In the metalworking sector specifically, AI can optimise tool paths improve machining precision and enables predictive maintenance by analysing real-time data from equipment. Sandvik Coromant uses distributed AI to monitor cutting conditions, adapt to material variations and reduce tool wear, ensuring consistent performance, reduced downtime and efficient resource utilisation, says, Sunil Joshi, President, Sandvik Coromant India in an interview with Rakesh Rao.

Sandvik Coromant’s 'Manufacturing Wellness' outlook, a series of eight habits that help to foster a thriving and sustainable manufacturing industry, places importance on people development. 

Despite the growth of the nation’s manufacturing sector in recent years, India is facing a shortfall of 150 million skilled staff in 2024. 

The lack of skilled professionals is particularly apparent in technical roles like those found in the manufacturing sector, with a study revealing that only 44% of Indian graduates are employable for technical roles. 

Addressing this skills shortage is crucial for the continued growth of India’s manufacturing industry. To support this, Sandvik Coromant offers a huge selection of learning opportunities for students, as well as for professionals at all stages of their career. 

For example, our Green Model Schools initiative in collaboration with Thinksharp Foundation has provided more than 900 disadvantaged students from rural and urban areas in Maharashtra with better access to books and computer equipment. Dropout rates have fallen by over a quarter and test scores have risen by 15 to 20% across all subjects. 

In addition, the Sandvik Coromant Academy offers upskilling opportunities both virtually and at our centre in Pune. These include in-person metal cutting technology training, as well as an e-learning platform with over 75 university-level short courses in skills such as threading, milling and turning.  

India has achieved significant milestones in many of these end-user industries during the past decade thanks to the ‘Make in India’ initiative, which aimed to transform India into an international manufacturing hub. 

India now has the third-largest automotive market globally, with the Faster Adoption and Manufacturing of Electric Vehicles (FAME) schemes encouraging buyers to opt for electric and hybrid vehicles. FAME II’s offer of upfront incentives for customers purchasing EVs saw over 1.36 million vehicles sold by December 2023. Consequently, this drives demand in the automotive industry for modern cutting tools that work effectively with lightweight, durable materials such as composites and aluminium. 

With India predicted to be the world’s largest aviation market by 2047, we’re increasingly seeing manufacturers looking for tooling options for precision aerospace components. 

Within the wider engineering industry, the introduction of the PLI scheme in 2020 means that manufacturers are looking to expand on their existing facilities, increase production and boost sales. As a result, we are experiencing demand for products that help to minimise downtime and reduce waste. 

Sandvik Coromant’s ‘Manufacturing Wellness’ vision promotes sustainable growth by encouraging manufacturers to implement eight positive habits that balance economic progress with environmental responsibility. This mindset focuses on efficiency, innovation and collaboration across the entire value chain. By making use of advanced technologies, data-driven insights and workforce development, manufacturers can optimise processes, reduce waste and minimise energy use.

This vision is particularly relevant today as India strives to reduce its 2021 carbon dioxide emissions by 22% by 2030 while meeting half of its energy requirements from renewable sources by the same year. Sandvik Coromant has developed new technologies to support manufacturers in this process, such as its Sustainability Analyser which allows manufacturers to measure — and consequently reduce — energy consumption and carbon emissions. 

From a sustainability perspective, an increased focus on lightweighting is essential for industries like automotive and aerospace. It not only reduces the use of finite resources, but also limits the amount of energy consumed by vehicles. Lightweighting drives significant changes in the cutting tools sector as manufacturers are increasingly tasked with machining lightweight materials such as aluminium and advanced composites, as well as producing weight-efficient components from traditional metals like steel and cast iron.

This shift demands cutting tools that enable higher precision, reduce material waste and improve energy efficiency. Sandvik Coromant’s CoroMill® MF80 was designed for ISO-K and ISO-P materials and supports smoother cutting actions, reduced forces and longer tool life — crucial for machining thin-walled and near-net shaped components used in lighter, fuel-efficient vehicles. 

Additionally, there is a growing need for schemes that effectively promote circularity within the cutting tools industry. For example, the planet only has 100 years of estimated reserves for raw tungsten — which makes up around three quarters of recyclable used carbide inserts. 

Sandvik Coromant launched its first tool buyback scheme almost 30 years ago but has recently upgraded the programme to simplify the recycling process. Customers can now use an online portal to receive an instant price for the tools they wish to recycle, secure an order pickup time and receive recycling boxes. They can also view data on the carbon emission reductions as a result of the recycled tools, which helps manufacturers to understand the tangible impact of the scheme. 

The increasing implementation of smart manufacturing practises is strongly impacting the machine tools industry. According to a report by Global Market Estimates, India’s smart manufacturing industry is set to grow by a compound annual growth rate (CAGR) of 8.1% between 2024 and 2029. 

As part of this shift, the machine tools sector must embrace technologies such as Internet of Things (IoT) and cloud-based systems, which will allow them to improve tool performance and reduce downtime. Manufacturers also need to ensure that their employees are prepared for smart manufacturing, with recent IBM research predicting that around two-fifths of the workforce will need to reskill due to the implementation of automation technologies. 

Sandvik Coromant’s 'Manufacturing Wellness' outlook encourages manufacturers to take a holistic perspective that considers all of the interconnected steps of the value chain. This means that when manufacturers implement new technologies, they must take into account the impact this has on other areas, such as staff development and sustainability. 

New technologies like AI, machine learning and additive manufacturing are transforming manufacturing by driving automation, precision and innovation. 

In the metalworking sector specifically, AI can optimise tool paths, improve machining precision and enables predictive maintenance by analysing real-time data from equipment. Sandvik Coromant uses distributed AI to monitor cutting conditions, adapt to material variations and reduce tool wear, ensuring consistent performance, reduced downtime and efficient resource utilisation. 

Sandvik Coromant integrates automation and new technological advancements into its Manufacturing Wellness framework, empowering manufacturers to achieve the cost-reduction and quality improvement benefits they can bring. 

Located in Hall 4 at booth B127, Sandvik Coromant’s stand will move beyond traditional displays of tooling products to an advisory booth concept to encourage valuable conversations around machine investment, process optimisation and our Manufacturing Wellness vision.  Both myself and Masahiro Yamamoto, Managing Director, Sandvik Japan, will be on hand to discuss how manufacturing wellness can be implemented across a range of industries that use metal cutting tools, such as automotive, aerospace and rail. In addition, we will be performing live tooling demonstrations, offering actionable advice on how to seamlessly integrate Sandvik Coromant solutions into existing workflows. 

At the midpoint of the decade, it is a good time to reflect on our growth so far and plan for the future. As the fastest-growing major economy in the world, India continues to offer excellent business opportunities for Sandvik Coromant. However, it is important to ensure that achieving healthy growth does not supersede the need for environmental sustainability. As we begin a new year, we will use the manufacturing wellness outlook to guide our approach and prepare us for a thriving and sustainable future.