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VOL 12  JUN-JUL 2019  ` 100 www.industr.com/en

Also available in China, Taiwan, Singapore, Malaysia, Thailand & Hong Kong

AUTOMATION & DIGITISATION

PHARMA 4.0:

Transforming life science manufacturing

A&D - Interview Shree Harsha, Marketing Director – India, Dassault Systèmes (p. 24)

In association with

P. 30

Fieldbuses & Networks

P. 36

Advt

FOCUS Power & Energy


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Does the situation look complex?

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Automation for a Changing world

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E D I TO R I A L

M

automahindra & to otive Mahin — a sta plant at Chakadra te-of-th manufa e-art eco-f n, Pune ri c Visit

turing

Making partnership work! With rapidly evolving automation technology that is increasingly becoming an absolute necessity than luxury, service providers are looking to harness this power, taking advantage of the growing capabilities of automation solutions to augment their services and significantly improve their response times by delivering better, more cost-effective services to end-users. However, in order to make an automation project successful all the stakeholders across the end-user organisation must be able to get the necessary support and resources from the service providers. This calls for a win-win partnership, allowing all the partners involved to realise the full potential of automation, bring up updated information, answer questions and solve problems faster than ever before. I got an opportunity to moderate a panel discussion recently, where the topic of partnership came up quite strongly, among others. With rapidly changing technology landscapes, you need to ensure that the technology choices you make are reliable, easy to integrate and support, and bring you an advantage. That’s where partnership becomes critical. It is important that end-user organisations choose their service providers wisely, to reduce the risks while investing in a forward-thinking strategy. They should have right expertise to understand their unique needs and service providers should be able to design and deliver solutions fulfilling those needs cost-effectively. Tools to help the users embrace selfsufficiency to select and price the right products/solutions for their applications will help to accelerate the execution. System integrators too play a very important role here in terms of solving a user’s problems by selecting the best possible solution from all the available products. We look forward to hearing from you on this topic. Please do write to us!

EDITORIAL ADVISORY BOARD

Shekhar Jitkar Publisher & Chief Editor shekhar.jitkar@publish-industry.net

P V Sivaram Chairman - Non Executive B&R Automation President - AIA (Automation Industry Association) Ravi Agarwal Director, Pepperl+Fuchs (Factory Automation) Vice President – AIA (Automation Industry Association) Raj Singh Rathee Managing Director Kuka Robotics India

Anup Wadhwa Director – AIA (Automation Industry Association) Jasbir Singh Vice President – Electrical & Instrument Essar Project Management Consultants Ganapathiraman G Vice President & GM (South and South-East Asia) ARC Advisory Group Dr KLS Sharma Advisor Automation Education & Training

Mandar Phadke CEO, Abhisam Software Former Head – Process Control Lanxess India Pvt Ltd

.

endly

AUTOMATION & DIGITISATION

Knowledge Partner

®

Progress through Research

INTERNATIONAL AUTOMOTIVE MANUFACTURING SUMMIT 2019 Manufacturing Excellence with Technology Innovations 16-17 July 2019 Pune, Maharashtra, India

Speakers from ARAI, Dept of Science & Technology, Mahindra & Mahindra, Fiat India Automobile, JBM Auto, Greaves Cotton, Tata Motors, Frost & Sullivan, Volkswagen, Bajaj Auto, Oerlikon Balzers, Ansys For Delegate Registration, Sponsorships, Paper Presentations & other details, contact:

Arcot Rajabahadur Automation Consultant

Dhiraj Bhalerao (West & South) dhiraj.bhalerao@publish-industry.net +91 9820211816

Thampy Mathew Chairman, Fieldbus Foundation India Regional Sales Director, Pepperl+Fuchs (Process Automation)

Sagar Tamhane (North) sagar.tamhane@publish-industry.net +91 9820692293

Overseas Partner: China, Taiwan, Hong Kong & South-East Asia

A&D India | Jun-Jul 19

facility

Alok Kumar (Bangalore) alok.kumar@publish-industry.net +91 8861009443 5


CONTENTS

Market

10

Management

Interview

NEWS 24

12

Power & Energy 30

“FLEXIBLE MANUFACTURING IS

“TECHNOLOGY IS STILL SOMEWHAT NASCENT

THE KEY TREND RIGHT NOW”

IN THE INDIAN CONTEXT”

Shree Harsha, Marketing Director – India, Dassault Systèmes

Interview with Dr Dheepa Srinivasan, Chief Technology Officer, Intech DMLS

16

“ARTIFICIAL INTELLIGENCE: REVOLUTIONISING

“ACHIEVING GROWTH & EFFICIENCY

THE MANUFACTURING INDUSTRY”

THROUGH INNOVATION”

This section features expert opinions on how Artificial Intelligence will bring about a drastic change in the manufacturing industry

Virginia M Ginni Rometty, Chair President & CEO, International Business Machines Corporation (IBM)

Start-up 14

“ADDITIVE MANUFACTURING ACTS AS A HELPING HAND IN CONVENTIONAL MANUFACTURING”

Interview with Ankit Sahu, Director, Objectify Technologies

Event Report 56

INNOVATION TO TRANSFORM THE ENERGY FUTURE

The article focuses on technologies that bring about constructive energy transformation, the hurdles that oil and gas companies face to reach the full value of digital initiatives, and what to consider while building a successful digital strategy for energy transition.

Leadership Insights

Viewpoint 26

Focus

“PRODUCTIVITY THROUGH DIGITAL TRANSFORMATION”

A post-event report on the conference on ‘Digital Transformation Driving Business Outcome’, organised by Rockwell Automation

UV

Cover Story 18

PHARMA 4.0: TRANSFORMING LIFE SCIENCE MANUFACTURING

The life science industry has a strong legacy in data collection and has embraced the methodology behind ‘Industry 4.0’ – which we will refer to as ‘Pharma 4.0’. In this article, the author explores Pharma 4.0, including the technologies and approaches that will facilitate change and the role of data.

IR

Expanding the field of vision


CONTENTS

Advt

Technology

Fieldbuses & Networks 36

FIELDBUSES IN ERA OF INDUSTRY 4.0

Digitisation 48

The article discusses the classifications of fieldbuses and how the rise of IIoT and new possibilities for connectivity with wireless and Ethernet are altering the protocol scene

The article discusses how to apply automation sustainably and make the most of it

Industrial robot arm; Safety for machine building; Diagnostic system for vibration sensors

61

Chainflex cables; Controller with integrated switch; Industrial gear unit; Clamping device for mounted points

62

Emerging trends in testing & measuring solutions

MAXIMISING DAIRY PRODUCTION WITH

PRINTED CIRCUIT BOARD 4.0

INTEGRATED PROCESSING PLANT

The article explores how the circuit boards and their manufacturers are evolving and working towards giving interactive products to the world

A case study on a dairy turning to Rockwell Automation with its requirements of bringing about process optimisation, manpower reduction, and an integrated liquid milk plant

Material Handling

Green Manufacturing

INDUSTRY 4.0 & FORK TRUCK FREE INITIATIVES

The article talks about how Industry 4.0 represents the way in which FTF initiatives capture the convergence of digital and physical worlds and how Industry 4.0 and FTF are really about smart machines

60

Advertorial 52

44

New Products

THE WHY, WHEN AND HOW

Test & Measurement 40

DETERMINING AUTOMATION VALUE:

54

Columns

ENSURING REDUCED CARBON FOOTPRINT WHILE DIGITISING ASSETS

05

This article explains how industries have brought the environment as a core part of their CSR, and throws light on edge architectures which help factories reduce e-waste and also become smart

06 08 64 64

Editorial Contents Guest Editorial Highlights – Next issue Company index

Advt

INTEGRATED MACHINE VISION More than embedded Complete portfolio: www.br-automation.com/vision


Deepak Aran

DIRECTOR CONTRINEX AUTOMATION

Today, the buzz of the town is intelligent sensors for the fourth industrial revolution, commonly known as Industry 4.0. Intelligent sensors are the fundamental building blocks of modern smart factories. The future now looks towards IO-Link, the feature which makes sensors intelligent. They enable sensors-supported production resources (machines, robots, etc) to configure, control, manage and optimise themselves. Precise, reliable sensor data is now more essential than ever. As the first standardised IO technology worldwide (IEC 61131-9) for communication with sensors and actuators, IO-Link is crucial to the fourth industrial revolution. Sensors of all types are common in automotive factories around the globe. Highly automated plants with demanding conformity requirements rely heavily on sensor technology in order to maintain world-class quality standards, particularly where harsh processes, such as, welding, metal finishing and high-temperature coating, are required. Manufacturing engineers working for automotive manufacturers and for first- and secondtier suppliers expect robust, reliable sensors that deliver accurate, repeatable results with minimal downtime. 8

COMMENTS & COMMENTARY

GUEST | EDITORIAL

“THE PACKAGING INDUSTRY IS HIGHLY INNOVATIVE WHILE USING SENSORS” Machine tools being another important area in the manufacturing industry impose harsh operating conditions on the sensors needed to control cutting, forming and joining processes that run continuously in many metalworking factories. Common hazards including cutting fluid, cooling sprays, swarf particles, and electromagnetic interference make sensor selection particularly difficult where world-class performance is essential. Size is another key factor, as modern tool-holders allow only limited space for the sensors needed to identify and position individual tools during rapid tool-changing. The intelligent sensors contribute to efficient production, without interruption or error. Also, on the journey from the manufacturer to customer, packaging

protects all types of products, including foods, pharmaceuticals, white goods and cosmetics. Although packaging helps bring competitive products to target markets in the best possible condition, costs are often significant and automation helps minimise the impact. The packaging industry is highly innovative while using sensors in order to identify, select and position packaging of all types. Reducing manufacturing costs and ensuring environmental sustainability are key objectives, and intelligent sensors for packaging machines are chosen to maximise efficiency while ensuring reliable and repeatable operation. Whatever the logistics system, choosing the right sensors is crucial to achieving the six “rights” of logistics: Ensuring that the right goods, in the right quantities, in the right condition, are delivered to the right place, at the right time, for the right cost. From largescale containerised shipping to everyday internal logistics, engineers select the right sensor technology for each container, conveyor, palletiser or robot, ensuring reliable, repeatable detection and identification, together with troublefree operation. ☐ A&D India | Jun-Jul 2019


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MARKET | NEWS

Siemens launches Siemens Opcenter Siemens Digital Industries Software recently announced the immediate availability of Siemens Opcenter™ software, which is a cohesive portfolio of software solutions for manufacturing operations management (MOM). The Opcenter expands by uniting the company’s products in a single, connected cloud-ready portfolio with a harmonised user experience that can help manufacturers meet demands for production efficiency, quality, visibility and reduced time to production. Expressing his views on the launch, Rene Wolf, Senior Vice President–Manufacturing Operations Management Software, Siemens Digital Industries Software, exerted, “Bringing these components together as Siemens Opcenter and harmonising the end user experience with other parts of our Digital Innovation Platform will make it much easier for manufacturers to manage their digital transformation process.”

