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Automation, digitalisation and electrification must go hand in hand
Interviews- Oct 31,23
….this is ABB’s vision, says Subrata Karmakar, President- Robotics and Discrete Automation, ABB India in this interview. The company follows a 5-step process of Enable, Integrate, Model, Analyse and Deliver leading to technology adoption, he added.
With the advent of AI, ML, IoT, 3D printing, cobots, digital twins, cloud, etc, how has the dynamics in manufacturing changed with respect to usage of technologies – i.e. hardware as well as software - in recent years?
The manufacturing segment has been consistently gaining the spotlight owing to its support towards revitalising the economy. The segment is constantly evolving with integration of fully automated, connected and digitally optimised factories, keeping up with the demand for new and innovative product methods. The industrial revolution 4.0 has witnessed the rise of core computing technologies like AI, ML, Big Data, Cloud Computing, Cyber Security along with other physical technologies like automation and robotics, IoT, CPS, AM. Since smart manufacturing systems are an enabler of fully integrated and collaborative manufacturing systems, these technologies ensure agility, flexibility in smart manufacturing. This results in meeting the ever-evolving needs in smart factories to meet the customer needs and keep up with the supply on a real time basis.
Additionally, with sustainability and eco-consciousness being on the rise, more companies are embedding sustainability goals into everything they do, also resulting in innovative business models. Unprecedented supply chain disruptions encourage the industry to move faster and become more resilient than ever before – to stay ahead of the curve. The growing infrastructure and road developments, also lead factories into a new era of connectivity. Problems can be solved as soon as they arise, ensuring safety, optimising production levels, and reducing costs. Software-defined solutions enable fast changeovers to meet the consumer requirements as well as workforce and supply chain dynamics.
Being a global company, how do you see the current status of the Indian manufacturing sector?
Today, India has become the world’s fifth largest economy as measured by manufacturing output. India also ranks tenth worldwide for number of annual Robot installations, which is very positive indicator. Manufacturers in India have accelerated their digital maturity due to current productivity, quality, and compliance. Automation is enabling manufacturers to optimise and make their processes more efficient while increasing production, adapt to changes, and adopt sustainable practices. There is a clear need for automation as demonstrated by the various manufacturers who have invested in making the shift to more automated operations.
The Indian manufacturing sector is also expected to benefit from the government's initiatives to boost competitiveness and attractiveness for investors. The Production Linked Incentive (PLI) scheme, for example, which is currently set to run until 2025, subsidises companies that create production capacity in India in robot customer industries like automotive, metal, pharmaceuticals, and food processing. It is showing the growth of the adoption of robotics and automation within the industries.
With companies (i.e. your customers) in India looking to opt for smart and digital manufacturing solutions, how is your company supporting them in this?
At ABB, we have always been focused on giving utmost importance to technology. Smart industries hold a huge potential if approached with a comprehensive and value-driven strategy. The key aspects of building smart industries are trust and collaboration, therefore, it is crucial to deploy the right technologies to tackle the challenges with precision. We have a demonstrated history of guiding businesses to identify and leverage their distinctive data points in their ecosystem. Our purpose is to maximise those data to garner concrete outcome. We follow a 5-step process of Enable, Integrate, Model, Analyse and Deliver. Additionally, to help companies navigate the complex landscape and pursue programs that delivers on value.
ABB has also chosen five solution areas - sustainability, asset performance (AI/ML), process performance, operational excellence and a connected workforce - because together they can be used to provide demonstratable evidence that digital transformation strategies are working. ABB´s vision is that automation, digitalisation and electrification must go hand in hand for real digital transformation and deliver on the values of sustainable and efficient operations.
What are key hurdles faced by companies when they adopt (or plan to adopt) automation/digitalisation? How can they mitigate these hurdles?
When adopting automation and digitalisation, manufacturing companies frequently face challenges, such as high implementation costs, employee resistance, integration difficulties, data security worries, talent gaps maintenance issues, undesired ROI, and regulatory compliance.
Companies should start with pilot projects, invest in thorough employee training, carefully choose appropriate technology, plan for seamless system integration, prioritise cybersecurity, implement predictive maintenance strategies, continuously improve operations through data analytics, ensure compliance expertise, manage change successfully, and consistently measure ROI to lessen these difficulties and make the transition easier. By following these guidelines, industrial companies may better manage the challenges of automation and digitalisation, increase efficiency, and maintain their competitiveness in the market.
High upfront cost is a big put-off for companies. Are there low-cost entry routes into digitalisation? How is ABB supporting the needs of SMEs?
By investing in cloud-based software, open-source options, mobile apps, and software-as-a-service (SaaS), Small and Medium Enterprises (SMEs) can embrace digital solutions affordably. SMEs can embrace digitalisation without incurring significant upfront expenditures by starting small, concentrating on high-ROI areas, and gradually growing digital activities. For example, ABB’s RobotStudio® programming tool enables users to create, simulate and test a complete robot installation in a virtual 3D environment without having to disturb their actual production line. This means that new product lines can be installed faster and ramped up to full speed without surprises during commissioning – a critical competency for manufacturers with today’s mass customisation and shorter product life cycles.
What are the emerging trends in the manufacturing sector with respect to digital manufacturing?
In the upcoming time, we will increasingly see smart factories and manufacturing plants leverage the power of AI, automation and robotics, IoT, cloud computing, cobots and digital twins along with sustainable manufacturing to drive more efficient operations and ultimately improve business outcomes.
For example, predictive maintenance, which refers to the use of sensor data and artificial intelligence to identify any failure patterns within the machinery and components, has started to become the norm. This helps to detect and solve issues in real time to avoid lengthy maintenance issues and downtime. Another rising trend within manufacturing is the use of robots, to help enhance the work of humans. Such robotics can work with humans to help with the more labor intensive and dangerous tasks within production. Collaborative robots, known as cobots have also become more popular as they are intelligent and specially designed to work alongside humans.
In its 130-year history, ABB has been constantly reinventing the wheel to aid industries in various industrial revolutions. As businesses prepare for the increased usage of automation and advanced AI applications within manufacturing, ABB India is innovating for industrial AI, leveraging capable IIoT startups, sharpening digital skills and the future of Industrial Control Systems in the age of AI.
At the heart of our cutting-edge solutions is ABB Ability™, which combines ABB’s deep domain expertise with connectivity and software innovation to empower real-time, data-driven decisions for safer and smarter operations that maximise resource efficiency and contribute to a low-carbon future. Our broad portfolio of digital offerings – from sensors to cloud – helps energy, infrastructure and transport organisations to automate, optimise and future-proof their businesses to achieve new heights in performance and drive sustainable progress.
What kinds of new opportunities are you looking to tap as digital manufacturing grow in India?
We are in the midst of a transformational decade. The world is evolving at a rapid pace, and robotics automation is critical for all clients in all industries to keep up. While the goal of automation has always been to increase production and quality, increased flexibility and simplicity of use have become a strategic imperative.
Consumers now demand items that are suited to their specific needs, they also want these faster than ever before. As a result, the factories of the future must be able to respond far more dynamically to the ever-changing consumer demands, altering demand, and current trends. On the one hand, for factories, this means that inflexible automation must give way to flexible production, which is characterised by flexibility and enabled by simplification, collaboration, and digitisation, all of which ABB is able to provide.
Subrata Karmakar
ABB India
AI
ML
Big Data
Cloud Computing
Cyber Security
IoT
CPS
AM
automation and robotics
ABB’s RobotStudio®
software-as-a-service (SaaS)
Small and Medium Enterprises (SMEs)
ABB Ability™
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