The best way to accelerate the journey is to start small – and think big
Published on : Sunday 05-03-2023
Sureshbabu Chigurupalli, Board Member-Director, Balasore Alloys Ltd.
Which are the three new technologies which would be interesting for factories to acquire and adopt? Why would it be attractive?
IIoT, AI and, ML, robotics are the trending technologies that the manufacturing sector would like to adopt. AI and its subfield, machine learning (ML), are gaining popularity in manufacturing industries as they have tremendous potential to increase efficiency, flexibility, and quality for optimised operations.
IIoT implementation in manufacturing industries provides advanced analytics to use real-time actionable insights to improve efficiency by taking the right actions. Manufacturing companies can have a substantial decrease in operational costs by using intelligent networks that communicate and collaborate autonomously with little involvement by operatives
Study indicates that the right combination of AI technologies can reduce producers' conversion costs by as much as 20%.
AI and ML have tremendous potential to increase efficiency, flexibility and quality for optimised operations by infusing computer intelligence and self-learning into factory processes.
Robotic automation can play a vital role in supply chain management. Robotics can help eliminate predictive and repetitive tasks like spraying, shifting, picking, and transferring material. Human errors and losses can be eliminated.
Are there any factories where this IIoT movement will take longer to reach? What can be the reasons for this? What needs to be done to accelerate their journey?
Business leaders are taking a wait-and-see approach towards adopting the Industrial Internet of Things (IIoT), lacking the necessary understanding of the benefits and failing to embrace these transformative technologies and fear cybersecurity threats as technology is integrated into manufacturing operations. They are looking for proven case studies before the adoption.
The manufacturing sector's challenges are resistance to change and fear of migrating from traditional processes to new transformative technology. An ageing workforce and diversified skill pool also become a challenge to implement.
The best way to accelerate the journey is to start small – and think big. Pilot projects in small pockets are to be considered by engaging employees and showing results like remote monitoring of energy parameters, troubleshooting, etc. The tiny successful results will inspire and engage to move forward for large-scale adoption. It is just a matter of time before someone takes the lead and opens the market.
There are two work areas – bringing raw materials into the factory and movement of work-in-progress inside the factory – where there is much scope for automation. Which technologies are relevant in this area for different types of factories?
Inventory management and demand forecasts are vital in the factory to run the business. Out-of-stock and overstock is revenue loss to a company. Tracking the delivery of goods in real-time, optimising travel routes, fuel optimisation, fleet tracking are scope for digitalisation.
RFID-based WIP tracking can immediately report if any deviation from the ideal process is encountered. This way, even the tiniest mistakes can be spotted and corrected in the initial stages, and companies can avoid pricey mistakes and scale down manufacturing errors.
Continuous monitoring of WIP by using RFID and barcode technologies ensures quality control, from picking the raw material to dispatching the final product. Minimises labour costs and helps us maintain the accuracy of inventory levels.
Material tracking systems ensure that the materials for through every stage of manufacturing and will eventually prevent returns due to manufacturing defects.
Inspection and quality is a very important topic. It is no longer just good enough to execute these functions rigorously, now it is a necessity to show off that it is being done. In other words customers might wish to view that inspection and quality check are being executed.
Poor quality is the primary cause of product defects that impacts business relationships and your brand image. The sooner issues are identified the sooner the process can be adjusted.
Manual inspection forms are not real-time analytics; one should analyse the gathered data to conclude. This could take hours and days. Manual quality control checks could be more inefficient and prone to errors. Changes in a parameter can affect the entire production process and the product lifecycle.
Digitalising the workflows and processes will lead to automated checks and help the rate of rejected products, rework, and customer claims due to quality issues. Improves traceability of information and reduces waste and cost.
Robots are going to be a presence in the factory. But importantly, which functions are going to get robotised? For instance, would cleaning the shopfloor be an application to use a mobile robot?
Robots are more efficient than humans when there is a need for precision positioning, repeatability, accurate inspection and measuring, and robots do not make mistakes because of fatigue.
Painting, shifting and packing, material handling, and hydraulic operations are popular areas where robots are deployed. They can be programmed to operate 24/7 for continuous production. Robots can perform complex functions tirelessly.
Manufacturing robots create efficiencies from raw material handling to finished product packing. They can be programmed to operate 24/7 for continuous production. They are highly flexible and can perform complex functions. They are cost-effective even in small manufacturing facilities.
Robotic Process Automation – RPA is an exciting productivity tool. How many factories use this? Why don't others use it?
Banking, health care, and insurance are prominent sectors using RPA. RPA plays a vital role in supply chain management in manufacturing sectors. Workflow can be reallocated towards other priorities requiring human input, leading to increased productivity and RoI. Reduce wait times for customers, leading to higher rates of customer satisfaction.
Traditional organisations are reluctant to use RPAs as they are still deciding on optimising the workforce and the threat of disruption in industrial harmony as it will eliminate the crew. Scaleup is another issue to get the full advantage of RPAs.
Implementing RPA with a well-strategised plan will result in matched expectations and can ensure the success of automation is maintained. If the processes change frequently, it will be challenging to keep the RPAs.The selection of wrong automation may lead to the defeat of the objective.
Sureshbabu Chigurupalli, Executive Director, is on the Board of Directors – Operations & Maintenance, Keynote Speaker/Lean Practitioner/Production Management/TPM Practitioner with 26+ years of experience. He is Director (Operations) at Balasore Alloys Limited, Balasore, Odisha. He did his B.Tech.in Instrumentation from Andhra University (1994). He is an enterprising leader & planner with a strong record of contributions in streamlining operations, invigorating businesses, heightening productivity, systems & procedures.
Sureshbabu has achievement-driven professional experience in spearheading entire unit/plant operations to maintain continuity and match organisational goals through supervising Operations, Quality Control, Production Goals, Automation, Maintenance, Process Improvements, Safety Guidelines, Manpower Development, New Policy/Procedure Guidelines, Resource Allocation and Cost Optimisations. He is leading and managing all plant operations with effective utilisation of all resources and implementing industry best practices such as TPM, Six Sigma, Lean Management & others Business Excellence initiatives that contribute to improve productivity and efficiency. He has exhibited leadership in closely collaborating with numerous Japanese Consultants for implementing TPM to enhance overall plant effectiveness.
(The views expressed in interviews are personal, not necessarily of the organisations represented)