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The fourth Industrial Revolution and India
Articles- Mar 01,19
Industry 4.0 is a blend of state-of-the-art manufacturing, cutting edge artificial intelligence and related cyber-physical systems.
Industry 4.0 is a blend of state-of-the-art manufacturing, cutting edge artificial intelligence and related cyber-physical systems. Sunil Gaekwad observes that in the era of Internet of Things (IoT) and Machine Learning, Industry 4.0 assumes immense relevance in transforming conventional manufacturing to digital manufacturing.
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Sunil Gaekwad, Assistant Professor, Department of Mechanical Engineering, NIE since August 2011, has been the coordinator for the NIE CNC Training Centre since June 2012. He completed his BE in Mechanical Engineering at NIE in 2009 and M.Tech in Tool Engineering at the government Tool Room & Training Centre in 2011. He is currently pursuing his PhD at the JSS Science & Technology University in the field of tooling applications of ABS through the use of additive manufacturing. He is a member of the executive committee of the Additive Manufacturing Society of India.
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The first time humankind could store and use energy at will was only possible because of its ability to control and manipulate steam. In the 18th century, Thomas Newcomen developed the first piston engine. Newcomen, along with Richard Trevithick, George Stephenson and their ilk ushered in the first Industrial Revolution. The power of mechanisation was so great that, by the early 19th century, the word ‘luddite’ cropped up. Luddites were people who wilfully destroyed machinery in fear of their livelihoods. It is this fear that is now rife amongst workers and machine operators in factory floors across the country.
The 4th industrial revolution, sometimes called 4IR or Industry 4.0, follows up what steam, electricity, assembly lines and computers have been doing in the past century. Industry 4.0 is a blend of state-of-the-art manufacturing, cutting edge artificial intelligence and related cyber-physical systems. Industry 4.0 is poised to strike a substantial blow to the old school. In the era of Internet of Things (IoT) and Machine Learning, Industry 4.0 assumes immense relevance in transforming conventional manufacturing to digital manufacturing.
‘The Fourth Industrial Revolution’is a book by Professor Klaus Schwab, Founder and Executive Chairman of the World Economic Forum, which outlines how this fourth revolution is fundamentally different from the previous three, all of which were driven by drastic advances in technology, through the amalgamation of the physical, digital, mechanical and biological. Additive manufacturing, along with internet of things, big data, advanced robotics and automation systems, is one of the horsemen of the 4th industrial revolution. Subtractive or conventional manufacturing, similar to and as intricate as sculpting, involves a block of metal being cut into a myriad of shapes and sizes.
Additive manufacturing, on the other hand, involves accurately positioning layer upon layer of material to build the final product. Additive manufacturing, which used to be called Rapid Prototyping and 3D printing, has the capability to handle plastics, alloys, food, and even human tissue. This immense flexibility has resulted in its use in all fields of science under the sun.
Scientists and doctors, along with engineers, are now working on ways to make or ‘print’ everything from spoons and spanners to surgical instruments and human organs. The current boom in additive manufacturing is so prevalent and the cost of the systems are at such a free fall, that, the Additive Manufacturing Society of India estimates that in the next few years most engineering colleges in the country will have some form of 3D printing systems as part of their curriculum. World Economic Forum indicates that India must become a centre for innovation and reap the social and economic benefit from accelerating progress in increasing the readiness of its people and firms to adopt new technology.
Importance of smart factories
It is this unrelenting march of technological progress that India faces in its immediate future. Forbes estimates that, by 2022, there will be more than 100 million new entrants into the job market. This would mean initiating a new system of employment that creates nearly 9 million jobs a year, which is a rate of increase the likes of which has never been seen in a country that will be the third largest economy in the world in the next decade. The Consortium of Indian Industries (CII), in association with Grant Thornton have published a comprehensive report titled ‘India’s Readiness for Industry 4.0’ which states that one of the most important cogs in Industry 4.0 is the creation of Smart Factories.
A smart factory is a manufacturing facility in which the production and logistics systems primarily organise themselves without human interventions. These factories rely on cyber physical systems linking the physical and virtual worlds by communicating through an innovative IT infrastructure. A system of this sort with perfect harmony between the digital and mechanical systems has been titled digital manufacturing. This new wave in the manufacturing arena which aspire in being more technologically advanced, more efficient, more reliable and more cost effective than the norm right now.
The human factor in these factories, the employees, help firms realise their digital transformation. An employee’s skills and their aptitude for new skills are always most affected by disruptive technology. This affects both the employees and the company’s effectiveness and efficiency. It requires them to acquire new skills in order to get well equipped with the digital workplace.
