Transforming the Manufacturing Landscape with Advanced Technologies
The evolution of automation and digital manufacturing is reshaping the Indian manufacturing sector, enabling it to compete globally and achieve significant growth. The sector has been experiencing significant changes in recent years due to the advent of artificial intelligence (AI), machine learning (ML), Internet of Things (IoT), data analytics, cobots and cloud technologies. These advancements are shaping the industry and enabling a shift towards smarter and safer manufacturing and Industry 4.0 practices.
Use of Robots/Cobots
Automation has gained traction in Indian manufacturing, leading to improved productivity, efficiency, and quality. Robots are being used for repetitive tasks, while robotic arms and automated assembly lines are streamlining production processes. Applications that require close working with human workers are being addressed by Cobots. This not only enhances precision and consistency but also allows human workers to focus on more complex and creative tasks.
Data Analytics Based Decision-Making
With the availability of vast amounts of data, Indian manufacturers are leveraging data analytics tools and techniques to gain insights and make data-driven decisions. Advanced analytics helps in identifying patterns, optimizing processes, and improving overall operational performance. This leads to better resource management and strategic planning, essential for maintaining a competitive edge.
Skilling and Workforce Transformation
The changing manufacturing landscape requires a skilled workforce to handle advanced technologies. Companies are investing in upskilling and reskilling programs to equip employees with the necessary skills to work with automation, AI, and other emerging technologies. This transformation is crucial for ensuring that the workforce can effectively operate and innovate within a technologically advanced environment.
Improved Product Development
Advanced technologies have accelerated the product development process. Virtual prototyping, simulation, and digital twin technologies enable manufacturers to design and test products virtually, reducing time-to-market and development costs. These innovations foster creativity and innovation, allowing for rapid adaptation to market demands.
Predictive Maintenance
IoT-enabled sensors and AI-powered analytics are being used to enable predictive maintenance for critical machines in real time. This improves efficiency, reduces costs, and minimizes disruptions by anticipating and addressing potential issues before they escalate into significant problems.
Sustainability and Energy Efficiency
Manufacturers are increasingly focusing on sustainability and energy efficiency. IoT sensors and data analytics help monitor energy consumption, identify areas for optimization, and reduce the environmental impact of manufacturing processes. By adopting sustainable practices, companies can reduce their carbon footprint and comply with environmental regulations.
AI in manufacturing
AI on the edge is helping speed up many processes, conserve energy and increase uptime. For example, AI based ‘teaching’ tools help reduce the set-up time of some Omron equipment by as much is 90%. Another example is the AI in machine controllers that enable PLCs to identify abnormalities at an early stage.
OMRON’s Role in Digital Manufacturing
To cater to this growing need and opportunity, OMRON, with its wide portfolio of automation solutions based on its “i-automation” concept, is committed to helping the manufacturing industry meet these challenges. The concept stands for “innovative-automation,” which is OMRON’s global manufacturing innovation direction based on three “i’s”: “integrated,” “intelligent,” and “interactive,” embodying three goals: “Digital engineering transformation,” “Autonomation beyond human abilities,” and “Advanced collaboration between people and machines.”
Empowered with this, OMRON strives to enable manufacturers with the right and customized automation solutions to increase productivity and quality, achieve more energy efficiency, and upskill the workforce with training and education services. While condition monitoring solutions and robotics portfolios offer significant benefits in achieving energy efficiency and productivity, OMRON’s i-BELT manufacturing site data utilization service streamlines the integrated management of diverse data to bring about further improvements in productivity and quality at manufacturing floors.
Overcoming Challenges in Automation Adoption
One of the major challenges in adopting automation and digitalization, especially for micro, small, and medium enterprises (MSMEs), is the need for better levels of flexibility, quality, and consistency amidst constraints like limited shop floor space, shortage of skilled manpower, and limited capital. Another hurdle is the availability of a partner ecosystem, particularly the role of system integrators (SIs) who can marry automation (including robots) with the required mechanical design and implement them at customer locations. This ecosystem is crucial for enabling MSMEs to adopt and benefit from automation technologies.
Emerging Trends in Automation
Some of the most promising and emerging technologies in the Indian automation and manufacturing space include data visualization, robotics, AI and machine vision inspection. Data visualization helps make vast amounts of shop floor data actionable, requiring an integrated architecture to gather and push data to the cloud layer in real time. Robot/Cobot adoption, while growing, needs to be faster to significantly impact productivity. Native AI on the edge is helping users to reduce the setting up time and improve uptime. Machine vision, widely adopted, can further benefit from advanced cameras and linking data to PLCs to achieve traceability across the supply chain.
The Future of Digital Manufacturing in India
Digital manufacturing is an important enabler for India’s manufacturing sector to achieve its trillion-dollar economy goal. It enhances competitiveness, drives innovation, and creates a sustainable and future-ready manufacturing ecosystem. By adopting digital manufacturing technologies, Indian manufacturers can improve operational efficiency, reduce costs, and enhance product quality, positioning India as an attractive destination for foreign direct investment (FDI) and technology collaborations.
By fostering digital manufacturing, India can further empower the MSMEs, optimize supply chain management, and drive productivity and efficiency. This transformation is essential for making India a global manufacturing hub and achieving long-term economic growth. OMRON is contributing to the same by empowering manufacturers with the right technology solutions to make world-class products in India for the entire world.