Bentley Systems announces the acquisition of Keynetix Bentley Systems recently announced the acquisition of Keynetix, which is a provider of cloud-based software for capturing, visualising, modelling, and sharing of geotechnical data. The addition of Keynetix software expands Bentley’s geotechnical offerings and accelerates Bentley’s vision of enabling subsurface digital twins for infrastructure projects and assets. Subsurface digital twins can be vital for assessing and managing risks in infrastructure projects, and to the planning, design, construction and operations of infrastructure assets. Enlisting the benefits of the acquisition, Bob Mankowski, VP and business unit executive digital cities– Bentley Systems, said, “The Keynetix team and their technology bring decades of experience and cutting-edge cloud services to Bentley’s geotechnical portfolio – gINT, PLAXIS, and SoilVision – and will accelerate the progress of our vision for subsurface digital twins.”

LANXESS to deploy Artificial Intelligence in product development LANXESS recently entered into close collaboration with Citrine Informatics, a US-based AI company, specialising in data-driven materials development. The two companies have launched a pilot project aimed at gauging the potential of AI for the plastics production. The aim is to further optimise the glass fibres that is used for reinforcing many high-performance plastics and ultimately to enhance the performance of the materials. Discussing the benefits of reduced development time for optimised formulations with the help of AI, Dr Axel Tuchlenski, Head of Global Product and Application Development, LANXESS High Performance Materials business unit, cited, “This will enable us to not only offer our customers even better tailor-made products, but also reduce time to market.” Looking as a beginning for AI with the development of high-performance plastics, Jörg Hellwig, Head of Digitalisation Initiative, LANXESS, quoted, “Artificial Intelligence is a vital technology for creating innovation from the myriad data within the Group.”

Hindustan Platinum acquires ABB Humacao, Puerto Rico manufacturing plant Hindustan Platinum recently announced the asset purchase of ABB’s Humacao electrical contacts manufacturing plant in Puerto Rico, hence strengthening its international footprint. The deal is expected to close in August 2019. The addition of the Humacao plant is of critical strategic interest to the company’s electrical contacts division as it is going to be the second electrical contacts manufacturing facility that will cater to the growing demand of the North American and Latin American markets. Deciphering the expectations, Ashish Choksi, Executive Vice President, Hindustan Platinum, asserted, “This strategic step is expected to have a great deal of synergy from the enhanced competitive positioning in terms of geographical footprint, customer base and range of solutions for electrical contact industry that will be available from both the facilities. We believe the addition of the Humacao plant will give us an opportunity and ability to integrate and align people, best technology, skills and processes, which will get reflected in the success of reaching our stated goal in the contacts business.”

10

A&D India | Jun-Jul 2019


NEWS | MARKET

igus provides robolink arms for Indian educational facilities igus recently provided eighty low-cost robots for research at Indian higher-education institutions as a result of increasing collaboration between India and Germany. The governments of the two countries have committed themselves to this goal. These efforts were intensified when the Indian Prime Minister, Narendra Modi, came on a visit to meet Angela Merkel, Chancellor of Germany in Berlin in July last year. When visiting Automatica and looking for robots to be used for teaching purposes, Vangapandu Venkatanagaraju’s, Founder, Indo Euro Synchronisation, attention was drawn to robolink, the cost-effective modular system, which was so convincing that over 80 robolink arms for 40 Indian educational facilities were ordered. Each facility will receive two robots: the robolink DCi with four axes, integrated control system and electric magnets, as well as a robolink robot arm with four axes and pneumatic suction cups. In the framework of a delegation trip, 24 Indian professors familiarised themselves with the robolink systems. The professors were trained by Alexander Mühlens and Kai Schmitz, low-cost robotics experts, igus, during an event in the Aachen Digital Capability Centre. Dr Christian Meyer, the developer of the robolink DCi software, Commonplace Robotics, instructed the professors on how to use the intuitive software. Explaining the training pattern, Meyer explained, “After additional Train the Trainer webinars, the trained professors will teach their students how robolink can be used in industrial applications.” After only a brief explanation, the professors were able to define some movements of the robot and see their success live. Further projects, such as, the use of low-cost robotics in the area of textile technology are already being planned in conjunction with APS GmbH.

Dassault Systèmes launches Connected Factory Dassault Systèmes recently launched the 3DEXPERIENCE on Wheels - Connected Factory, which is a tech-nology showcase of a fully functional factory assembly line mounted on a vehicle that showcase transformational experiences for a smart and connected factory of the future, in Pune. The 3DEXPERIENCE on Wheels – Connected Factory campaign will tour at various manufacturing hubs, industrial corridors, start-up incubators, and academic institutes. Elaborating on the campaign, Kiran Divekar, Director – DELMIA, Dassault Systèmes, explained how people can experience lean management, advanced production & scheduling, manufacturing operations management, manufacturing analytics and 3DEXPERIENCE Twin. At the launch, Samson Khaou, MD, India, Dassault Systèmes, cited, “We have the vision & strategy in Industry Renaissance and with the 3DEXPERIENCE platform, we are a game-changer, leveraging our capacity to help manufacturers in India to reinvent themselves.” Similarly, sharing his thoughts about the near future, Guillaume Vendroux, CEO – DELMIA, Dassault Systèmes, quoted, “Those who don’t digitise their industrial operations in the next five years will find themselves in a peculiar situation because they’ll lose out to their competitors in terms of response time.” Kothapalle Reddy, VP, Business Transformation, Dassault Systèmes, asserted, “Today, manufacturing companies must innovate, manage production capacity and improve quality, digitalise to improve exports and invest in new technologies. We are constantly looking out for new technologies that seamlessly connect into existing systems and enhance collaboration.” Sharing his perspective, Shree Harsha, Indian Marketing Director, Dassault Systèmes, anticipated, “Manufacturing is changing too fast. The goods, products and services are no longer enough but the experience that the customers connect with the product is what matters.”

A&D India | Jun-Jul 2019

11


MARKET | INTERVIEW

“Our softwares and solution will speed up mass production” … says Dr Dheepa Srinivasan, Chief Technology Officer, Intech DMLS, in this conversation with Anvita Pillai, discussing about their latest alliance, partnerships, trends, objectives and more. Excerpts… Intech recently entered into a partnership agreement with DMG Mori. How, according to you, is this alliance going to be a game changer for both, Intech and DMG Mori, globally as well as in India? Intech DMLS is a pioneer in the metal AM field, not only in India, but globally. They have been able to run several 1000s of hours on the lasers and have a wealth of knowledge on the parameters to produce reliable parts for various sectors (automotive, aerospace, healthcare, tool and die, general engineering, space etc). DMG Mori stands to gain from the vast technical know-how generated at Intech to enter the AM market globally. Likewise, DMG-Mori being a market leader in the machine tool industry, our company stands to gain enormously from their reach to spread this technology and our name in the global context. Both application and sector wise, this partnership will be a game changer in revolutionising the metal additive industry.

Your company is already catering to aerospace tool & die, automotive, and general engineering industry what other verticals are you hoping to venture into? We are looking forward to venture into the healthcare industry; to enable affordable healthcare solutions for the patient population and doctors alike is our next big goal.

Many industries are embracing 3D printing as a critical part of their R&D. Can you highlight the upcoming trends in this area? A huge awareness has crept in India in all types of application sectors about metal AM. Over 60 metal 3D printing machines are now running in various laboratories, universities, national labs, and over 15 entrepreneurs have started metal 3D printing as a service in the recent two years in India. While most of them are still trying to establish additive technology and part production, research in this area is upcoming with new powder development, acceleration in software for enabling distortion-free complex geometries, mass production at affordable costs via productivity enhancements, establishing various mechanical properties and structure correlations and adopting design for additive manufacturing approaches.

You have been driving the vision and roadmap for large new technology and new product development projects. Do you think enough is happening in this space in the Indian industry and academic institutions? If not, which are the areas that need attention? This technology is still somewhat nascent in the Indian context. The awareness has now crept in all sectors, which is a great thing, since curiosity and competitiveness will now take over to drive metal AM into various manufacturing applications. In particular, with the head start that is already existing on a dozen alloys, adaptation of AM in several sectors could be much more accelerated. Our additive software and hardware solutions with expert technological services will speed up the industry towards mass production, strongly competing against conventional cost. ☐

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Tell us more about Intech’s partnership with academic institutes. What kinds of projects are planned with them? We are actively working with over two dozen premier institutions in India as well as abroad, successfully, via joint proposals to goverment funded programs, such as, IMPRINT, UAY, DST-SERB etc, student interns working on programs at Intech, summer internships from various Universities, industrial visits for students, to name a few. Besides, MOUs have been signed with IISc, IIT, Ropar, VIT, Vellore for long-term strategic partnership in AM material and product development.