Hiccups
Forbes says by 2026, 64 per cent of India’s population will be in the 15-60 age group. In other words, in the next 8 years our country will have an immense workforce ready for the millions of jobs that Industry 4.0 will need. However, the greatest hurdle that faces us is the lack of skill and training that this workforce actually has. The fact that our workforce is hesitant to learn and unwillingto adapt to these revolutionary changes makes it doubly difficult to be progressive.
This is the challenge facing industry and academia alike. It is imperative for students and graduates to understand that being trained in obsolete technology will not get them jobs. It falls on the educators in the country to prepare the students to be more adept at learning. The students need a better blend of theoretical and practical teaching. More the students use their hands, the better their chances of learning the technology. Research, innovation and development in technology all have their roots in an innate understanding of the basics which can only be mastered by the students working with the technology rather than just being taught how to use it. All this is only possible if the often contentious connection between academia & industry is strengthened and focussed.
The panacea
The industry, on its part, must ensure that its work force is kept relevant and made future proof. The good news is that both parties understand the issue and are working towards agreeable solutions. Corporate and technology giants in the country are now in continuous touch with academia to develop relevant curriculum and infrastructure. The number of students seeking internships and on-site training is increasing every year. The private sector is working with state and central governments to set up skill development centres throughout the country. The Government has set up numerous schemes and programmes to aid the effort in making India ready for the 4th industrial revolution.
According to Indian Brand Equity Foundation, the Government of India has set an ambitious target of increasing the contribution of manufacturing output to 25 per cent of Gross Domestic Product (GDP) by 2025 from the present 16 per cent. The role of the government as a facilitator is not only to extend support to the manufacturing sector, but also take reformative steps to encourage wider adoption of technology.
Taking cues from countries such as Germany, the central government is working towards proposing a proper regulatory framework, induce competitiveness and form a conducive policy environment to enable Industry 4.0 ecosystem in the country. One such grassroots movement is the Skill India Campaign. It was launched in 2015 and aims to train over 400 million people in various skills by 2022. It involves numerous schemes such as National Skill Development Mission, Pradhan Mantri Kaushal Vikas Yojana and National Policy for Scheme Development and Entrepreneurship. In the budget of fiscal year 2017-18 the Government of India set aside ?Rs 17,000 crore, the highest ever allocation to this sector, in order to boost the Skill India Mission.
The Automotive Mission Plan 2016-26 (AMP 2026) is another initiative and emphasizes the government’s collective vision on how the automotive sector should grow regarding size, contribution to national development, technological maturity, global competitiveness and institutional structure. It aims to make India among the top three automotive industries in the world and increase exports exponentially to reach 35-40 per cent of overall output. It also intends to increase the contribution of automotive industry to the GDP to over 12 per cent, generating 65 million more jobs as well as increasing the size to $300 billion by 2026.
In addition, the Government has launched the Faster Adoption and Manufacturing of Hybrid and Electric (FAME) India scheme in 2015 with a capital outlay of $122.3 million. It is based on NEMMP (National Electric Mobility Plan) 2020 road map and covers all segments i.e two, three wheelers, cars, LCVs, buses, and all forms of hybrid and pure electric vehicles. A recent report by McKinsey & Company, states that, if Indian firms adopt Industry 4.0 across manufacturing, supply chain, logistics and procurement, they can boost profits by 40 per cent at less than 10 per cent of the planned capital expenditure.
It is clear that Industry 4.0 presents tremendous opportunities and highlights the need for a highly trained and flexible workforce and production capacity that can answer the needs of tomorrow as well as those of today. It is time to lead the country into the new world and not just participate in the process.
Over the past century the world has moved on from ‘knocker-uppers’ to alarm clocks on mobile phones, from ‘lamp lighters’ to wireless charging. As Eric Hoffer, an American philosopher said, “In times of change, learners inherit the earth; while the learned find themselves beautifully equipped to deal with a world that no longer exists.” It is now more important than ever to exhibit humankind’s true super power, the ability to adapt to new challenges and in the end overcome them.
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"It is clear that Industry 4.0 presents tremendous opportunities and highlights the need for a highly trained and flexible workforce, and production capacity, that can answer the needs of tomorrow as well as those of today."
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Sunil Gaekwad
NIE
Thomas Newcomen
Richard Trevithick
George Stephenson
Klaus Schwab
World Economic Forum
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