Pepperl+Fuchs' factory automation division specialises in cutting-edge sensor technologies and Industry 4.0 solutions, supporting industries worldwide with enhanced automation and efficiency. In this interview, Aman Monga, General Manager - Sales, Pepperl+Fuchs Factory Automation Pvt Ltd, delves into challenges faced by manufacturing companies and how Pepperl+Fuchs is helping them navigate through these hurdles to improve their efficiency and productivity. 

How is Pepperl-Fuchs helping its industrial customers?

Pepperl+Fuchs' factory automation division helps industries achieve higher levels of automation, efficiency, reliability, and addresses the complex demands of modern industrial environments.

We are present in India as a 100-per cent sales subsidiary of Pepperl+Fuchs SE which is a German multinational. The company has two divisions factory automation and process automation with its Indian headquarters in Gurgaon and Bangalore, respectively. Our manufacturing facilities are located in different parts of the globe and manufacture products for both the divisions. 

Our product portfolio consists of inductive, photoelectric, capacitive, magnetic, and ultrasonic sensors. Additionally, we offer powerful components such as rotary encoders, positioning and identification systems (RFID, Data Matrix, Barcode), AS-Interface. Industrial vision systems and vision sensors are the latest additions in product range. We, in India, offer both pre and post sales services and solutions to our customers.

We are the ideal partner for a wide variety of industries in the Indian market. These include industries like automotive, material handling, packaging, print and paper, steel, metal, textile, dairy, doors, gates and elevator construction, process equipment, mobile equipment, and renewable energy.

What are key challenges before industries today? How is your company helping them solve of these challenges?

The manufacturing industries face several key challenges today. Some of them are:

• Adoption of advanced technologies: Integrating technologies such as IoT, AI, and robotics into existing systems are complex and costly. Many companies struggle with the initial investment and the skills required to implement and manage these technologies?.
• Talent acquisition: Finding skilled workers is becoming challenging day by day. There is a growing need for training and development programs to equip the workforce with the necessary skills.?
• Inflation and cost pressures: Rising costs for raw materials, energy, and transportation add financial pressure on manufacturing and logistics operations. Managing these costs while maintaining competitive pricing is a significant challenge?.
• Stringent regulations: Compliance with international quality standards and regulations requires continuous monitoring and adaptation of processes. This can be resource-intensive and complex, particularly for smaller companies.
• Market fluctuations: Economic and political instability and fluctuating market demands impact production planning and financial stability. Companies need to plan well in advance. 

We, as a company, try to address key challenges in the manufacturing industries through various innovative solutions and technologies:

• Real-time data and monitoring: Pepperl+Fuchs’ advanced sensor technologies and RFID systems enable real-time tracking and monitoring of goods throughout the supply chain. This improves visibility, allowing companies to quickly respond to disruptions and optimize inventory management 
• Automated systems: By providing automation solutions such as Automated Guided Vehicles (AGVs) and robotic systems, Pepperl+Fuchs helps reduce dependency on manual labour and enhances the efficiency and reliability of logistics operations 
• Industry 4.0 solutions: We offer a range of Industry 4.0 technologies, including IoT devices, industrial networking products, and smart sensors. These solutions facilitate seamless integration and communication between machines, improving operational efficiency and enabling predictive maintenance.
• Training and support: As a corporate responsibility, we provide extensive training programs and technical support to the industry to understand and effectively use available advanced technologies. This helps bridge the skills gap and ensures that the workforce is proficient in handling new systems.
• Flexible and scalable solutions: Our products are designed to be flexible and scalable, allowing businesses to quickly adjust to market fluctuations and economic changes. This adaptability is crucial for maintaining operational stability and competitiveness. 
• Cost-effective technologies: Pepperl+Fuchs focuses on providing cost-effective automation solutions that deliver high RoI, helping companies manage their budgets more efficiently while still investing in necessary technological advancements. 
• Advanced quality control and quality compliances: Our machine vision systems and sensors are used for precise quality control and inspection processes, ensuring that product meet stringent regulatory and quality standards. This is particularly important in industries such as automotive and food & beverage.

By leveraging these advanced technologies and solutions, Pepperl+Fuchs is effectively addressing some of the most pressing challenges faced by the manufacturing industries today, driving efficiency, sustainability, and resilience.

How is the intralogistics market in India? 

The intralogistics market in India is experiencing significant growth and is expected to grow robustly, with a projected CAGR of 14.93 per cent from 2024 to 2032. It is primarily driven by the expanding e-commerce sector and fuelled by the rising adoption of automation technologies. 

There is a strong focus on integrating advanced technologies such as automated storage and retrieval systems, industrial and mobile robots, conveyor systems, and sortation systems. These technologies help streamline operations, minimise manual errors, and enhance overall productivity.? 

Pepperl+Fuchs is contributing to the intralogistics industry through a variety of advanced technologies and solutions that enhance automation, efficiency, and safety. Here are some key ways in which Pepperl+Fuchs is helping the industry:

·         Sensors for material handling: Sensors for material handling are crucial for object detection, position monitoring, and distance measurement within warehouses. They facilitate efficient material handling and inventory management by ensuring precise detection and tracking of goods. 

