Smart Manufacturing : Simpler Than You Think, More Essential Than Ever

“Smart manufacturing isn’t about adopting the latest buzzwords—it’s about solving real problems with clarity, creativity, and courage. In India, that’s not just innovation. It's a survival strategy.”— Dr. K. Subramanian, Senior Vice President, Ashok Leyland

May 2025 : At the recently concluded ACMA Automotive Smart Manufacturing THINK TURF 2025, powered by Pro MFG Media in Chennai to explore strategies for accelerating the shift to next-generation manufacturing.

Among the highlights was a thought-provoking keynote by Dr. K. Subramanian, Senior Vice President at Ashok Leyland, who offered a refreshing and relatable perspective on what it truly means to go "smart" in manufacturing—especially in the Indian context.

"Smart manufacturing," he began, "isn’t about complexity or buzzwords. It’s about purposeful action, simplified thinking, and contextual innovation."

Dr. Subramanian’s address opened with a seemingly unrelated but insightful analogy: buying a luxury car in India. While most would argue that our roads aren’t suited for luxury vehicles, he flipped the logic. Precisely because of poor road conditions, luxury cars—with their superior suspension and comfort—make more sense. Similarly, in a landscape marked by fragmented supply chains, daily operational firefighting, and infrastructure limitations, smart manufacturing is not a luxury—it's a necessity.

Drawing from decades of experience across both Indian and global settings—including a research stint in MEMS (Micro ElectroMechanical Systems) at Cornell University and manufacturing leadership roles at GE and Ashok Leyland—Dr. Subramanian shared vivid anecdotes illustrating how smart ideas don’t always require big budgets.

He cited real-world examples, including using 3D printing to solve common household issues like replacing broken pressure cooker knobs, and leveraging TRIZ, a structured Russian methodology for inventive problem-solving, to reconcile contradictory manufacturing demands such as formability and strength in advanced materials.

A recurring theme in his talk was resilience as a core outcome of smart manufacturing. Referencing Toyota’s swift recovery from a fire-induced supply chain disruption—thanks to real-time dashboards and digital twins—he stressed that agility in the face of crisis is perhaps the smartest capability any manufacturer can build.

Crucially, Dr. Subramanian underscored that India’s manufacturing sector doesn’t need massive digital overhauls to go smart. “Start small,” he advised. “Pick one KPI, one production line, one process. Run a 90-day pilot. If the ROI is clear, scale it.” Even simple interventions like video analytics to manage workforce groupings, WhatsApp groups for vendor updates, or dashboard-based shopfloor visibility can yield outsized benefits.

His four-point playbook for Indian manufacturers was clear:
1. Start small – Begin with a pilot that delivers quick wins.
2. Stay grounded – Simplicity scales faster than complexity.
3. Empower people – It’s not about replacing jobs, but transforming them.
4. Leverage India’s strengths – A young, tech-savvy workforce and proactive policy support.

From historical lessons on lean thinking to humorous nods to Charlie Chaplin’s Modern Times, Dr. Subramanian reminded the audience that true smart manufacturing blends people, machines, and purpose.

“Smart manufacturing isn’t about adopting the latest buzzwords—it’s about solving real problems with clarity, creativity, and courage. In India, that’s not just innovation. It’s a survival strategy,” he noted.

As India eyes its transition from a component manufacturer to a full-fledged global manufacturing leader, the time to act is now. And as Dr. Subramanian aptly concluded, smart starts small—but it must start.

Pro MFG Media Newsletter

Get regular manufacturing insights that matter and enable business.