A&D India | Jun-Jul 2019


S TA R T- U P | I N T E R V I E W

“Additive Manufacturing acts as a helping hand in conventional manufacturing” ... says Ankit Sahu, Director, Objectify Technologies, in this interview with Anvita Pillai, where he indulges in a discussion about Additive Manufacturing, the array of opportunities it has opened, India’s adoption and reception of the technology and more. What was the aim & idea behind starting/launching Objectify? We started by working on a small research and development project at IIT Kanpur with a Makerbot FFF desktop printer. We identified a massive gap within the manufacturing industry for quick short batch requirements for sample testing in the R&D and NPD departments in different organisations. We wanted to hit in somewhere between the supplychain to act as a catalyst. We started evaluating 3D printing to minimise this and we think we have been able to help a lot of industries bring products to shelf faster than they ever could. You recently signed an agreement with MSC to use MSC’s 'Simufact Additive' for Additive Manufacturing (AM) simulation and MSC One Suite of products. How is this latest advancement going to contribute towards the growth of Objectify? In AM the major pillars are design, simulation, and manufacturing. Hence, simulation plays a crucial role in making the end product come to life. It helps us to be decisive about the orientation, segmentation (if any) and material composition as well as run tests on the end product in terms of its functionality in the real scenario. MSC’s ‘Simufact Additive’ and MSC one suite of products provide us an array of opportunities to ease the process further. It can be used to explore the process space, which helps us predict shrinkage, warpage of the component, residual stresses, optimal location of part support structure and calculate the deformation of the base plate, helping us reduce time and efficiently address client issues. What would you say is the biggest challenge you face in the field of Additive Manufacturing, 3D printing & rapid prototyping? AM, in India lacks awareness about the applications and benefits among the manufacturing fraternity, which is one of the reasons the adoption has been slow. Having said that we have seen a huge improvement in approach towards AM in the last couple of years. The Indian manufacturing industry is in the process of shift from conventional to modern technologies complementing their existing manufacturing process. The major challenge is the shifting of comfort zone for current manufacturing units and the

14

myth of how 3D printing can be costly, which is not true. In the long run, the cost of manufacturing of components is negligible when we see the time which is saved in deciding on the right iteration for mass production. With the regular development in 3D printing, the cost of production will decrease drastically. As mentioned by you, there is a huge improvement in approach towards AM at present. How would you say these improvements would complement the existing manufacturing process? India has been a slow and steady adopter of the AM technology but it is getting better out here. The quality of discussions in the Indian AM fraternity is increasing and getting on par with the rest of the world. Soon, you will be hearing a lot of good moves from the Indian AM industry. AM acts as a helping hand in the conventional manufacturing process. It is not here to replace it but to complement it. This needs to be propagated throughout the industrial fraternity. You once mentioned that your long-term goal is to create synergy with industries in major manufacturing sectors, such as, automotive, aerospace, tooling, space research & medical in order to ensure sustainable manufacturability. How far off are you from achieving these goals? What is next for Objectify in the coming years? The automotive sector is one of the most cost-driven industries and it was very difficult to convince them on the cost but slowly and steadily they have been adopting the technology in their NPD and R&D, which is changing the course of adoption and accelerating it. We are very much confident about the future of Additive Manufacturing in India. We see huge demand coming in from small tooling suppliers to large automotive and aerospace OEMs. We want to act as a catalyst in educating the industry, the application and benefits of AM. Meaning, not just in manufacturing but we want to help companies in things like training, design, consulting and lab setup as well. We want to be the end-to-end solution providers in AM space and help the Indian manufacturing industry in their path to becoming ‘Global Manufacturing Hub’. ☐

A&D India | Jun-Jul 2019


LEADERSHIP INSIGHTS

Achieving growth & efficiency through innovation Virginia M Ginni Rometty CHAIR PRESIDENT & CEO, INTERNATIONAL BUSINESS MACHINES CORPORATION (IBM)

Charismatic, articulate and visionary would be the perfect description of the first woman CEO and chair president of IBM, Ginni Rometty. A systems engineer at IBM during the start of her career, she subsequently carved her way to become the head of sales, marketing and strategy. During this period, her work in negotiation & integration of the “largest acquisition in professional services history” of IBM, the purchase of PricewaterhouseCoopers IT consulting business proved her as an asset to the company. Initially an intern with General Motors, she made her big move to IBM in 1981 post her graduation in computer science and electrical engineering from Chicago’s Northwestern University. She replaced Sam Palmisano as IBM’s CEO on October 1, 2012. Since her taking the reins of the multinational corporation, some of the noteworthy changes include reinventing the company to lead in the new era of AI, blockchain, cybersecurity & quantum technologies. With over three decades of a career at IBM, Rometty has always been aware that staying in one’s comfort zone is an obstruction for self and organisational growth. “I learned to always take on things I’d never done before. Growth and comfort 16

GROWTH AND COMFORT DO NOT COEXIST do not coexist” quotes Rometty. She has proved successful during times of fraught by taking risks and applying sweeping changes/ strategies to beat her rivals. IBM has been successful in staying ahead of its rivals under Rometty’s leadership, because of her constant push for innovation. Through her leadership, Rometty has worked towards aligning her workforces and to motivate employees to the fullest. She has more extensively worked towards including a diverse work culture and various advanced leadership measures. She has worked in the direction of ensuring that women have equal opportunities at the institution by taking steps, like extending parental work leaves and the “returnship” program which gives women returning from a parental leave hands-on experience on emerging technologies. To ensure that employees have a goal which they can jointly work towards, she has carved out various long-term strategic beliefs guaranteeing employees have a higher

goal to work towards. She says, “For CEOs today, it’s all about achieving growth and efficiency through innovation. It’s not about product innovation so much anymore as about innovating business models; process, culture and management”. Rometty, through her leadership, has also been trying to ensure that the society is prepared for future advancement, technology and data. This comprises preparing employees for “new collar” job roles in emerging technology fields that do not require a bachelor’s degree. Being amongst one of the largest tech companies, IBM’s prominence and authority had somewhat reduced in the last two decades. Since Ginni Rometty coming into power as the CEO and President, her vast experience at the company and skillful leadership has made a remarkable difference in bringing success to the institution.

Anvita Pillai SUB-EDITOR & CORRESPONDENT A&D India | Jun-Jul 2019


C O V E R S TO R Y | T E C H N O L O G Y

PHARMA 4.0: Transforming life science manufacturing

The life science industry has a strong legacy in data collection and has embraced the methodology behind ‘Industry 4.0’ – which we will refer to as Pharma 4.0 - before the term existed. In this article, the author explores Industry 4.0 or ‘Pharma 4.0’, including the technologies and approaches that will facilitate change and the role of data.

18

David Staunton Global Services Director Zenith Technologies

A&D India | Jun-Jul 2019


T E C H N O L O G Y | C O V E R S TO R Y

The life science industry is reducing risk with the Pharma 4.0 revolution - the new products, processes and services will be cheaper, faster, safer and higher quality than their predecessors

Pharma 4.0 refers to the new tools and processes that are enabling smart, decentralised production, with intelligent factories, integrated IT systems, IoT and flexible, highly integrated and automated manufacturing systems. The life science industry has been collecting data in large historian systems for over 40 years and the industry continues to complete projects to physically connect all devices and systems. Data collection and visualisation to improve the performance of the manufacturing supply chain has been a goal for the life science industry for a very long time. However, in GMP manufacturing, it is not about being new – it is about using proven solutions and approaches to create never before seen quality and reliability standards.

The market There is growing interest among the leaders and decisionmakers in the pharma industry around Pharma 4.0. Pharma manufacturers face an ever-present need to remain competitive in a marketplace where product portfolios are diversifying, innovative start-ups challenging the status-quo, supply chain partners becoming more integrated and patients more involved in decisions around their care. Realising the promises of Pharma 4.0 will be the market differentiator for businesses competing in this environment.

Change & reward with reduced patient risk Pharma 4.0 is a revolution and with any revolution comes change and ultimately reward for those that adapt the quickest and most effectively. We’re already seeing some examples of revolutionary new thinking when it comes to digital-to-physical transfer

A&D India | Jun-Jul 2019

(transferring digital instructions to the physical world). Johnson & Johnson is working with HP Inc on 3D printing medical devices including contact lenses in community settings. Scale is currently a challenge but it’s only a matter of time before factories are redundant. The life science industry is reducing risk with the Pharma 4.0 revolution - the new products, processes and services will be cheaper, faster, safer and higher quality than their predecessors.

Appetite for change In a survey of business and operational leaders from across the life science sector conducted by Zenith Technologies in 2018, 58% of respondents said that Pharma 4.0 will drive the most change in life sciences over the next 5 years – more than any other technology area. Interestingly, the same number of respondents said that they are currently most focussed on digitalisation, with only 46% stating that Pharma 4.0 was their current priority. When asked their motivation for investing in new technology: • 77% said they want to save money in manufacturing processes • 69% want to save time • 62% are aiming for increases in revenue • Only 19% want to understand patients better Ultimately, the criteria that drives decision-making and investment in the life science industry remains the same - business leaders want to reduce cost, increase efficiency and revenue. This remains true for Pharma 4.0.

Automation In the Zenith survey, respondents were asked about

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C O V E R S TO R Y | T E C H N O L O G Y

The potential that Pharma 4.0 holds for automation is massive with individual management processes throughout manufacturing expected to become automated

automation; 42% of participants said they are currently ‘very automated’ and 12% ‘automated wherever possible.’ In 5 years, 50% want to be ‘very automated’ and 23% ‘automated wherever possible’. The desire for automation is clear as it offers several operational benefits – faster, more reliable and ultimately cheaper processes – but its adoption has been a decades-long and gradual process. The potential that Pharma 4.0 holds for automation is massive with individual management processes throughout manufacturing expected to become automated. A simple example is the approach to a temperature gauge giving a higher than expected reading during manufacture. An automated system could detect this reading, interpret event data against previous information and decide upon a course of action and rectify the situation. This would negate the need for an operator to intervene and make an assessment on the required course of action and carry out said action. The time saving for each event will often be minimal, but when scaled across an entire factory or at the enterprise level – the impact becomes significant. Future developments will also allow machine learning algorithms to adjust manufacturing lines and production scheduling much more quickly than with human intervention. New developments will also pave the way for predictive maintenance and the opportunity to identify and correct issues before they happen.

MES While MES systems are becoming more widely adopted, they have added more complexity to manufacturing environments. This has brought about implementation challenges. In response, long-term thinking sits at the forefront

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of every project to ensure that the process is cost-effective and continuously delivers value. With the shift from paper-based processes to intelligent, electronic systems that will be accelerated by Pharma 4.0, MES systems will give more meaningful business insight, remove room for error, and enable resources to be better used. For example, instead of just measuring the downtime of a piece of equipment for overall equipment effectiveness (OEE), MES can provide batch, cleaning, maintenance and operator inputs as context for the downtime to allow for detailed trend analysis and precise preventative measures to be put in place. As better approaches to recording and accessing data in realtime are adopted, production, both in single plants and across global facilities, will be completely revolutionised by increasingly sophisticated and more connected MES systems.