·         Automated guided vehicles (AGVs): Pepperl+Fuchs offers critical components for AGVs, such as advanced navigation sensors and safety systems. These components ensure the safe and efficient operation of AGVs, which are increasingly used for automated material transport within warehouses?. The innovative product offered to the warehouse industry by Pepperl-Fuchs is 360 degree LiDAR which has been able to solve numerous navigation applications in a warehouse.

·         Machine vision systems: Pepperl+Fuchs offer advanced machine vision systems to perform tasks such as barcode reading (1D &2D), object recognition, and quality inspection. These systems improve the accuracy and speed of sorting and handling processes in warehouses, contributing to higher efficiency and reduced error rates.

·         RFID systems: Pepperl+Fuchs' RFID technology enhances the tracking and management of goods. RFID systems provide real-time data on the location and status of items, enabling better inventory control and reducing errors in the supply chain?.

·         Technical expertise and support: With extensive experience in industrial automation, we provide valuable technical support and expertise to help customers implement and optimise their intralogistics systems effectively?.

Could you please highlight on some of your recent innovations?

Pepperl+Fuchs has introduced several innovations recently.

RFID systems: Pepperl+Fuchs has expanded its RFID portfolio with UHF RFID, which enhances identification and tracking capabilities. These systems are essential for automation and control in manufacturing and logistics environments.

Radar sensors: Pepperl+Fuchs has integrated multiple measuring modes into their radar sensors, enabling precise determination of distance, direction, and speed of objects. These sensors can operate in different modes such as ‘first object’, ‘best reflection’, and ‘fastest object’, enhancing their versatility for applications like collision protection for AGVs and material handling.

Ultrasonic sensors: The USi-safety ultrasonic sensor system is designed for safety applications in challenging environments. Advanced range of ultrasonic sensors with IO-Link offers a comprehensive range of settings for flexible and easy adjustments?.

How do you see the current status of the Indian manufacturing sector? 

The current status of the Indian manufacturing sector reflects a dynamic and evolving landscape driven by several key factors and initiatives. This sector has shown robust growth, with an 11.6 per cent increase in FY 2023-24. Exports have reached record levels, indicating strong global demand for Indian manufactured goods. The sector's value added is projected to reach $231.5 billion in 2024, highlighting its critical role in the Indian economy.?

Manufacturing sector is experiencing a paradigm shift. The government is particularly focused on emerging sectors like semiconductor manufacturing and renewable energy components. By 2030, India aims to position itself as a global manufacturing hub, potentially exporting goods worth $1 trillion.

To compete with global players, Indian manufacturers are rapidly embracing Industry 4.0 principles, incorporating advanced technologies such as AI, robotics, AI and digitalisation to enhance efficiency and productivity. Automation is becoming a cornerstone, with significant investments in smart factories and digitalisation to streamline operations and reduce lead times.

What are the emerging trends in the industry?

The emerging trends in the manufacturing industry in 2024 highlight a shift towards advanced technologies, sustainability, and workforce innovation. Here are some key trends:

Smart factories and Industry 4.0: The adoption of smart factory solutions and Industry 4.0 technologies is accelerating. These include the integration of IoT, AI, machine learning, and robotics to create highly automated and interconnected manufacturing environments. Smart factories enhance operational efficiency, reduce downtime, and improve product quality by enabling real-time monitoring and predictive maintenance.

Product electrification and decarbonisation: The trend towards electrification of products, especially in the automotive industry, is gaining momentum. Manufacturers are investing in the development of electric vehicles (EVs) and energy-efficient technologies. Decarbonization efforts include adopting cleaner production methods and reducing the carbon footprint across the supply chain.

Digital transformation and supply chain digitalization: Manufacturers are increasingly investing in digital tools to enhance supply chain performance and resilience. Digital transformation initiatives include the use of blockchain for supply chain transparency, AI for demand forecasting, and advanced analytics for inventory management. These technologies help manufacturers respond swiftly to market changes and disruptions.

Sustainability and green manufacturing: There is a growing focus on sustainability and reducing the environmental impact of manufacturing processes. Companies are adopting green manufacturing practices, such as using renewable energy sources, minimising waste, and developing eco-friendly products. The push for net-zero emissions is driving innovation in product design and production techniques.

Advanced materials and additive manufacturing: The use of advanced materials, such as composites and nanomaterials, is on the rise. Additive manufacturing (3D printing) is becoming more prevalent, enabling manufacturers to produce complex designs with greater precision and less material waste. This technology is particularly beneficial for prototyping and small-batch production

What are your growth plans?

Pepperl+Fuchs is well-positioned to capitalise on emerging market opportunities, and has outlined several growth plans and initiatives to drive its future development. We are investing heavily in technologies related to Industry 4.0 and the Internet of Things (IoT). These initiatives include developing cloud-based data collection applications and mobile computing devices, which are essential for the next phase of industrial automation?. 

We have also formed strategic partnerships to enhance technology offerings and market reach, in collaboration with VMT for advance vision solutions to automotive and allied industries.? Lastly, we have successfully solved a diverse range of applications and are continuously developing new technologies to make processes more reliable and efficient in material handling area.