Shubhankar Chatterji, Chief Supply Chain Officer, Cummins India.

How has the adoption of robots and cobots evolved in the manufacturing sector over the past decade?

Over the past decade, the integration of robots and cobots in manufacturing has accelerated significantly across regions, including India. Rising costs and the adoption of Industry 4.0 have spurred this shift, heralding a technological revolution that is reshaping global industries.

India, especially, has emerged as a formidable player in sectors such as automotive and pharmaceuticals. According to the International Federation of Robotics (IFR), India ranks 7th in annual robot installations worldwide. Companies have integrated robots for welding and painting, significantly enhancing precision and efficiency. Startups are revolutionising logistics through warehouse automation, utilising autonomous mobile robots (AMRs). The emergence of cost-effective cobots is empowering small and medium enterprises (SMEs) to automate precision tasks affordably. Furthermore, India is on the path to smart factories, leveraging public-private partnerships such as the National Manufacturing Policy to drive innovation in manufacturing.

At Cummins, our dedication to such innovation and operational efficiency drives us to embrace robotic and cobot technology in our manufacturing processes. From quality control to material handling, we’re leveraging technologies such as Intelligent Mobile Robots (IMRs), which are transforming our operations and delivering substantial cost savings and productivity improvements. This ongoing evolution in robotics integration marks a new era of human-machine collaboration, enhancing manufacturing processes and boosting productivity across industries.

Which industries or manufacturing processes are seeing the most significant adoption of robotic automation?

Certain industries are at the forefront of robotic automation, driven by high RoI and the need for precision and speed. These sectors benefit significantly from robotic integration due to their reliance on repetitive tasks and the necessity for process precision, which offsets costs like energy, yielding a strong competitive edge.

Leading the charge is the e-commerce sector. Companies have transformed warehousing, sorting, and logistics through a blend of Industry 4.0 technologies, digitalisation, and robotics, significantly improving operational efficiency. Similarly, the automotive, semiconductor, machinery, computer, and hardware industries are major adopters of robotic automation. These sectors capitalise on robotic technology to enhance efficiency, precision, and production speed, aligning technology with strategic business goals to drive remarkable growth and innovation. According to a report, in 2023, the automotive industry witnessed a remarkable 139% increase in robotic installations, reaching 3,551 units, driven by both car manufacturers and parts suppliers, thus commanding 42% of the market share. Additionally, the rubber and plastics industry lead the general industry in India, with a 17% increase in installations to 408 units, while the metal industry maintained a steady 329 units. These advancements underscore the pivotal role of robotics in driving innovation and growth across various sectors.

The key considerations for automation are: What part of the manufacturing process is automatable? How significant is the impact on productivity? These questions guide industries in their automation journey, ensuring they maximise the benefits of their investments. This evolution represents a powerful convergence of technology and strategy, fueling unprecedented growth and innovation.

What are the key factors driving the increased use of collaborative robots (cobots) over traditional industrial robots?

The increased adoption of collaborative robots (cobots) over traditional industrial robots is driven by key factors that align with industry needs and RoI considerations. Cobots are more cost-effective, requiring less maintenance and no additional safety features, which enables quicker returns on investment compared to the more expensive industrial robots that necessitate extensive safety measures. Although industrial robots operate at higher speeds, cobots offer sufficient speed coupled with agility, making them ideal for dynamic environments requiring flexibility. In terms of accuracy and sensitivity, industrial robots excel due to their precision, making them suitable for repetitive tasks requiring consistent results. However, cobots are better for flexible automation tasks, using advanced sensing technologies to perceive human motion and force, allowing them to adapt their movements for delicate operations.

Moreover, cobots are flexible and can be reprogrammed for various tasks, which is crucial for companies needing to adapt their processes. These factors collectively allow industries to make informed choices based on specific operational needs, investment capabilities, and RoI expectations. For example, industrial robots are ideal for metal stamping, which needs high speed and safety without human access, while cobots are better for warehouse tasks where people work with materials, allowing safe and efficient teamwork.

How do AI, machine learning, and vision systems enhance the capabilities of robots in manufacturing?

Artificial intelligence (AI), machine learning, and vision systems are transforming the manufacturing landscape by enhancing robotic capabilities. These technologies enable robots to ‘see’ and identify objects with precision, akin to skilled craftsmen, ensuring flawless execution of assembly and quality control tasks. Machine learning algorithms empower robots to continuously improve their performance by predicting failures before they occur and optimising processes, thereby becoming smarter and more efficient over time. AI facilitates safe and collaborative integration of robots with human workers, allowing them to adapt quickly to new tasks and complement human strengths in a harmonious working environment. Equipped with real-time data and sensors, robots can autonomously navigate factory floors, sort items, and manage inventory with the dexterity of logistics experts, ensuring precise and timely operations. By leveraging these advanced technologies, manufacturers can enhance productivity, minimise errors, and reduce costs, resulting in factories that are faster, more adaptable, and prepared to meet the demands of the future.

Are there concerns about job displacement, and how can companies address workforce transition challenges?

Automation and AI simultaneously create new opportunities for workforce development and innovation. Companies can address the transition challenges by implementing strategies that focus on upskilling and reskilling employees for high-value roles. For instance, transitioning factory workers into skilled roles such as robot maintenance technicians or programming experts not only preserves jobs but also enhances workforce capabilities, making them essential in an automated landscape. Investing in comprehensive training programs is essential, covering topics from basic robotics and AI principles to advanced programming and maintenance techniques. By offering these learning opportunities, companies empower their employees to remain relevant and competitive.

Additionally, supporting STEM education and encouraging young talent to pursue technology-related careers can ensure a future workforce well-prepared for an automated world. As automation and AI grow more prevalent, new roles will emerge in tech oversight and management, focusing on deploying and operating automated systems efficiently and ethically. By cultivating these roles, companies can maintain control over their technological advancements while fostering a culture of responsibility and innovation, ultimately leading to a harmonious integration of automation into the workforce.

Where do you see the biggest innovations in robotics for manufacturing in the next 5-10 years?

In the next 5-10 years, we anticipate significant innovations in robotics for manufacturing, with a strong emphasis on AI-driven autonomy, collaborative robots (cobots), and adaptable production lines. Advances in machine vision and real-time decision-making will enable robots to tackle intricate and unforeseen tasks with minimal programming, resembling skilled workforce adapting to new challenges. Soft robotics and adaptive grippers will revolutionise delicate object handling, allowing robots to manipulate fragile items with the gentleness of a human touch. Swarm robotics could transform large-scale logistics, as fleets of robots collaborate seamlessly to manage complex operations. The adoption of digital twins – virtual replicas of physical systems – will optimise production processes and predict maintenance needs, creating smarter and faster factories. The introduction of 5G-connected robots will facilitate real-time communication and coordination, enhancing factory responsiveness and agility. Another pivotal focus will be sustainability, with the development of energy-efficient systems and recycling automation. This will drive factories not only to produce goods efficiently but to minimise environmental impact, contributing to a greener future.

(The views expressed in interviews are personal, not necessarily of the organisations represented)