The use of automation and robotics is rapidly impacting the manufacturing industry, and this trend is expected to continue in the coming years. At the same time, Industry 4.0 technologies such as Artificial Intelligence (AI), Machine Learning (ML), Virtual Reality (VR), Industrial Internet of Things (IIoT), predictive data analytics, and Augmented Reality (AR) will continue to advance and make manufacturing more data driven. As a result, manufacturing will evolve from automation to autonomous operations.
Headquartered in Pune, over the years, Cybernetik has expanded its national and international presence. It is among the reputed automation companies with global offices in the United States, Europe, Vietnam, and the Middle East. They have four manufacturing units – two each in Pune and Gujarat with sprawling infrastructure of 30,000+ sq. m. workspace manned by 175 engineers, 128 technicians. Cybernetik has been working on turnkey solutions for the auto, food, marine and pharma industry. With the recent spotlight on EVs, the company has been actively working with auto companies to build battery packs that could prevent the issues which were raised on their safety and are tuned to the Indian conditions.
Can you tell us about Cybernetik and its expertise in integrating automation and robotics in manufacturing.
At Cybernetik, we specialise in integrating automation and robotics in manufacturing by undertaking tasks such as designing, building, and installing end-to-end turnkey automation systems. Our expertise has been utilised by various players across segments in India, including BASF, Sanofi, Bayer, Suzlon, Bajaj Auto, and Bharat Forge. What sets us apart is our diverse industry presence, ranging from food, pharmaceutical, chemical, automotive to wind energy. This enables us to develop unique solutions to technological problems. In addition, we work with major robotic manufacturers such as ABB, Omron, Yaskawa, and Epson to execute complex turnkey projects that require intricate integration of robots, vision, haptic sensing, and servo controls.
What are some of the latest automation technologies you use in your turnkey solutions?
Our company has taken bold strides towards automated solutions that involve extracting organic materials for cosmetic and bio-product purposes. This initiative aligns with our objective to expand our operations into diverse markets. Concurrently, we have been actively engaging with automakers to design battery packs for electric vehicles that prioritise safety and are customised for Indian terrains. Furthermore, we have diversified our business portfolio by venturing into the wind energy sector. Our cutting-edge robotic machining system executes various operations with utmost precision, guaranteeing flawless and durable solutions for machining wind turbines and other wind energy equipment.
How does Cybernetik approach the customisation of its solutions to meet the unique needs of each customer?
Customisation goes hand in hand with innovation. And innovation is a part of Cybernetik’s DNA. Our thinking is tuned to achieve the required functionality while making sizable improvements in productivity, safety, efficiency, and ergonomics. The challenge is to achieve technological goals via strong fundamentals and broad-based experience.
To be specific, the first step we initiate is a thorough understanding of the client’s concept, then comes the design stage wherein we put to use the vast collective experience and wisdom of our teams to arrive at solutions in active collaboration with the client’s team. These are then tested virtually. The identified shortcomings and prospects for improvement, if any, are incorporated in the design. It is only after virtual commissioning that we move to the production stage.
Not all challenges are identifiable at the design and virtual commissioning phases. During a recent EV Battery Assembly project, we came across an issue related to weld electrodes caused by the electrode cleaning system. The issue came to the fore during trials and affected the positional accuracy of the weld. Here again, the practical know-how of our team helped them resolve the challenge.
What are some of the biggest challenges you face when integrating automation and robotics into a manufacturing process, and how do you overcome them?
The integration of automation and robotics into a manufacturing process can present significant challenges such as high initial costs, integration with existing systems, workforce training, maintenance and repair, and safety. However, these challenges can be overcome through meticulous planning, including a thorough cost-benefit analysis, providing comprehensive training for employees, implementing safety measures, and establishing a maintenance and repair plan. By taking these steps, manufacturers can ensure seamless integration and maximise the long-term benefits of automation and robotics.
Can you give us an example of a project where Cybernetik successfully integrated automation and robotics to deliver a customised turnkey solution?
For Green Mountain Firewood, we were able to enhance their processing line by incorporating a cooling tunnel, which aided in eliminating bottlenecks, and also automated important procedures like packing and palletising, resulting in a production of more than 4,000 logs per hour.
Additionally, we offer customised automation solutions for the wind energy sector with our turnkey robotic root-end machining, which involves attaching the blades to the hub to strengthen the structural integrity of the wind turbine. Our wind energy solutions provide superior precision, shorter cycle times, and improved operational safety.
How do you ensure that the automation and robotics solutions you provide are reliable and efficient?
At Cybernetik, we employ the latest technologies and highly qualified personnel to guarantee delivery of top-notch systems that comply with the latest manufacturing standards. Our success in achieving high productivity is attributed to our ample infrastructure. Our spacious and well-organised plants are equipped with state-of-the-art machines and systems that are manned by experts in their respective fields. To ensure the utmost professionalism in meeting all deliverables, we incorporate quality infrastructure and employ the best institutional practices.
In what ways do you see automation and robotics transforming the manufacturing industry in the next 5-10 years?
The use of automation and robotics in manufacturing is increasing rapidly, and this trend is expected to continue in the coming years. With the help of these technologies, manufacturers can reduce labour costs, increase efficiency, and improve quality control.
Industry 4.0 technologies such as Artificial Intelligence (AI), Machine Learning (ML), Virtual Reality (VR), Industrial Internet of Things (IIoT), predictive data analytics, and Augmented Reality (AR) will continue to advance and make manufacturing more data driven. As a result, manufacturing will shift from automation to autonomous operations.
How does Cybernetik stay up to date with the latest advancements in automation and robotics technology to continue to provide cutting-edge solutions to its customers?
Our teams actively participate in industry events and trade shows across the world. This is not only a great way to keep abreast of the cutting-edge developments in robotics and automation technology, but also to grasp the big picture and thereby assess where we stand in the overall scheme of things.
Another source of such knowledge is interaction with prospects and clients. The force of necessity is the driver of innovations. In combination with the insights that our teams have developed through experience, these interactions help us understand what the market wants. Such practical discussions also enable a rough estimation of future technological trends.
We also maintain strong relations with the global giants in automation components, robotic manufacturers, and other suppliers.
How does Cybernetik approach the training and education of its clients in the use of automation and robotics technology?
Getting clients on the same page for operating and maintaining a functional system is a critical requirement. More so, when you deal with uniquely innovative products.
Although client training is a continuous process, it acquires tangible form when we run them through the virtual system using Virtual Reality (VR) headsets. The 3D model is imported in real size in the VR software and is scaled to human height to enable the client to check functionality, ergonomics, and accessibility for maintenance. It also allows them to suggest changes.
Thereafter, when the system is physically ready, we conduct the Factory Acceptance Test (FAT) in the premises of our factory units. Next comes the Site Acceptance Test (SAT) at the client’s plant. During both these tests, members of the client team are present, and our personnel provide guidance. At least one technician from Cybernetik is physically present at the client’s factory during SAT.
Cybernetik also provides after sales services. Our technicians are either present on the client’s shop floor or we offer remote support and troubleshooting. We use technologies such as Anybus, Vuforia Chalk, and Microsoft Teams for remote support wherein the annotations feature real-world mark-ups, way-finding arrows, audio, and video to keep everyone on the same page.