Connecting everything and creating context The foundation of any change to a manufacturing environment driven by Pharma 4.0 thinking will be contextualised data and connectivity. Every system and piece of equipment needs to be able to record and distribute reliable event data, communicate with other systems and pieces of equipment and subsequently access relevant and reliable data. Once this connectivity is in place, operational teams have the basis for making better choices, or have the need to make choices removed as self-learning systems do this by interpreting data. It is imperative that data is contextualised for it to be useful – the integrated technologies need to know what the data is and when it was created. A database with time-stamped data is essential as consistent time data makes every subsequent interpretation and decision simpler and more reliable. If we use

A&D India | Jun-Jul 2019


T E C H N O L O G Y | C O V E R S TO R Y

With the right systems, software and approach in place - operators can find specific batches, filter by products or phases and create and overlay profiles for good and bad batches

the example of the temperature gauge again, when an irregular temperature reading is given, the automated system will look for data around a previous event that mirrors the current one – it simply cannot do this reliably if said data is not accurately time-stamped.

Batch context By adding context information, such as, product or recipe names, process phases or batch identification to time-series data in process historians, the value of the data for process engineers is greatly increased. However, historians are ‘write’ optimised and not ‘read’ optimised, creating a technical constraint as they store and compress new data making extraction and interpretation arduous. Finding the relevant historical event and building the process context around it can be laborious, requiring manual manipulation of data rather than an automated approach. With the right systems, software and approach in place operators can find specific batches, filter by products or phases and create and overlay profiles for good and bad batches. The ability to search data over a specific timeline and visualise all related events in that timeframe quickly and efficiently will allow users (and eventually machines) to predict more precisely what is occurring or what will occur across industrial processes. Human-machine interfaces such as this are one of the many lauded Pharma 4.0 disruptions that will revolutionise pharma manufacturing.

Big Data Big Data analytics draws data from sources that have traditionally been disconnected and looks for relationships

A&D India | Jun-Jul 2019

and trends that were previously undetectable. For example, combining production data with that from sales and dispatch systems can streamline production planning. ERP tools can already do some of this on a much smaller scale, however they use smaller data sets than a Pharma 4.0 plant will generate so the conclusions and recommendations are comparatively less valid. The life science industry has been doing Big Data analysis for over 20 years. However, there are inherent dangers that will be exponentially more problematic when interpreting the larger data sets that will be created by Pharma 4.0 approaches. Spurious correlations, which are inevitable when dealing with numerous variables and data points, will no doubt seem attractive to operators and engineers but must be ignored to ensure data is used effectively. If a business acts on this data without confidence, the consequences can be very problematic and even detrimental. It is vital that businesses adopt the datadriven improvement cycle approach – DMAIC (Define, Measure, Analyse, Improve, Control). The only correlations that should be acted upon must be carefully hypothesised, tested and validated. Process engineers must measure a large amount of data with a small number of variables, wait, monitor and define improvements before implementing change and starting the cycle again. This iterative approach will only be successful if complete, contextualised and accurate data is collected from a fully integrated network of systems and machines.

Disruptive thinking & technology There are a number of systems and technologies that will develop to enable the better gathering and use of data as the pharmaceutical industry embraces Pharma 4.0.

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C O V E R S TO R Y | T E C H N O L O G Y

Fully automated and connected facilities that can create, interpret and act upon reliable data will take advantage of all that digital manufacturing has to offer

• Data lakes Big Data is stored in a data lake. It is vital that businesses upload the data into the data lake correctly through optimised ingestion practices, otherwise it becomes a data swamp. Ingestion tools are already readily available, allowing for more time to be spent on analysis. As discussed previously, contextualising data is important - a time stamp makes data ingestion easier and importantly, when records are created at the same time as a batch, the correct ingestion allows time-series and context data to be linked. These ingestion tools can then make accurate suggestions and semi-automate the linking of data. • Edge devices / edge computing Edge devices collect data and run local analytics on a piece of equipment or process. They store local data for a limited time and only send information to the data lake if there is an event. This keeps the data lake clean of unnecessary information. The resulting data can be used to create insights into performance. • Machine learning & digital twins Machine learning and Artificial Intelligence will lead to significant change in manufacturing practices. With ‘deep learning’, computers will train themselves by running scenarios and learning from the outcomes using the massive amounts of data available in data lakes with the aim of creating a digital twin. Using simulations to model a process and running scenarios in this virtual system, rather than running experiments on real equipment, is already used in pharmaceutical process development. The concept of the digital twin goes beyond traditional modeling simulation to create a generic digital representation of an asset. The twin captures multiple characteristics of the asset from sensor data, and the data can be used for deviation or anomaly detection, prediction, and simulation. The digital twin models can also learn continuously as they adapt to new information. Building on the DMAIC approach, digital twins will reduce variables by modelling processes, removing a variable and supporting tests for improvement.

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• Asset performance management & utilisation Asset performance, throughout its lifecycle, is key to every organisation. When assets can talk to each other and communicate data, engineers can get a better understanding of causes and effects of faults and their impact on performance on a much more detailed scale. Asset performance management tools that can access, interpret and visualise the relevant data in a data lake will offer better predictive asset analytics, risk-based maintenance and condition-based monitoring. Data can also be used to monitor utilisation more effectively and inform decisions around purchasing extra machines by confirming whether current assets are being fully utilised. • Industrial apps Contextualised data in a lake will open the door for the development of clever industrial apps that monitor asset utilisation and performance. These apps will be significantly cheaper than current industrial-scale software, and offer realtime, remote, visual monitoring of assets.

The future of production The life science industry has been slower to adopt cuttingedge technologies than other sectors. However, it has spent decades using data to drive operational improvement. Embracing the potential for Pharma 4.0 is going to be critical to future operations of all manufacturers. Fully automated and connected facilities that can create, interpret and act upon reliable data will take advantage of all that digital manufacturing has to offer. The life science industry has spent many years becoming more energy-efficient and using better materials and equipment to make improvements. Pharma 4.0 will see the industry connect equipment across plant and enterprises and use better, more reliable and larger volumes of data to revolutionise manufacturing. Zenith Technologies’ role in the Pharma 4.0 revolution is to help manufacturers connect their systems and equipment and ingest and analyse the data created to inform operational decisions. ☐

A&D India | Jun-Jul 2019


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MANAGEMENT | INTERVIEW

“Flexible manufacturing is the key trend right now” … says Shree Harsha, Marketing Director – India, Dassault Systèmes, in this conversation with Juili Eklahare. He explains how the industry in India has matured quite a lot from a CAD market perspective, highlights various trends in factory automation & robotics, and the company’s work towards promoting EV start-ups in India. Excerpts…

The 3DEXPERIENCE adoption is really happening now and growing rapidly. Are there any great success cases that you would like to share with us? We have around 10,000 customers in India today. Globally, we have many success cases, including Tesla, Boeing, Airbus, Johnson Controls, etc. In fact, our top 50 suppliers of 100 are on the 3DEXPERIENCE platform. Coming exclusively to India, some companies include Royal Enfield and Endurance Technologies. How have you seen the 3D software industry changing? What key trends do you see in this area? India has matured quite a lot from a CAD market perspective. The country was 2D-centric earlier. However, we have reached 3D now. We’re using 3D as a communication object. Besides, there are the manufacturing tolerances that include the design tolerances, which manufacturing is expected to meet, such as, the surface finish, quality of the component, etc. These are all getting communicated in 3D. Another shift is the tech communication, where the illustrations, materials, etc are turning 3D now. Coming to the

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trends, the biggest trend that we see in this area is that CAD and CAE are coming closer. For example, earlier, I would design in 3D, give it to a specialist who is a CAE, asking him/her for feedback on whether the material can meet the structure, for which he/she gets back to me six weeks later. This leads to losing a lot of time. So, CAD & CAE coming closer makes it easier. Additionally, manufacturing and design are working closely. Another completely new dimension of 3D that’s evolving is 3D printing. Also, there is a lot of success when it comes to startups, especially within electric vehicles selecting the 3DEXPERIENCE platform. Can you please share your views on this? Driverless, connected & electric cars are ushering in a new era of travel that is efficient, affordable, clean and green. Experts predict these systems will transform travel in the years to come and shape the future of mobility, smart cities, and interactive communities. Bringing this new generation of cars onto the road requires new vehicle innovators and OEM leaders alike to rethink the way we experience their products, and the way they engineer them. Dassault Systèmes and the 3DEXPERIENCE platform is tackling this very challenge with solutions and key technologies to design, evaluate and optimise EVs in an interconnected, multidiscipline framework from vehicle system architecture, battery thermal management, high-speed electric motor lubrication to multi discipline collaboration. The 3DEXPERIENCE platform and the capabilities delivered by its cloud-based applications can pave the way for EV start-ups to quickly innovate, expand its business, and create value.

A&D India | Jun-Jul 2019


INTERVIEW | MANAGEMENT

Shree Harsha is a Mechanical Engineering graduate and an alumni of Indian School of Business and Indian Institute of Management, Ahmedabad, with focus on manufacturing & operations. He joined Dassault Systèmes in 1999 as an applications engineer and has worked in partnership with customers across multiple geographies including Japan, China and Germany. He has helped advanced customers in this region shape their transportation & mobility solution to suit their needs and spearheaded the team to increase awareness of the company’s technology.

