Over the last five decades, the rise of computers, digital technologies and the Internet has unbridled an absolute and unprecedented transformation. Operating on the intersections of human-and-machine interaction (HMI) and machine-and-machine interaction (MMI), factories today are operating at speed, scale and efficiency that would have been unimaginable before.
Building on this brilliance, we have now entered into the fourth aeon of the industrial revolution, also known as Industry 4.0. Simply put, industry 4.0 is ‘Industrial Internet of Things’ (IIoT) – a blend of physical and technological capabilities that allows machines and devices to interact and synchronize with each other and also with humans in real-time over wireless internet.
The still-nascent ecosystem is witnessing an influx of various new-fangled technologies like machine learning, automation, robotics, big data and analytics, simulation, sensors, augmented reality (AR) and artificial intelligence (AI) and so forth. A digitally-enabled industrial operation leads to a shorter product development cycle, reduced production costs and higher output without quality loss. Man, machine and material risk mitigation, better resource management for more sustainable operations and agile production lines being other key advantages.
Every industry and factory system, however, is different and cookie-cutter solutions may not work for all. Digital innovators and service providers should be proficient in providing customized solutions to get them on board with digital transformation. Hitachi, which is renowned for its deep OT X IT expertise, has been supporting patrons (private as well as public entities) across the world via its cutting-edge digital solutions that suit their unique needs.
Needless to say that with progressive uptake of digitalization effectuating a transformational change, the existing industrial paradigm would become obsolete sooner or later.
Given that the manufacturing industry is a major contributor to the global economy (accounting for 16% of the world’s GDP in 2018, as per the World Bank), the governments and policymakers across the world, including India, are keenly watching this disruption while corporates are enthusiastic about it.
Going forward, ramping up its manufacturing for domestic consumption and exports apart, India is also aspiring to become the next global manufacturing powerhouse.
Significantly, the government-industry-experts reckon that developing Manufacturing 4.0 capabilities is imperative to make Indian manufacturers globally competitive. The move also augurs well with the government’s broader objectives: “Make in India”, “Vocal for Local” and “AatmaNirbhar Bharat” (self-reliant India).
The ball has started rolling already for realizing ‘smart’ or digitally-integrated factories in India!
Trailblazing manufacturers from sectors like auto, electronics, clothing, footwear, medical equipment et al. are have started deploying technologies like AI-enabled preventive maintenance to tackle machine interruptions; IoT to detect logjams and improve throughput across interconnected production units; 3D printing or additive technology to create customized products that can be prototyped quickly; Big data enabling data-driven decisions; software solutions for volume management and compliance to name a few.
Drawing on its superior automation capabilities and OT X IT expertise, Tata Hitachi Construction Machinery Company. Pvt. Ltd., a Hitachi Group Company, has come up with a software application, namely BOTS, to help manufacturers manage volume and compliance and apply predictive analysis on machine performance.
Furthermore, Tata Hitachi has also introduced an excellent automation solution for manually-driven and error-prone assembly production. It has innovated a leading export-oriented Digital Gearbox Assembly Shop deploying automation and IoT in the assembly process. From kitting of parts, assembly, painting to dispatch, the entire transmission gearbox is now digitally assembled.
The use of advanced sensors like high definition cameras and flow meters to digitally monitor and control vital parameters reduced inline quality defects by 70%. Digitally tracked real-time loss analysis enhanced the operational efficiency of each shift from 65% to 80%. Real-time preventive maintenance lessened mean time failures by 50%. Digital monitoring ensured that parts stock and reordering is error-free.
All the processes during previous manual setup exhibited a variance of 50% in cycle time between the models, the automated operation, however, helped cut down the total cycle time of all the models by 30%, saving costs and improving efficiency.
reduction in unplanned downtime(1)
increase in overall equipment effectiveness(1)
growth in manufacturing output(1)
reduction in costs, mainly in energy consumption, maintenance, logistics, and material loss(1)
improvement in employee engagement(1)
With the government encouraging manufacturing 4.0 and enhanced awareness among industry participants, the pace of integration of factory systems with smart technologies in India is expected to increase in the coming times. Always in the vanguards of innovation, Hitachi is relentlessly working to create the most advanced digital solutions that augment India’s smart manufacturing capabilities and enhance the Social, Environmental and Economic values.
Through its Social Innovation Business solutions, Hitachi is also committed to helping the manufacturing industry embrace the latest tools and technology that shape both the physical and operational aspects of factory systems, thus ‘Powering Good’ and contributing to sustainable growth of the industry as well as nation.
1. https://cio.economictimes.indiatimes.com/news/strategy-and-management/heres-how-smart-factories-can-become-game-changers-for-enterprises/70995107
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