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India is in process of transitioning towards adopting automation
Interviews- Nov 02,23
In this interview with Rakesh Rao, Ankit Jain, IT Head, WIKA India, explains how IoT enabled devices & solutions contribute to creating a smart manufacturing ecosystem.
Test and measurement (T&M) equipment form an integral part of various industrial sectors as these devices are used throughout different stages of a product's life cycle. WIKA, a leading global player in pressure and temperature measurement segment, offer a diverse range of IoT-enabled smart instruments and sensors. In this interview with Rakesh Rao, Ankit Jain, IT Head, WIKA India, explains how these AI-integrated solutions contribute to creating a 'smart' manufacturing ecosystem.
Which IT/automation tools (like AI, ML, IoT, data analytics, cloud, robots/cobots, etc) have witnessed increased usage in the manufacturing facilities in India in the last few years?
India has experienced a huge surge in the adoption and integration of various IT and automation tools within manufacturing facilities. In particular, artificial intelligence (AI) has witnessed extensive adoption in the manufacturing sector. According to the market research company Statista, the AI market in India is currently valued at $ 4.11 billion and is expected to grow at a CAGR of 19.99 per cent to reach a market size of $14.72 billion by 2030.
AI technologies including predictive maintenance, quality control, supply chain optimisation and production planning, have been embraced by the industry to enhance efficiency and decision-making. Furthermore, data analytics has played a crucial role in extracting valuable insights from manufacturing databases, optimising operations, enabling predictive maintenance, and improving product quality.
Predictive maintenance helps anticipate machinery breakdowns, reducing unplanned downtime and enhancing productivity, while quality control mechanisms have significantly improved accuracy and efficiency in identifying defects, leading to higher-quality end products.
All this has not just revolutionised the Indian manufacturing industry but has also paved the way for future technologies like autonomous systems and smart factories to harness the potential of AI technologies in India.
How are you leveraging digital manufacturing tools to improve productivity and efficiency at your facilities?
Test and measurement equipment form an integral part of various industrial sectors. These devices are used throughout different stages of a product's life cycle. WIKA has leveraged these advanced sensors by offering a diverse range of IoT-enabled smart instruments and sensors. These instruments are seamlessly integrated with radio units, facilitating connectivity between WIKA and third-party measuring instruments through standard interfaces. These AI-integrated solutions also contribute to creating a 'smart' manufacturing ecosystem in the era of smart machines.
Furthermore, our devices are completely connected to manufacturing machines to monitor their availability, planned vs actual production and quality. Monitoring other critical parameters of the machine facilitates predictive maintenance and enhances overall equipment efficiency (OEE). Today, WIKA’s IoT-enabled sensors are playing a vital role in achieving 85 per cent OEE, with an aim to reach 90 per cent.
What are the key hurdles faced by companies when they are planning to adopt automation/digitalization?
India is still in the process of transitioning towards adopting automation. While many companies have adopted an enthusiastic approach to adopting these technologies, several others are still taking measured strides. These companies often encounter hurdles in the areas of:
Employee buy-in/resistance to change: One significant challenge is gaining employee support or countering their resistance to change. At times, resistance arises due to employees accustomed to traditional methods, being overwhelmed by new technologies and the fear of job displacement.
Lack of time, budget and trained resources: For the implementation of automation and digitalization, companies require adequate time, financial resources and a strong pool of trained personnel. However, many companies struggle with limited budgets, tight schedules and a shortage of skilled individuals to manage and implement these technologies effectively bringing more roadblocks and unsatisfactory results post-implementation.
Alignment with the vision of the organisation: Changing business dynamics calls for revisions in the organisational modus operandi. Instead of making automation and digitalization a mechanical move, they should be made to align with the organisation's broader vision and objectives. Lack of alignment can lead to incoherent efforts, wasted resources and an ineffective implementation strategy.
To facilitate a smoother adoption process and a hassle-free transformation, companies should focus on continuous communication with the employees and top management explaining the advantages of digital transformation. Investing in training and awareness programs can alleviate concerns and prepare them for the transition. The companies can also initiate the transition with smaller-scale pilot projects to demonstrate the benefits of automation, allowing employees to experience the positive impact firsthand. This can then be gradually scaled up for a complete transition. Companies need to strategically address these challenges and navigate the organisation toward seamless integration.
Are there low-cost entry routes into digitalization, especially for small & medium enterprises (SMEs)?