Can you highlight trends in factory automation & robotics when way to cost-effectively manage customisation, configuration, new technology concepts, like IoT & digital manufacturing are personalisation, and delivery as well as vastly improve the becoming the buzzword? performance of traditional product supply There are functional blocks on how to chains. Further, integration between improve efficiency in the factory, how to business functional areas is essential reduce cost, and how to be more innovative for more reliable supply and aligned THE NEXT GENERATION SUPPLY in the existing factory so that new products production, procurement, transportation CHAIN REQUIRES NEW, can be introduced faster. These are the and workforce plans. Supply chain INTELLIGENT APPROACHES TO reasons why IoT & digital manufacturing planning encompasses detailed workforce FACE TODAY’S PROBLEMS. are becoming the buzzword. Therefore, planning based on the needs specified by flexible manufacturing is the key trend, the master production schedule. A strong which is one of the hot topics in the industry technical architecture integrates with right now. It comes down to how one can align one’s factory S&OP to provide visibility across the entire supply chain and shop. For example, if I have a small car coming in, then introduce allow daily dynamic re-planning, based on all latest information a Sedan, and then further introduce an SUV, then my conveyors, regarding material and work order progress, bottlenecks, sales fixtures, etc should be flexible enough to accommodate multiple budget allocation, resource shutdowns and achieved yields. and mixed models in the factory. This is also highly linked to Master production planning helps increase throughput, reduce personalisation, which is another trend in the industry in India. inventory and lead times and improve customer service across So, unless and until one does not know whether one’s equipment the supply chain. will work correctly with the new product data and existing line, one cannot be sure if a new product can be introduced. These What can we expect from 3DPLM Dassault Systems this year? are trends not just followed by OEMs, but by suppliers as well, India is the biggest R&D centre for us, with more than 2800 people, because at the end of the day, it’s about saving money. contributing to global customers as well as those in India. We have been growing at a double digit rate for the past three years How can one make use of digital tools to resolve existing and have future plans of diversification in new domains, such as, challenges and optimise supply chain in manufacturing? EVs, batteries, etc. In fact, we plan to promote EV start-ups in The next generation supply chain is upon us and it requires India thorough our start-up incubation programmes, especially new, intelligent approaches to face today’s problems. Managing in India. We will be offering free licences to all the start-ups for unique consumer product configurations require being able almost 1-2 years, who will get qualified through our programmes. to quickly scale production, redirect manufacturing skills, and They will be mentored on how to develop new batteries, come up quickly manage material requirements. It will also require being with new solutions around the concept of mobility, etc. Besides, flexible and finding ways to deliver unique products directly to if they are looking to come up with their own products, we have the consumer efficiently and quickly. The result will be a new labs right here where these start-ups will be coached. ☐

‘‘

A&D India | Jun-Jul 2019

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I MA G E C O URT ES Y: Shutterstock

VIEWPOINT | TECHNOLOGY

Artificial Intelligence: Revolutionising the Manufacturing Industry

The manufacturing sector is leading the way in the application of Artificial Intelligence technology. Artificial Intelligence (AI) is programmed to comprehend the user’s intentions, which make the system more spontaneous, that leads to superior output and fewer errors. With the introduction of AI, the manufacturing industry is set to improve efficiency, quality of work, and safety of employees. In this context, this Viewpoint section seeks out opinion on how Artificial Intelligence will bring about a Anvita Pillai Sub-Editor & Correspondent anvita.pillai@publish-industry.net drastic change in the growing manufacturing industry.

“AI in manufacturing can be applied to prevent quality failures”

Dr Pradeep Chatterjee, Part of the Global Delivery Centre of a leading Indian Automobile company

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AI is driving a paradigm shift in the manufacturing industry. There is a shift towards a strategic approach with 2-3 years plan laid down to transform a factory into a future factory. Lot of supervision work in accordance to Standard Operating Procedure (SOP) can be taken up by AI engines. AI in products has a lot of potential applications, depending on the category of product manufactured. AI in manufacturing can be applied to prevent quality failures and detect potential failures, such as, right fitment of parts or identification of cracks/rust/dents, etc. In after sales support, it can greatly help with diagnostics with faster resolution time. It can help in intelligent scheduling or predicting production failures even for external factors, so that corrective actions can be taken in time. Besides, AI can automate lots of processes and make it Zero-Touch, so that payments, settlements lead time, etc can be reduced drastically. AI will

A&D India | Jun-Jul 2019


TECHNOLOGY | VIEWPOINT

build expert knowledge and decision-making capability, reducing dependency on expertise of individuals. This will help improve productivity, cost effectiveness, decisions in accordance to market dynamics, and predict what can go wrong. AI will aid making decisions that might not be humanly possible. The biggest hinderance, however, would be, acceptance by people that machines can think intelligently and make decisions. Secondly, if one looks for solutions from third parties, vendors come up with an exorbitant price tags even for small solutions, which is unreasonable if one knows the implicit technology. Moreover, the per transaction cost may look small but if one calculates total annual cash out, it will result in large outflow, which does not support a business case. Also, protection of IP in digital solutions should be conceptualised unless you develop it in-house. Business strategy and operations must change catering to the changes in external environment. Indian digital eco-system is still not geared up completely to adopt AI. Basic requirement for AI is data. In many cases we do not have sensors or the means to capture all relevant data. Second is connectivity, so that you have access to data even on the go. Speed of network or even availability of network at places is still an issue.

“AI is poised to radically revolutionise the foundation of every industry”

Sangram Kadam, Vice President & Head (APAC & META), Birlasoft

A&D India | Jun-Jul 2019

In India, AI has just started to establish its foothold in the manufacturing industry, which is still trying to decode the implication and overall economics of adopting this new-age technology. The manufacturing industry has always been open towards adopting new technologies. While AI is poised to radically revolutionise the foundation of every industry, the manufacturing industry stands to gain significantly from this technological disruption. With the adoption of AI, companies can keep inventories lean and reduce the cost. There is a high chance that the Indian manufacturing industry will experience an encouraging growth. In the future, Artificial Intelligence will be the key determining factor that will decide the survival of the industry in an increasingly competitive scenario. Not adopting the futuristic technologies will keep costs elevated, inefficiencies in production and ultimately make operations unviable viz-a-viz competition. Under the ‘Make in India’ initiative, the government aims to increase the share of GDP from the manufacturing sector to 25% by 2022. This will only be possible if timely and effective interventions by the government are implemented to foster growth of the industry through promotion of technology. There’s no doubt that the manufacturing sector is leading the way in the application of AI technology. The Indian manufacturing industry is growing from strength to strength, developing capabilities around digital verticals and customer segments, expanding global delivery presence across traditional and emerging markets, and increasing focus on high value services. Artificial Intelligence has brought us into a new dimension that extends beyond the walls, opening the sheer scope of possible applications, from real-time maintenance of equipment to virtual design, improved and customised products, smart supply chain and the creation of new business models. There’s no question that Artificial Intelligence holds the key to future growth and success in manufacturing.

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VIEWPOINT | TECHNOLOGY

“The future factories will be driven by robots with the help of data and AI”

Feroz Khan, Associate Director, Boston Consulting Group

With Industry 4.0 coming into reality, it leverages to a lot of Artificial Intelligence and machine learning capabilities. The manufacturing industry is poised to transform its way of working. The future factories will be driven by robots with the help of data and AI which will enable running of machineries, equipment and transport unmanned by computer-controlled robotics automation. With the success of technology, there comes some challenges and AI is no different. The most important challenge is the legal and statutory aspect which comes due to erroneous data and algorithm, which leads to incorrect decision making. Other challenges, like technical knowledge and its application in industry domain leads to hyper optimism. In addition to this, lack of strategic importance is another big challenge wherein the organisation gives less importance to AI led automation and does not fit into the overall business plan. Besides, AI is already bringing lot of disruption in manufacturing operations, especially in supply chain and shop floor execution. The manufacturing industry in India has still not excelled to become an evangelist in AI adoption, but the stage has been set and the pull can be clearly seen with Auto OEM leading this scape. Although the foundation of infrastructure is being laid for AI, ML and IoT, the mindset has still not evolved and most importantly, the change management is not being very effective. Still, there is a fear of human job loss due to which the skills and mindset change will take some more time. Some major applications, like Industry 4.0 and smart maintenance are already in the play, in addition to quality control and decision making process. With AI under the hood, warehousing process with robotics and autonomous transport have become more intelligent. AI will definitely be able to solve internal challenges, like expertise shortage and decision making over a period of time, which comes with the implementation of cognitive computing, which is more and more dependent upon the data collected over a period of time. This will bring in productivity, cost control and will improve market dynamics.

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with a fresh new look and user-friendly navigation, updated with the latest information on the manufacturing technology world Available on all digital devices globally, www.industr.com/en is an umbrella portal that integrates content of our two magazines – EM (Efficient Manufacturing) and A&D India (Automation & Drives). Click and be a part of our online community!

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POWER & ENERGY | FOCUS

Innovation to transform the energy future Energy transition is a slow process, but the enabler is most definitely today’s technology and future breakthroughs, supported by radical changes in energy use by consumers. As the world demands more energy, it also demands that it be produced and delivered in new ways, with fewer emissions. The article focuses on technologies that bring about constructive energy transformation, the hurdles that oil & gas Madhav Vemuri, companies face to reach the full value of digital initiatives, & what to President, Industrial Automation Division, ABB India consider to build a successful digital strategy for energy transition. For many years, the oil and gas industry has confronted many diverse challenges, whether that be between onshore and offshore, different geographies or national versus international oil companies. As the industry looks toward transitioning to a different energy mix, adding to these challenges will be local versus global energy policies, the reliance on oil and gas for national budgets and employment, the skills shortage and the uncertainty over oil and gas prices and demand. There are

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many trends accelerating the introduction of new energy sources and delivery platforms into the global energy system. Four stand-out developments can potentially transform the global energy landscape: • Global population growth brings new expectations and requirements: By 2025, the population of millennials are expected to make up 75% of the global workforce. They are already enthusiastically embracing the sharing economy as

A&D India | Jun-Jul 2019


FOCUS | POWER & ENERGY

witnessed by new digital business models providing efficient solutions for transportation, accommodation and food delivery. This, in turn, is leading to greater use of assets, such as, shared vehicles. They are prepared and willing to make bold changes, such as switching to eco-friendly energy providers or brands to help tackle these challenges. These developments are already affecting demand for oil and natural gas. • Electric vehicles: Road transport, aviation and shipping account for more than 60% of the world’s oil consumption and approximately the same proportion of emissions. At the 2015 United Nations Climate Change Conference in Paris, the United Nations Environment Programme set a target for at least 20 percent of road transport vehicles to be driven electrically by 2030. This shift has the potential to drastically impact the demand for oil in the coming years. To meet increasing demand, the big automobile manufacturers are investing billions in the conversion of their product ranges and production facilities. Analysts predict that by 2040 more electric cars will be produced worldwide than petrol or diesel vehicles. • Cost of power generation: Beyond the charging infrastructure, e-mobility requires a transformation of the energy system – an Energy Revolution, in fact – both to ensure that the grid can cope with the increased demand for power and to expand the contribution of renewables. An Accenture survey found that 56% of millennials are interested in investing in solar panels and 69% in energy trading marketplaces. This trend is driving startups to create platforms that give consumers the freedom to choose their energy source. • Distributed generation: As communities continue to grow in size and complexity, new models of energy distribution have developed. Methods of generation such as roof top solar and self-generation by industrial consumers, are becoming more common on a larger scale. The evolving power system needs to be increasingly flexible and interconnected, as well as more reliable & intelligent.

