastructures and ensuring that the upcoming inventions in technology are up to par with emergent Industry 4.0 centres.

Operational excellence

After the erudition of the initial addresses, the conference proceeded to its presentations segment. The jury for the segment were Shailesh Seth, former MD, Corporate Strategy Advisor; Satish Jamdar, former MD, Blue Star; Suresh Tanwar, former Chief— Group Safety & Health, Tata Sons; Ravi Damodaran, Chief Technology Officer, Greaves Cotton; Shalini Kamath, Founder & CEO, Shalini Kamath & Associates; and Kiran Natraj, Co-Founder & CEO, Entrib Analytics Technology. The opening presentations were on the topic of operational excellence, and were presented by Salcomp Manufacturing Co, Chennai; Takshi Auto Components, Pune; and Fiat India, Ranjangaon, Pune. These presentations were directed towards the use of lean techniques in industries and work spaces.

For their presentation, Arun Kumar and Vijay Kumar, both from Salcomp Manufacturing Co, spoke on their key initiatives on becoming a Lean company. They addressed that, by having a different culture, focus could be laid upon improving quality and lowering costs. The presentation also gave a brief introduction to SLIM — Salcomp Lean Initiative for Manufacturing and MWE — a term coined to mean must-win battles.

For Takshi Auto Components, the presentation delivered by Ravindra Samudra and Jayanti from the same company, illustrated their techniques of OE, which included quality enhancements, value engineering and supplier upgradation — a programme to uplift suppliers in their business. The presentation acquainted the audience with their culture of innovation which, through their concept of idea management where the workers suggest implementable ideas, enables value-addition through innovation and has successfully improved 20% of the cycle time and enhanced productivity.

Next, the presentation by Fiat India was led by Krishnan Ramachandran and Rajesh Pawar from the same company, who addressed their system of operational excellence, and which further used 386 methods and tools as key activity perfection indicators. With their attention focussed on the production of engines and transmission systems, FIAT emphasised on the benefit versus cost ratio measured through e-matrices, to ensure safety and quality of their products.

Weld 4.0

Following this, the conference held a keynote session on Weld 4.0: Future of Intelligent Manufacturing. The keynote session was delivered by Rashmi Ranjan Mohapatra, MD, Kemppi India and expounded on welding as an integral part of manufacturing. Also elaborating on digitalisation in welding, he presented how the onset of Welding 4.0 will affect the industry in regards to decreasing the costs and increasing potential. This digitalisation would also help with documentation, which would aid the co-ordinator and welding processes with cloud-based solutions, such as, Weld Eye. He pointed out that training is a prerequisite in handling Industry 4.0, as welding requires physical dexterity, but Industry 4.0 will dwell on how a machine is welding and communicating with other machines.

Environment, health & safety

With the oncoming urgency to maintain a healthy environment within the industries as well as regulate safety measure, the first presentation in this segment was by BASF India, Mumbai, presented by Sharad Murudkar and Dr Dhananjay Deulgaonkar. With plants in various chemical sectors, the presentation addressed BASF’s responsible care initiative, which implements systems and rebuilds sites from EHS perspectives. The key initiatives named were recovery of resources by process of optimisation and reduction in hazardous wastes.

Following this, the presentation by Onkar Nalage and Meghraj Mahanawar from Godrej & Boyce, Shirwal Plant, mentioned the sustenance of the company in the global market by addressing the initiatives for improvement of environment at the company as well as near-by villages. The representative cited, “Our main motto, the basic philosophy is based on garden green outside, hospital clean inside.”

Gender diversity and inclusion

The undisputable gender divide in the industry proved to be an ardent topic for the upcoming presentations, which were under the segment of Gender Diversity and Inclusion. The presentation by Cummins India, Pune, was put forward by representatives from the HR team, Chahat Garg and Soumitra Mehrotra, who highlighted the need to change the mindset for having working women in manufacturing. With suitable infrastructural changes, the company addressed the question of bringing women on board head-on. They also addressed the growing participation of women, which had grown from a meagre 9% to a stunning 31% over the course of just a few years.

