Although automation & robotics applications are on a steady rise, manufacturers still grapple with concerns about job losses, safety of humans working alongside, and security of data.
by mitalee kurdekar
If a business has to succeed, then it has to remain competitive all the time. This is best understood in the Indian business environment, where the market is highly price-sensitive. However, Indian manufacturers have started to become conscious of other requirements like quality, safety and service. Continuous improvement in all these parameters is the norm from a customer aspirations’ viewpoint. The question remains: how does one remain competitive and still differentiate oneself from peers in the market? The answer lies in technology.
Technological applications in all areas of product manufacture have become vital to staying ahead. This appetite for technology enhancement and competitiveness gives rise to automation requirements, with robotics being the latest manifestation of the same. Robotic applications are one form of automation where humans are assisted by specially designed robots to undertake mundane, repetitive and sometimes risky or hazardous tasks easily and consistently, with quality performance.
Today, we notice that many Indian manufacturers are keenly inviting innovative technologies from overseas partners, collaborators or parent concerns, while many of them are actually seen to be investing in new areas of automation, data analytics using artificial intelligence (AI) and Internet of Things (IoT) support.
Advent of Advanced Automation
As Takayuki Inaba, MD, NEC Technologies India, points out, “Fourth industrial revolution technologies and the many ways they can interact with each other enhances human performance, and can be used to achieve solutions from the mundane to the marvelous. In the next 3-5 years, automation will be an extension of robotics and can be termed as the next phase of the industrial revolution.”
He goes on to add, “The use of robotics will expand. It will get more sophisticated and adept at complex task performance. With the advent of advanced analytics and data sciences, as in artificial intelligence, it will be possible to automate complex tasks in manufacturing industries that can act intelligently like humans, thus reducing the labour costs. It will help in increasing the worker quality of life as automation will be used to complete the menial and mindless tasks that are normally done by human workers. Also, it will help in reduction of product cost as most of the laborious efforts will be overpowered by automation.”
Providing a user viewpoint on this new generation technological advancement, Suresh KV, country head, ZF India, suggests, “Industry 4.0 is a buzzword in our industry today, because it has brought in various advanced technological solutions for manufacturing auto parts and components. It has brought together robots, data and connected devices for creating a productive environment. It has also streamlined operations and offered new business opportunities. The digital revolution is transforming industrial technology and heralding unimagined possibilities in terms of technological advances.”
Suresh further states, “At ZF, we recognised the importance of Industry 4.0 in the early stages itself. We have been optimising our production operations for years, through systematic digitisation. Collaborative robots are one element of the fundamental restructuring that is already happening in full swing on shop floors in factories around the world.”
In fact, such applications are increasingly becoming a part of ZF’s manufacturing ecosystem. YuMi, a small-parts assembly robot introduced in 2015 by ABB, which has a payload of 500 g, has been integrated into ZF’s global assembly lines, and helped the company significantly increase productivity. The robot’s arms are padded, and its sophisticated system of sensors helps it to ‘see’ and ‘feel’, enabling it to avoid collisions with its human co-workers. Additionally, it is capable of performing complex assembly routines with the highest precision.
In essence, automation is definitely making its presence felt in the manufacturing arena, and is here to stay. Meenu Singhal, VP, industry business, Schneider Electric, agrees that, “Automation is set to take over highly-repetitive and monotonous jobs, while simultaneously boosting the capabilities of domestic manufacturers. It ensures speed, higher precision and zero errors, thereby immensely increasing productivity and profitability.”
Tidal Wave of Technology
With computer programming developed tremendously, and the help of macros and programming logic, one can replicate human actions for repetitive tasks. Therefore, a lot of robotic applications are now being put to use in industries such as automotive, textiles, metalworking including key areas like defence, space and atomic energy, etc., wherein human intervention can be minimised for known reasons.
Ninad Deshpande, head, marketing, B&R Industrial Automation, explains, “The use of robots in manufacturing set-ups and shop floors is exponentially increasing, with many speaking of this growth doubling in coming years. Today, the time needed for technology transfer from western countries to India has reduced drastically, and many Indian organisations are already on their path to evaluating & adopting new technologies. India does not want to be known as a low-cost manufacturing hub, but a technologically-advanced, globally-competent manufacturing hub. Adopting next generation automation and robotics solutions is the way forward for these Indian organisations.”
There are many application areas for robotic functions, which can be integrated with automation of the manufacturing line. On this front, Ajey Phatak, head, marketing, Beckhoff Automation, says, “Over the next five years, as more and more companies go for customised manufacturing, automation will play a significant role in terms of automated assembly & handling systems, automated testing systems, and automated logistics. There is no doubt that automation will be the basic pre-requisite for higher productivity and has become a necessity for all manufacturing industries.”