Technologies that enable effective energy transition As the oil and gas companies expand their portfolios towards future energy markets, there is a realisation that the need for efficient operations and enhanced production uptime is more prevalent than ever. ‘Digital’ has become more important than ever in today’s industrial space. It has been shown that by properly using digital technologies, the oil, gas and chemicals sector can

A&D India | Jun-Jul 2019

reduce capital and operating expenditures by up to 30%. The same technology will have a massive impact on tying the entire energy ecosystem together. Technologies are moving companies to an era where critical assets equipped with smart sensors now that tell people what is wrong, long before failures even occur. Providing operators with quick access to hundreds of years of data and analytics, rather than relying on the experience of individual employees, increases efficiencies, reduces downtime and avoids costly shutdowns. When data and technologies across a plant and enterprises are integrated into a holistic view, this opens whole new approaches to how operators and experts collaborate and use asset information and process analytics for quick decisionmaking and lost time prevention. Connected operations: The future will bring more enterprisewide use of remote-enabled condition monitoring technologies, predictive and descriptive data analytics, and advanced process control applications so that operational effectiveness of plants can be understood in near-real time. This provides the right blend of technology, expertise and information. Providing the correct information when it is most needed means the best decisions can be taken. Industrial Internet of Things (IIoT): Digital success, and ultimately the profitability of a business, hinges not on individual technologies but the integration of the IIoT. Key to this is collaborative operation centres and control rooms which pull the data from these sensors and devices together. They enable analytics reporting and monitoring, while presenting dashboards that are relevant to all stakeholders, including executives, production managers, operations personnel & maintenance staff. Digital twin applications: A good digital infrastructure is almost impossible to implement without a digital model of the plant. A typical modern industrial device already creates a formidable digital data-trail. This includes CAD drawings and simulations during the design phase, information on location, connected equipment and configuration from the integration phase, as well as subsequently collected utilisation, diagnostic and maintenance data. This information can be used to simulate the behaviour of the physical object. Collaborative operations: Collaborative operations enable remote operations and fleet wide management. It uses digital technologies to monitor and analyse assets and processes. Collaborative operation centres help to maximise productivity and enhances safety. These centres pave the way for the application of further technology advancements.

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POWER & ENERGY | FOCUS

A diagrammatic representation of how industries are gradually shifting from automation to collaborative operations

Intelligent project execution: In the plan and build phase digital technologies are successfully streamlining project execution and integrating traditionally separate systems in the planning and build phase. Because of cloud engineering, virtual factory testing and simulation, electrical, automation, instrumentation, and telecoms are no longer designed as separate systems, but instead are built into one collaborative environment, thereby optimising customer objectives at every stage of the lifecycle.

Hurdles ahead Oil and gas companies face significant hurdles to realising the full value of the digital initiatives, not only in any future energy ecosystem, but also in their current exploration and production environment. Some of the more regularly debated barriers are detailed below: Regulation: Some commentators believe that today’s data security regulations are not fit for purpose and that much effort is needed to ensure this happens in the new world order. This can only be addressed through technology, as well as due diligence in the operational use of data and a recognition that compromise is not an option. As companies continue to navigate the new energy ecosystem, conversations around intellectual property frameworks need to be further explored. Understanding data sharing models will allow companies to innovate further, while maintaining data integrity. Data accessibility: When data is collected across large enterprises it can often appear in formats that are not easily managed. This can affect how the information is processed and the subsequent insights that are gathered. ExxonMobil’s work with Lockheed Martin, to develop an open standard, open architecture control system that runs on commercial software and hardware, is an excellent example of how the oil and gas industry can embrace the proven digital strategies of other industries to improve performance. Integration: To address challenges such as increased productivity,

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and improved efficiency while maintaining safe operations, companies need to adopt an integrated approach. Each asset needs to be connected across the value chain to realize the benefits of digitalization. An integrated information system is essential as companies move into the digitalisation age. The exploration and production (E&P) departments of oil companies often do not share data, even between themselves. This must change, especially as the transition is seeing a move from the once dominant “exploration” departments to an era where the “production” departments are the value drivers. Business models: Unless work processes and business models are changed, oil and gas companies risk losing out to new rivals from inside and outside the industry. Companies from other sectors have often already adapted to changing markets by embracing new business models and integrating information technology (IT) with operational technology (OT) to reduce costs and boost efficiencies. People focused: Oil and gas companies tend to be capital and technology-centric, while, at the same time, being people intensive. Future concerns include how many people will be needed, the training that they should be given and the types of people that should be hired who are fit for purpose. The industry is inherently unable to take more of an experimental, “fail-fast” approach because of its conservative nature and concern about the potential consequences of change. It is important to start now in preparing the workforce to manage and operate new technologies and digital plants of the future. Knowledge transfer: Technology is an enabler of the energy transition but requires a cultural change to be fully realized. It is important to actively capture process knowledge by converting data collection and analysis practices into software applications that can be deployed remotely. These “advanced digital service” developments are fundamental to the collaborative operations way of working described earlier. Cyber security: Many traditional cyber security best practices do not apply to industrial control systems. A malicious command

A&D India | Jun-Jul 2019


Solving Smart Grid IEC Communication challenges!

IEC

61850

IEC 60870-5-104

HMS's SG-Gateway family supports IEC61850 client / server and IEC60870-5-104 client / server protocols which is designed to specifically target Demand Response - networking of industrial electric loads - and Virtual Power Plants - networking of energy resources like biogas plants or Smart Grid and Sub-station automation applications.

HMS Industrial Networks India Private Ltd. Corporate Plaza, Unit 1A & 1B, Senapati Bapat Road, Near Chatushrungi Temple, Pune – 411016. (M.S.) Tel.: +91 83800 66578. E-mail : sta@hms.se

www.hms-networks.com


POWER & ENERGY | FOCUS

Internet of things

Plug and play

Smart appliances

Low cost batteries

sent to an industrial device often looks identical to a legitimate command. There needs to be a better understanding of pattern of life analysis. Generally, national and international oil companies adopt a “keep data within our gates” policy. There are many reasons ranging from close ties to government, sensitive commercial data and international conflicts. Many of these reasons are not related to cyber security issues but follow a “better safe than sorry” approach which, in effect limits the usefulness of the digital ecosystem. IT/OT integration: A key benefit of IT/OT data integration is that it addresses the challenges of managing ever increasing costs, minimising schedule overruns, mitigating risk, optimising or maximising production and controlling energy expenditure and efficiency. IT and OT cannot operate in silos if good shareholder returns are to be delivered considering an increasingly difficult and uncertain market realities. Companies are coming to realise that addressing emerging challenges effectively means transitioning to an environment which provides remote asset diagnostics, continuous automation and production optimisation made possible through a fully integrated approach to power, automation and telecom systems.

Building a digital strategy for energy transition Success during the energy transition relies heavily on the creation of a robust digital strategy that has buy-in from the boardroom. Here are some key considerations that will help avoid investing scarce resources without realising the benefits: • Prepare and retrain executives: The energy transition’s success resides on an effective digital transformation roadmap, driven by a culture of innovation and technology adoption. All levels of the organisation need to embrace the digital transformation. Leadership should play an active role in establishing clear goals while creating an environment that supports ideation across multidisciplinary teams. • Invest in talent: The fall in the oil price forced the industry to

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Digital success hinges not on individual technologies but the integration of the IIoT

think differently. It introduced new technologies which depend on a new breed of engineer to fully understand the impact on a business. Companies need to continually assess the current skill levels and rapidly identify any gaps. They need to build a digital strategic workforce plan to address any shortage of skills. • Continually explore the potential of digital: Building an endto-end digital infrastructure that connects all data sources into a centralised platform needs much investment – in time and resources. Going forward, many oil and gas companies will not have full control over the supply chain, with distribution networks owned by partners. This alone will require a robust digital infrastructure where collaboration is essential. • Assess and benchmark current data architecture: There is an abundance of critical, yet disparate, software applications deeply embedded within operations. Without a strong foundation in capturing, safeguarding and sharing data, potentially business transforming insights are lost. Without adequate integration, new investments will be wasted as they will not be able to rely on historic data and will merely add fresh, high-quality, insufficiently used data to the rest. • Work the data harder: Today’s analytics are more sophisticated at diagnosing, sorting, comparing and identifying cost savings and performance improvement areas than ever before, and certainly at a pace far faster than the average employee. Using digital insights to automate processes boosts throughput by eliminating delays from human decision-making and frees up employees to focus on higher value-adding activities. • Collaborate: Working closely with partners to develop new customer-centric solutions will be essential to the success of these new models. Harnessing innovative ideas and, more importantly, turning them into reality will not be possible without industry collaboration, both by production companies and suppliers along the value chain. Only in doing so will oil and gas companies drive innovation in the industry and secure competitiveness. ☐

A&D India | Jun-Jul 2019


Safe motion: Fast. EfďŹ cient.

Choose Pilz for servo drive technology: We support precise motion sequences with highperformance products. This ensures the best possible cycle times and an increase in the productivity of your machine of up to 20 %. You achieve performance level PL e with all common motor feedbacks and fieldbuses. Benefit from the safe motion solutions from Pilz!

Pilz India Pvt Ltd

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+91 20 49221100

info@pilz.in


FIELDBUSES & NETWORKS | TECHNOLOGY

Fieldbuses in era of Industry 4.0 Fieldbus technology in industrial automation is not only fairly intricate because of the various solutions conceivable, but also because of the assortment of applications. Numerous fieldbus networks go on to dictate industrial automation and process control. The article discusses the classifications of fieldbuses and how the rise of IIoT and new possibilities for connectivity with wireless and Ethernet are altering the protocol scene. There are many, some may say too many, fieldbuses in use in manufacturing plants. The term fieldbus defines a method of connectivity between the essential elements in geographically enclosed areas, such as, a manufacturing plant or factory. We use Ethernet LAN for all our normal connectivity in our offices, so why do manufacturing plants not follow the same trend? In the era of Industry 4.0, in which connectivity is a core element and IIoT is on every agenda, how relevant are fieldbuses? If there are so many fieldbuses, how do control elements manage to talk to each other? In other words, how is the serious topic of interoperability addressed? The original objective of fieldbus was to replace any pointto-point links between sensors to PLCs or CNCs or other controllers. The fieldbus defines the electrical characteristics of the connection and also the protocol. With flexible electronic

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modules, the attention to the electrical characteristics has diminished, and attention to protocols has increased.

