Digitalization is the Road to transform Manufacturing Sector in India

#SmartManufacturing #DigitalTransformation #Baumer

Shyam Warialani

In the present times, digitalization has transformed numerous sectors and it is on its way to transform the manufacturing sector. Mr. Shyam Warialani, Managing Director, Baumer Technology India Pvt Ltd., shared with Pro MFG Media the journey of digitalization and smart manufacturing.

Q: Digital technologies are transforming the manufacturing sector. Could you share with us changes in the process instrumentation and sensor-based solutions?

Mr. Warialani: The process instrumentation provides real time process values whereas sensors help you to take real time information compared with process parameters required to optimise the productivity or trends that are needed to sustain in terms of output required. With digitalisation comes the rise of trends such as Industry 4.0, smart manufacturing, and smart factories.

Digital transformation is a combination of traditional manufacturing processes enhanced with new advance technologies involving Robotics, Sensors, large data analytic, working together to drive manufacturing forward and address inefficiencies in the current sector. Driven by technology, Industry 4.0 will transform production and reshape businesses, creating greater efficiency and better relationships between producers, suppliers, and customers. According to me digital transformation is “the integration of digital technology into all areas of a business, resulting in fundamental changes to how businesses operate and how they deliver value to customers.” With digitalisation comes the rise of trends such as Industry 4.0, smart manufacturing and smart factories.

Industry 4.0, also known as the fourth industrial revolution, is all about focusing on connectivity and communication. It presents us with a future where devices are connected so that they can communicate and make smart decisions.

Q: You have been a witness to the evolution of manufacturing for over four decades? Could you give sectorial insights with regards to the implementation of smart manufacturing? Which sectors are fast adopting advanced solutions to make their shop floors smart?

Mr. Warialani: Smart manufacturing is applicable in every manufacturing segment such as oil & gas, petrochemicals, refining, fertilizer, power, etc., which are highly influenced by the government. These sectors are equipped with large budgets and extremely concerned with safety and regulations. Initially all these sectors adopted smart manufacturing and eventually giant cement, power, steel plants and major Pharma plants embraced smart manufacturing.

Numerous private players saw early benefits of cost saving, reduced shutdowns, higher efficiency, and reliability, behind adopting smart manufacturing. Currently, there is immense focus on smart manufacturing in automotive, metal and allied industries such as pumps, valves, and FMCG. The white goods manufacturers are also adopting robotic and smart manufacturing.

Q: One of the major challenges faced is the integration of legacy systems with the new control and instrumentation solutions. What is your advice to the system integrators on the best practices for optimized solutions?

Mr. Warialani: Constant change and upgradation is one of the biggest challenges faced by automation industry. Apart from that identifying and choosing the suitable smart device is another challenge for automation industry. It is essential that organizations assess and evaluate their present and future requirements before adopting any smart devices. I would advice organizations to opt the latest and universal solutions and must considering over all return on investment, speed, quality improvement, reduced human skills, safe & multiple device data transmission, and overall safety of equipment, plants, and human beings.

Q: How can MSMEs overcome barriers for implementation of smart technologies and transform manufacturing to digitisation?

Mr. Warialani: This is one of the biggest challenges faced by the manufacturing sector. Unable to evaluate through the benefits and overall cost reduction plays the major hurdle in MSMEs implementing smart technologies. The large manufacturers and system integrators must indulge in training, knowledge distribution to MSME. Automations such as Robot, Cobos, and other equipment must be made available on lease by large system integrators to MSME which will help them to visualize returns and benefits. MSME must go through a learning curve for them to really visualize smart manufacturing. Our organization is a good example wherein we have adopted the operation of CNC with help of Cobo. Also, we are learning to integrate CNCs for data analysis which will help us to minimise cycle times, reduce wasteful activities, monitor operators for higher output etc. Several activities that are hand driven must be tried with simple and effective automation for consistent and quality production with higher speed.

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