The presentation by Gangadhar Gulviand and Shivani Jagadale from Pernod Ricard India, Nashik, laid focus on the paradigm shift in women-based occupations. From employing and training tribal women to the availability of provisions, such as, canteens and medical health centres and training them in self-defense, the presentation stressed on the company’s focus to make women self-reliant in every aspect.

Role of technology

Following the presentations, the subsequent keynote session was conducted on the topic, ‘Is Technology a Disruptor or Enabler?’ by Amol Ghuge, Manufacturing Account Cluster Head—IoT, Industry 4.0, Tata Consultancy Services. He stated that the industry today focuses on quality over quantity.

Research & development

The next segment of presentations was under the topic of ‘Organised and Impactful R&D Efforts’. The segment commenced with a presentation by Ador Welding, Mumbai, presented by Anirudh Vilekar and Sachin Dobhada. While elucidating on the initiatives, the representatives spoke on the projects undertaken for the national cause, projects which increased the turnover and projects, which were significant in making about a change.

This was followed by a presentation by Bharat Forge, Pune, which highlighted R&D in the artillery sector. Speaking on this topic, Sameer Bhale and Pramod Puranik noted, “We have a dream of being the global power house in the artillery system,” while speaking about the development of artillery weapons.

Next, Sameer Kelkar and Abhishek Mahajan from Grind Master Machines, Aurangabad, briefed about the R&D in specialised robotic machining. The presentation addressed the collaborative technologies used to develop equipment and machines that are supplied to global markets.

The final presentation was by Kuntesh Radadiya and Trinayan Jyoti Saikia from Sahajanand Technologies, Ahmedabad, which highlighted the challenges in the diamond industry prior to the introduction of machinery for cutting and sawing with the use of lasers and machinery for shaping and polishing diamonds.

Industry 4.0: The Indian context

The keynote session on the topic of perhaps the most significance in the present context of digitisation in India was conducted as ‘Industry 4.0–Growth Engine for Indian Manufacturing’. The session was led by Saibal Roy, General Manager–Industry Services, Siemens India, who briefed on the impacts of Industry 4.0 on industrial aspirations in India. “Technology is moving at a pace we never thought of,” observed Roy during his address. The presentation briefed on how digitalisation has changed the way we think, the way products are manufactured and brought a change in the pace of innovation.

Future-ready manufacturing

The upcoming presentations approached the topic of ‘Future Ready Manufacturing’, which was given by Abhishek Sharma and Prashant Khulla from Godrej & Boyce, Mohali Plant. They spoke on initiatives undertaken to realise the vision of lowest cost appliance producer by practising excellence tools. The phases for realising this included using basic lean tools for improving production, lean management and introduction of TPM for plant efficiency.

Following this, S Rajendren and S K Satpathy from J K Tyre & Industries, Chennai, in their presentation, expounded the manufacturing of kiosk system used by workers for HR purposes like, accessing their records & applying for leaves as well as getting them sanctioned. “We give importance to talent and individual plans,” cited the representatives while conferring about worker assessment to provide opportunities for skill growth.

Leaders of tomorrow

For this dynamic topic, the first presentation was delivered by Kelkar from Grind Master Machines, Aurangabad, who highlighted his passion to innovate and build newer technologies. The subsequent presentation was by Sanjay Thorat from Fiat India Automobiles, Ranjangaon, Pune, who spoke on his projects on capacity enhancement, accommodating demands and catering to requirements. The segment concluded with the presentation by Siddheshwar Kumbhar from Godrej & Boyce, Shirwal Plant, who highlighted the vision of the company and the opportunity it presented to make more than just a career from a job.

Globalisation 4.0

The valedictory session was on Globalisation 4.0–India’s Advantages and Challenges. The session was conducted by Parakram Sinh Jadeja, CMD, Jyoti CNC Automation and S Sundarram, MD, Lincoln Electric. In his address, Jadeja discussed globalisation with respect to the challenges faced by India. Also speaking on the topic was S Sundarram, who focussed on why globalisation is essential and which areas to focus upon. He emphasised on the advantages of the Indian market with respect to Industry 4.0 and addressed the socio - economic changes.

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