Electrical characteristics, protocol & standardisation Fieldbuses could be classified by several features or characteristics. Mostly, one checks for speed (bit-rate), number of nodes permitted (single-master, multi-master), flexibility in topology (linear, multidrop, ring, tree, star), enhanced availability (redundancy), methods of data capture (polling, cyclical, event initiated), how new nodes can be added (system reset, on-the-fly), how fall-out of one or more nodes is detected and corresponding recovery procedures and so on. Communication protocol is the set of rules which define

A&D India | Jun-Jul 2019


TECHNOLOGY | FIELDBUSES & NETWORKS

Industrial ethernet market

the different syntax elements and the ‘grammar’ – the position of the elements, the allowed values and significance of the same. By following a protocol, it is possible to initiate a communication, flag errors in communication, detect a broken communication, and recover from the break. Also, more than anything else, communication protocols should be common across vendors, to ease the job of maintenance and spares. Yet, the world of fieldbuses is a veritable Tower Of Babel, and the species and sub-species of protocols can easily be compared with the zoological tree, mostly not quite compatible to each other.

Why are there so many fieldbuses? Due to the wide variety of application areas and equally varied demand on the properties, a large number of fieldbuses have sprung up. Manufacturers defined and developed own protocols in order to obtain the best performance from their products. The various application areas are process plants, discrete manufacturing, building automation, and to some smaller extent, safety automation. Subspecies emerged from specific industries, like power generation, oil & gas, automobiles, breweries, and so on. The area of sensors (this was called the ‘field’ and hence, comes the name, fieldbus), had their own buses.

Ethernet dominates With the universal spread of Office LAN, ethernet has obtained a position of dominance in networks. It is important to remember that the ethernet standard is not a complete protocol. In its basic form, ethernet is not even a deterministic protocol. However, with increase in speed (bit-rates), these disadvantages have been overcome by different manufacturers. Famous protocols at this level are PROFINET, Modbus/TCP, EthernetPOWERLINK, EtherCAT, DeviceNet and many others.

A&D India | Jun-Jul 2019

Now we may reach a situation where such bus systems can become a homogeneous solution all across the plant, from sensors to the management terminals.

Achieving interoperability As we are all along intoning, there are just too many protocols for comfort. But essentially what is desired is interoperability. That means no matter what bus runs as the backbone in the plant, a freedom should exist to buy and connect a device from any vendor, and the system should be able to talk to this new device and vice-versa. The interesting thing about this is that interoperability can be achieved at several levels. Here we take a reference model from ISO, the famous 7-layer model. The communication stack is abstracted into seven layers – a standard called The Basic Reference Model for Open Systems Interconnection. What’s more, we can show interoperability for two devices at any one or more of the seven layers. The task of protocol conversion gets shifted to the next higher level.

Standard protocols Over the period, many attempts were made to arrive at a standard protocol. This gave rise to many ‘standard’ protocols – vendors’ standard protocols, buyers’ standard protocols, industry body standard protocols. Some organisations, usually consortiums of vendor manufacturers, have evolved standards – meaning an agreement among their members. In the nature of things, these members, after achieving agreement, went ahead and, during implementation, provided additional features of their own to give special benefits. Unfortunately, these add-ons prevent complete interoperability. Another approach was from large user companies or communities. They defined standards which they tried to

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FIELDBUSES & NETWORKS | TECHNOLOGY

OPC Unified Architecture (OPC UA) bridges the gap between the IP-based world of IT and the production floor

compel all their vendors to follow. However, since different groups of manufacturers framed standards to suit their area of application, this did not result in any major reform.

Open protocols & focus of Industry 4.0 A different approach is to provide the entire protocol stack in the public domain. With this, every manufacturer has a possibility to incorporate compatibility into his devices with such a protocol, without having to pay any license or royalty fees. The open source approach has many enthusiastic followers. But if manufacturers would push in add-on features on the top of this definition, once again we have some incompatibility. Besides, Industry 4.0 is a new era in manufacturing and business. The focus of today is to extract value out of data for various purposes. One important strategy is aggregation of data from various sources and recording it together with the context of creation of data.

Interplay with data systems In this era of Industry 4.0, we are hungry for data. The requirement of data for these purposes is very different from the real-time deterministic demands of operation and control. However, the sources of data are quite nearly same, and so we should see many changes in the times to come. Since Industry 4.0 lays a strong emphasis on collaboration end-to-end along the value chain, there has to evolve better ways to share data. The emergence of the Industrial Internet of Things (IIoT) and new possibilities for connectivity with wireless and ethernet are changing the protocol landscape. New value in integrating public and private enterprise clouds, operational systems and

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business domains is presenting new opportunities for protocol harmonisation in industrial environments. Deployment of wireless in shopfloor is in the beginning stages. Already a number of protocols have sprung up, such as, LoRA, ZigBee, Wireless HART etc.

OPC-UA and beyond OPC Unified Architecture (OPC UA) bridges the gap between the IP-based world of IT and the production floor. Interfaces, gateways and the associated loss of information are a thing of the past because all production process data is transferred via a single protocol – within a machine, between machines or between a machine and a cloud database. OPC UA is eliminating the need for traditional factory-level fieldbus systems. The soft facts like easy implementation, openness, vendor independent, risk avoidance, conformity, interoperability, long-term availability, and overall distribution that makes OPC UA gain acceptance in today’s industries. OPC UA has had its limitations when it comes to complex processes with real-time requirements until now. Adoption of publish-subscribe model (pub/sub) and implementation of IEEE 802.1 standard for time-sensitive networking (TSN) aim to give the OPC UA communication standard real-time capability. Moore’s Law has been in operation since nearly forty years and shows no signs of relaxation. Just on the horizon are 5G communication, satellite based broadband, rapid advances in computation. A combination of all of these, with Artificial Intelligence assisting development, would change the way communications happen – between sensors, machines, machine and humans, and who knows, humans and humans. ☐ Courtesy: B&R Industrial Automation

A&D India | Jun-Jul 2019


PHOTOELECTRIC SENSORS

MINIATURE MINIATURE SENSOR IN PLACE OF OPTICAL FIBER  Self-contained, embeddable sensor in 4 mm or M5 housing  IO-Link interface available on PNP types  Visible red light spot for ease of setup  Accurate target detection due to focused light beam  Calibrated sensing ranges, up to 600 mm for through-beam types  High switching frequency  Connection by cable or M8 pigtail  Housing in stainless steel V2A, IP67

www.contrinex.com


TEST & MEASUREMENT | TECHNOLOGY

Printed Circuit Board 4.0 Automation is increasing rapidly. The upcoming generation has already been dubbed as “Native Robotics”. Circuit boards are at the heart of all electrical appliances, automobiles, robots, smartphones, tablets and more. A printed circuit board must, therefore, be reliable and meet increasing quality demands – yet manufacturing costs must decrease even as the complexity of the end product increases. The article Olaf Wilmsmeier explores how the circuit boards and their manufactures are evolving Business Development Manager RFID, HARTING Technology Group & working towards giving us the products that are interactive. An order via a control board is placed with one of the MES service providers in Germany. After being entered, the order is scheduled, production then commences, and all relevant production and quality data are stored in the backend system (a database). The complete process is controlled centrally from the leading backend system. Although the printed circuit board is clearly detected during production, possibly via a lasered 2DCode, the printed circuit board is unaware of any process parameters or quality features. Although this is a very simplified explanation, this is the classic process of how a printed circuit board is created. But this is not the future, as it is far too expensive and inflexible in terms of the lifecycle. There is a lot more Industry 4.0 in a printed circuit board than many people imagine.

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UHF integration The raw circuit board is loaded with memory at the time of its manufacture. In addition, it can actively influence all other processes – not just in production, but over a “lifetime”. A small UHF RFID chip with a tiny antenna structure makes this possible. This is wholly unnoticeable, embedded in the circuit board. The space requirement is comparable to a 2DCode. From now on, even the raw circuit board can store production data that is retrievable at any time. For example, the date of manufacture and properties, such as, thickness and number of layers. Of course, it can be uniquely identified as well, even in bulk and over relatively large distances. Ranges greater than one meter is not unrealistic. Warehousing logistics processes can

A&D India | Jun-Jul 2019


TEST & MEASUREMENT | TECHNOLOGY

therefore, already be optimised by automated (bulk) detection. When the circuit board reaches the MES service provider, the placer, and finally the SMD production line, the circuit board or panel on the production line logs in. Manufacturing machines with integrated UHF RFID technology make this possible. Circuit boards can be recognised, the stored information can be read as well as updated or supplemented if necessary. Parameters, such as, when, on which machine, and with which production time, are only some of the variables which can be stored. Even special events, such as, relevant disturbances within a production machine can be stored. If the printed circuit board or the panel is manually fed to a new manufacturing process after being unstacked, the circuit board can indicate if it should be there or whether it potentially needs to go through another process step.

Ideal solution for raw circuit board All this is made possible by state-of-the-art UHF RFID technology. Thanks to the coaxial cable-based Ha-VIS LOCFIELD® antenna and the flexible UHF RFID reader Ha-VIS RF-R350 from HARTING, implementation is possible with little effort. The LOCFIELD is a space-saving antenna that enables data communication with the circuit boards within the production line. The antenna array follows a coaxial conductor and therefore, allows communication at full speed with multiple boards in a board panel. Because of flexible and standards-compliant data processing by the UHF RFID reader-writer Ha-VIS RF-R350, data can be preprocessed directly in the reader. Reader and antenna can be easily integrated into new and old systems. The compact design and the high (IP67) degree of protection also make retrofitting easier. Full data integration into production systems is possible at any time but is not mandatory. Of course, existing backend systems can and should be integrated, too. The solution can grow very easily and flexibly in tandem with the demands and ideas of the PCB placer and its customers. The data storage on the RFID chip of the printed circuit board conforms to ISO standards and GS1 standards, which are already familiar from commercial freight transport. Not only the ID of the circuit board itself is meant here, but also the process and manufacturing data, which are stored in the RFID chip’s so-called user memory. Everything is transparent and can be easily used later by third parties as well. Embedding the UHF RFID chip directly into the raw circuit board is certainly the most elegant solution, but not the only one. The embedded chip, which, thanks to a Beta LAYOUT process is used fully automatically in the printed circuit board, allows the entire lifecycle and the entire production chain to be

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mapped directly in the printed circuit board. Even during the placement process, the chip can be applied to the circuit boards as an SMD component. muRata offers corresponding UHF RFID chips and transponders via its MagicStrap.