Digitization is the only way forward. Many SMEs can take small yet decisive steps to embark on their digitalization journey. The initial step is to make a complete digitization roadmap by plugging all the gaps and touchpoints. This involves conducting a thorough assessment of the digital maturity of the company and identifying the goals and vision of the organisation to imbibe digitization.
Once the goals are defined, the next step is to bring buy-in of all the team/stakeholders by providing the necessary digital skills training to enhance their understanding of digital technologies relevant to their roles.
It is not necessary to transition in one go. Instead, break the digital roadmap into small modules. By breaking down the digitalization journey into manageable modules, each focusing on high-impact areas, organisations can boost management confidence, ease their adaptation to new technology and gradually evolve into a fully digitalized organisation. This approach ensures a cost-effective and efficient transformation, driving the organisation towards success.
What steps are you taking to make your products/solutions “smart”, “intelligent”, etc? Any recent example, you would like to share with us?
Most industries are moving towards incorporating smart electronics into their operations. WIKA has always been future-ready with IoT-enabled instrumentation products and solutions that align with the industry trend. The global instrumentation giant has a road map in place to manufacture IoT-enabled automated solutions throughout the value chain, covering pressure, temperature, level, flow and force solutions. They set a standard of excellence in every operation. To align our products globally and make them ‘smart’ and ‘intelligent’, WIKA has a robust and centralised Research & Development Centre in Klingenberg, Germany. The centre vehemently works to incorporate the company's dynamism and innovation potential in every product WIKA offers. Our smart instrumentation solutions are further customized are tailored to meet the unique requirements of various industries.
How is the automation and digital manufacturing space changing?
Several transformative trends are shaping the automation and digital manufacturing industry, revolutionising the way businesses operate. Some of these trends include:
Artificial Intelligence: AI is at the forefront of digital transformation, enabling machines to learn from data, adapt to new inputs and make decisions autonomously for tasks that traditionally required human intelligence. It has also enhanced predictive maintenance, process optimisation and quality control in every operation.
Advanced Robotics: Many companies are incorporating advanced robotics in their operations. These sophisticated, agile and collaborative robots can handle complex tasks with precision, improving efficiency, productivity and safety in manufacturing processes.
Industrial Internet of Things: IIoT interconnects devices and sensors, facilitating real-time data collection and analysis. This connectivity optimises production, reduces downtime and enhances overall operational efficiency.
Edge & Cloud Computing: Edge computing processes data locally on devices, minimizes latency and enhances real-time decision-making. Cloud computing, on the other hand, provides extensive storage and computational power for data analysis and long-term insights.
Cybersecurity: Increased digitalization and interconnected devices make robust cybersecurity essential to protect sensitive data and systems from cyber threats, ultimately maintaining the integrity and confidentiality of operations.
Digitalization and Industry 4.0/5.0: As industries are moving from Industry 4.0 to 5.0, the digital technologies of AI, IoT and data analytics are further enhanced for optimised manufacturing processes, supply chain management and customer engagement through data-driven insights and automation.
3D Printing: 3D printing, or additive manufacturing, is an area that is gaining prominence for rapid prototyping, customization and cost-effective production. It allows intricate designs and reduces waste by using only the necessary materials.
Sustainable Manufacturing: Most manufacturers are putting an additional focus on eco-friendly practices, energy efficiency, waste reduction and circular economy principles to reduce their environmental impact and contribute to a greener future. Automated and smart solutions are playing a pivotal role in enhancing these criteria.
All these trends are collectively driving the transformation of the automation and digital manufacturing landscape, offering increased efficiency, sustainability and innovation to the industry.
How important will digital manufacturing be for India to become a $1 trillion manufacturing economy?
Digital manufacturing holds immense importance for India's ambition to achieve a $1 trillion manufacturing economy. Adopting digital technologies like automation, robotics and IoT principles has helped India to significantly enhance its manufacturing efficiency and productivity. This, in turn, has enabled Indian manufacturers to compete more effectively in global markets, by producing higher-quality goods and improved time to market.
Digitalization of the manufacturing industry is of vital importance as it weighs 14% of India’s total GDP. By fully integrating digitalization, this sector can not only improve its efficiency and productivity, but also attract more investments, generate employment and drive technological advancements. Achieving the $1 trillion manufacturing economy goal requires a holistic approach that leverages digital technologies to optimise operations, reduce costs and meet the increasing demand for high-quality products domestically and internationally.
Test and measurement equipment
pressure and temperature measurement
IoT-enabled smart instruments
sensors
Rakesh Rao
Ankit Jain
WIKA India
smart manufacturing
smart machines
Digital manufacturing
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