Sameer Gandhi, MD, Omron Automation, India, is also optimistic about this development, and offers, “Industry 4.0, though in its infancy stage, has been witnessing gradual adoption by some of the progressive manufacturing giants across varied manufacturing industries such as automotive, FMCG, food & beverage, and pharmaceuticals, to name just a few. Based on this current situation, we can say that the automation industry (including robotics) is in the evolution phase. Manufacturers have started understanding its role in attaining compliance with global standards, towards improving operational excellence, to achieve zero defects, and realise productivity and quality improvements, etc.”
An Investment, not a Cost
The decision to go in for advanced automation & robotics applications is not an easy one financially, given that there is significant portion of import-content in building and installing these applications at manufacturing sites in India. Given our traditional approach of looking at return on investment (ROI), especially quick returns as one considers India’s cost competitive environment, the decision can drag into prolonged debate.
Gandhi cautions, “Most of the components that go into a robot are in any case imported, and hence not very significant savings can be expected by local manufacturing, especially until the volumes pick up. Once the volumes pick up, the case to establish factories in India will become much stronger.”
Phatak agrees and states, “Technology products have their share of cost, and so do automation & robotics products. However, with direct benefits and given the value proposition, there is always a win-win situation. Automation solutions can be built with optimum cost and higher deliverables. Thus, automation is an investment and not a cost.”
Deshpande feels, “Benefits would always be associated with some costs. It is important for Indian manufacturing to take a systematic approach while moving in the direction of Industry 4.0. They should consider placing the solutions around their challenges and take an organised approach.”
Sounding positive on this aspect, Suresh proclaims, “Usage of automation & robotics is definitely gaining momentum in the automotive industry. Automation & robotic applications are transforming manufacturing facilities into smart & connected factories. Adopting automation & robotics in operations requires initial set-up cost and regular maintenance. These applications demand a lot of capital investment for initial set up. Since automation & robotic applications run on software, regular monitoring and installation of latest software updates is necessary. Though there are certain concerns in adoption, we cannot overlook the ROI that these applications give.”
Crossing Hurdles
Implementing robotic solutions and automation applications is no mean task. Besides having initial investment decisions and ROI considerations to tackle with, there are obvious concerns surrounding issues relating to safety in operations, job losses and upskilling of labour. Many users in the manufacturing space have been debating over these issues with their vendors. On their part, vendors are incorporating valid suggestions to make the transfer of technology as smooth as can be. Japan is one country where automation in manufacturing has blossomed so much, that the use of robotics is also significantly high. But India is keen to catch up, and fast.
Inaba views these concerns positively, when he says, “As people embrace technologies such as IoT, Big Data, the Cloud, and mobility, security must be more than an afterthought.” He also believes that, “In the digital era, the focus needs to shift from securing network perimeters to safeguarding data spread across systems, devices, and the Cloud. The key to addressing those risks and threats is building security into applications, as well as into interconnected devices, right from the start.”
Gandhi feels that safety is a matter of design. He suggests, “For many fixed robots, physical guarding or safety sensors are provided. On the other hand, cobots or mobile robots have their own on-board sensors to ensure safety of humans that they work with. So, it’s a manageable concern.”
Singhal explains that safety concerns are rising with larger adaptation of IIoT. Schneider Electric has a safety layer built in, with cyber security layers within processors. Also, they have increased their focus on machine & process safety with their products & solutions.
Regarding job losses and upskilling, the views of vendors and some key users are quite interesting. “Automation does not imply lesser employment opportunities, because there will always be a need for newer skill sets to use and maintain the automated system and new opportunities will be created. Yes, a knowledgeable worker will get priority. Hence, reskilling the existing workforce is the one way to retain quality manpower, while ensuring redeployment of semi-skilled manpower for other productive uses,” declares Phatak.
Deshpande shares this sentiment. He offers, “Adding automation & robotics to the manufacturing sector need not be looked upon as an employment killer. It is possible to reskill the workforce in factories to adapt to new technologies. Considering the current trends and future challenges, few manufacturers have already started investing in training and skill development centres. These centres allow their employees to try complex concepts in industrial processes.”
On the other hand, Gandhi acknowledges the job loss issue as a concern, and says, “We need to understand that automation automates activities and not jobs. The bedrock of a smart factory is the harmony between automation solutions and human beings.”
As a user, Suresh provides a piece of advice. He proposes, “To overcome these hurdles/concerns, manufacturers should first implement these applications on a small scale. Once the small-scale model demonstrates that these applications have improved performance substantially whilst cutting costs, then you can apply them as best-practice models for other areas as well.”
All things considered, the co-operation between men and machines is bound to not only stay, but, in fact, prosper in the future. And in doing so, it is also expected to have a significant impact on the industry in terms of its functioning, and also on the population in the way that it will revolutionise their lives.