As industry continues its rapid evolution, manufacturers that adopt automation will have a leg up in the digitised and connected world, says Sanjeev Srivastava.

In today’s era of Smart Manufacturing (Industry 4.0), factory-level automation is revolutionising the manufacturing landscape. It offers a multitude of advantages that are reshaping the industry as we know it. Industrial automation converts traditional processes into smart, flexible systems that operate at a high level of efficiency. Automation cutting-edge technologies like robotics, artificial intelligence (AI), machine learning (ML), and the Internet of Things (IoT) decrease costs, improve product quality, and streamline manufacturing processes.

Improved operational efficiency & productivity

Factory-level automation also saves operational time by eliminating bottlenecks and reducing two common types of manual errors that also cost a lot of time — the time lost to do things over, and the time lost to track everything down. This allows real-time production monitoring, optimising resource utilisation and enabling a 24x7 operation with minimal downtime. The outcome has been intelligent automation that improves planning and scheduling, lowers idle time, and standardises output.

Realising cost benefits and optimal utilisation

Automation helps to save a considerable amount of work by reducing human involvement in repetitive tasks. Furthermore, IoT-based predictive maintenance helps lower maintenance costs, extends the lifecycle of machine equipment, and reduces equipment failures as well. Automation also maximises raw material consumption, reducing waste and aiding eco-friendly production methods.

Better quality products and their consistency

Ensuring product quality remains a critical part of modern manufacturing. AI-driven quality control mechanisms use vision inspection systems and real-time monitoring tools to spot defects early thereby lowering the risk of human errors. Going forward manufacturing processes will get refined through analytical tools, quality continues to improve, ensuring compliance with industry requirements.

Workplace safety and risk mitigation

Prevention of human exposure to hazardous environments increases workplace safety with the help of automation. Collaborative robots (cobots) can carry out hazardous tasks, while IoT-enabled safety systems track conditions to pinpoint hazards, ensuring real-time alerts to avert disasters. Making workplaces safer while ensuring compliance to health and safety laws.

Growth of real-time data analytics and predictive decision-making

A seamless combination of IoT, AI, and big data analytical tools leads to real-time data collection and prompts informed and proactive decision-making. Predictive analytics helps manufacturers identify where equipment is most likely to fail in order to maximise efficiency and throughput, while digital twins create simulated versions of physical equipment that can help companies identify areas for process improvement.

Digital twins are digital representations of physical systems and processes, letting manufacturers analyse data from the real world and help modify future errors. Digital twins allow companies to optimise their operations, run scenarios without putting anything at risk, and improve product designs, resulting in better efficiency and more innovation. They also help with understanding how systems behave when conditions change, enable predictive maintenance by analysing wear patterns in machinery, and allow for changes to be tested without the cost and risk of physical alterations.

Scalability, flexibility and adaptability

As the market is evolving all the time, manufacturers need to scale up as quickly as possible. In such a time, downtime is minimised, speed and flexibility are maximised, and intelligent manufacturing—harvesting data, analytics and 3D printing—allows for the production of high-value products. Advanced levels of robotic systems are easily reprogrammable between compatible product designs, and flexible manufacturing systems support low manpower levels in customisation and small-lot production.

The energy efficiency and sustainability of supercomputer centers

With the critical importance of sustainability in the manufacturing sector, automation is playing its part in better energy consumption with AI-driven energy management systems. IoT sensors reduce energy waste, which will cut operational costs and lower environmental impact. Predictive maintenance also enhances sustainability by avoiding unnecessary wear and tear on machinery as well as supporting green initiatives.

Smart factories: Data protection and cybersecurity

As smart factories continue to expand, cybersecurity protects sensitive manufacturing data. The data collected from the industrial control systems are automated, and the security mechanisms should be structured around Secure by Design, Resilience, and Incident Response. Secure by Design ensures that machines are deployed with built-in protections, such as application trust listing. Resilience relies on AI-based ransomware detection and offsite backups to maintain data integrity and enable rapid recovery. Incident Response focuses on vulnerability management, identifying software supply chain risks to fortify security update procedures against evolving cyber threats. A proactive, layered approach is key to securing smart factories.

Latest trends in smart manufacturing automation

Examples of emerging technologies include AI-powered autonomic systems that facilitate automatic optimising of production lines, as well as the 5G network rollout, which promotes communication between IoT devices for effortless automation. It enables real-time optimisation and immersive training experiences through technologies like digital twins and augmented reality.

As industry continues its rapid evolution, these manufacturers that adopt automation will have a leg up in a more and more digitised and connected world. Through unlocking the potential of AI, IoT, robotics, and predictive analytics, organisations realise a manufacturing paradigm that is scalable, adaptable, and secure, with a collaborative innovation engine at its center, resulting in digitised sustainable industrial systems with far more effective, flexible, and resilient ecosystems.

Sanjeev Srivastava, Head of Automation Business, Delta Electronics India, is an industry veteran of more than 30 years, having worked on automation, energy, and industrial solutions. Currently serving as the Head of Automation Business at Delta Electronics India, he has played a critical role in driving growth and innovation since he joined the organisation in 2016. Prior to this, he held the position of Global Strategic Account Director, where he effectively managed customer relationships and achieved significant business growth.

As the Head of Automation Business at Delta Electronics India, Sanjeev champions sustainable and energy-efficient automation solutions, demonstrating dynamic leadership and a capability to navigate complex challenges, which positions him as a thought leader in the automation industry.