A versatile addition to machines Once equipped with UHF RFID technology, this can, of course, be used on demand for an entire circuit board lifetime. In addition to warehouse logistics applications – since bulk detection of multiple boards at once is possible, e.g. repair processes can be optimised. Even if the printed circuit board no longer works, i.e. can no longer be switched on, stored information, such as, delivered firmware versions can still be queried. In addition, the information can also easily be queried if the board was already installed in a finished product. If the housing is not completely made of metal and certain basic physical principles are adhered to, the information contained in the RFID chip can continue to be used and updated. The possibilities of the UHF RFID technology are available until the PCB is disposed of and can facilitate and improve various applications. Is this all mere theory, or is it already being implemented? Nokia is already taking advantage of UHF RFID-based PCB manufacturing in its new modular Industry 4.0 production line. The first products produced there are already equipped with UHF RFID transponders. The machines used by various manufacturers, including a reflow soldering system from Rehm Thermal Systems, are equipped with the described UHF RFID products from HARTING and thus, meet the requirements of Industry 4.0-capable printed circuit board production. ASM Assembly Systems GmbH & Co KG also integrates RFID technology into its machines. Machines and printed circuit boards are not the only things that can be equipped with RFID technology. Consumables, such as, cleaning rollers used in solder paste printers can also be detected automatically. Associated products are offered by the company Vliesstoff Kasper. Zollner Elektronik AG has been demonstrating the possibilities of this technology for some time now in its technical centre in Cham. The consortium’s comrades-in-arms have numerous ideas to use the UHF RFID technology in an even more versatile manner. Among other things, the TU Dresden is involved in efforts to develop completely new modules. UHF RFID technology makes the circuit board industry even more versatile, manufacturing processes much more flexible, safer and opens up completely new application scenarios, including improving the sustainable handling of the raw materials of a printed circuit board and through to proper disposal. ☐

A&D India | Jun-Jul 2019


PowerProx: THE NEW HOME OF SENSING RANGE.

The new standard for reliable detection with an extended sensing range can‘t be measured with a conventional yardstick. After all, with sensing ranges from 5 cm to 3.8 m, no object goes undetected by the PowerProx MultiTask photoelectric sensor. To achieve this, SICK has not only packed all the advantages of time-of-flight technology into the smallest housing the world has ever seen, but has also increased detection speed. This means that even objects being transported at high speed, small and flat objects, and jet-black and shiny objects can now be reliably detected over an extensive sensing range. PowerProx combines sensing range, speed, precision, and reliability in a single sensor family. We think that’s intelligent. www.sick.de/powerprox


M AT E R I A L H A N D L I N G | T E C H N O L O G Y

Industry 4.0 & fork truck free initiatives Integrated supply chain management utilising fork truck free (FTF) initiatives are revolutionising the way products are designed and delivered while maximising efficiencies. The article talks about how Industry 4.0 represents the way in which FTF initiatives capture the convergence of digital and physical worlds and how Industry 4.0 and FTF are really about smart machines. Improving efficiency, transparency, and productivity in the supply chain is possible by intelligently networking elements in the logistics system, logging massive amounts of data, learning from conditional results, and adapting system behaviours. By 2025, the intralogistics industry must be capable of supporting a highly diverse set of order and distribution channels in keeping with mass customised products and delivery methods. Industry 4.0 data driven approach when combined with FTF will play an integral role here.

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Ed Brown, Founder, Topper Industrial

Ryan Brown, President, Industrial Cart FTF Revolution

Mother-daughter cart system Steps walked throughout a plant or repetitive fork truck running back and forth are eliminated with mother-daughter carts. Mother-daughter carts are an industrial cart system consisting of one large mother cart and two or more, smaller daughter carts. The daughter carts are designed to fit within the mother cart’s framework. Once inside, the daughter carts are locked into the mother cart. The mother cart and daughter carts

A&D India | Jun-Jul 2019


T E C H N O L O G Y | M AT E R I A L H A N D L I N G

Insightful decision-making becomes possible in the FTF space because all raw materials, finished goods, are delivered to a manufacturing cell or shipping dock precisely as needed

are then able to be tugged as one. Daughter carts are often different types of carts. One mother cart can be designed to carry a static cart as one daughter cart and a rotation cart as another daughter cart. The mother-daughter cart system is a very flexible, effective cart system. It facilitates an integrated supply chain by bringing products to the line as needed, increasing efficiencies.

Prescriptive analytics Prescriptive analytics are also part of an FTF initiative. By maximising outcomes based on predictive analytics ensures optimal uptime and sustained performance. With this, carts deliver a high-level of material flow, bringing the right product to the line at the correct time.

from linear, sequential supply chain operations to an interconnected, open system of supply operations, allowing manufacturers to fully realise the digital supply network. A new manufacturing line can produce one product and up to 25 variants, with a 10% increase in productivity and a 30% decrease in inventory by using Industry 4.0 technologies. While productivity, throughput, and operational efficiency are an obvious outcome of FTF initiative, the prognosis of Industry 4.0 to transform manufacturing operations far exceed the initial benefits of productivity. Flexibility, quality, and speed are natural consequences achieved as organisations use FTF initiatives to become best-practice manufacturers.

Driving safety

Manufacturing plants operating under Industry 4.0 and FTF principles present an opportunity for dramatic safety improvements if handled correctly. Reconfiguration of Real-time visibility allows carts to be monitored and reduce production areas at short notice, involving the rapid changes of (even eliminate) fork truck utilisation. Insightful decision- tooling and even the physical movement of equipment, can pose making becomes possible in the FTF space because all raw a range of safety challenges. Each new production configuration materials, finished goods, are delivered to a manufacturing cell or entails a separate risk and safety assessment. shipping dock precisely as needed. Zero wait-time is accomplished, A range of devices can be fitted onto equipment capable of which eliminates downtime, improves labour efficiency, and detecting and reporting operator behaviour which may pose a ensures maximum productivity. risk to safety. This equipment can take a number of forms; among the most common are intelligent cameras which gather digital images or footage and pass these to a central control point, FTF initiatives—An extension of Industry 4.0 automatically highlighting any abnormal behaviours, such as, Because Industry 4.0 is an extension of both engineering and entry into a restricted area. Many systems designers also opt to IT, the ability to properly sequence production becomes an equip their machines with safety sensing devices which can automated exercise. Industry 4.0 represents the way in which FTF immediately sense if a human operator has moved into an unsafe initiatives capture the convergence of the digital and physical area or positioned themselves too close to a particular piece of worlds—including IT and OT. plant. The default response is usually to power down the machine This transformation of the supply chain increasingly shifts or, in the case of a collaborative robot, to slow down to a safe

Real-time visibility

A&D India | Jun-Jul 2019

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M AT E R I A L H A N D L I N G | T E C H N O L O G Y

New Industry 4.0 metrics now overlay physiological and biomechanical data with workplace data (hours worked, tasks conducted, welfare records, etc) and run advanced analytics incorporating machine learning, and allow floor supervisors to recognise when floor workers are reaching a point of physical or mental harm

speed, allowing the individual time to move away from the hazard. In the case of carts, these calculations are embedded in the design to ensure a runaway cart cannot happen. With the single largest cause of injury on a manufacturing plant floor being a fork truck, reducing or eliminating this machinery may prove the most efficacious solution to safety improvement metrics. New Industry 4.0 metrics now overlay physiological and biomechanical data with workplace data (hours worked, tasks conducted, welfare records, etc) and run advanced analytics incorporating machine learning, and allow floor supervisors to recognise when floor workers are reaching a point of physical or mental harm.

Automated material handling Automated material handling in the FTF environment creates a more efficient material workflow that exceeds expectations with minimal overhead. Self-driving vehicles tug a string of connected carts increasing throughput by automating pick-up, drop-off, and transport, executing put-away, cross-docking, replenishment, and all other point-to-point deliveries. The industrial carts and tuggers are infrastructure-free, adaptable, and scalable to operational, seasonal, and production shifts and re-tooling. Safety is not compromised because vehicles and carts are safely navigated around obstacles and alongside workers. FTF is particularly useful as a total fulfillment solution combining the strengths of humans and robots with real-time Industry 4.0 intelligence. By automating piece picking, cart picking, and case picking operations, industrial strength topper carts deliver totes, cases, and pallets autonomously.

Exceeding throughput goals Guided vehicles can be easily programmed by manufacturing plant floor staff to perform exactly as trained each and every time, running a 24/7 three shift operation. Topper Industrial has a string of carts behind Automated Guided Vehicles (AGVs)

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eliminating costly downtime and increasing throughput productivity. All parts of the FTF initiatives and integration with Industry 4.0 methodologies, both AGV and cart consistency are critical to meeting and exceeding throughput goals. Industry 4.0 and FTF are about smart machines and smarter materials handling. Industry leaders are investing in sensorequipped technologies that capture data and allow them to monitor material flow in real-time. Since most AGVs are now connected to the Internet, data-rich sensors collecting predictive data, self-driving vehicles are an extension of Industry 4.0, FTF and lean initiatives.

Industry 4.0 FTF & material flows Individually, customised or mass-produced custom products require more items to be managed as well as leaner material flows. These factors exponentially increase the complexity of logistics. Nearly half of manufacturing disruptions are due to problems with materials—wrong or defective parts, missing parts, or unavailability of parts during production. State-of-the-art factories are preparing for the increase in logistics complexity, which is evident as there is a boom in warehouse automation and WMS (Warehouse Management Systems). More precision and efficiency in receiving drives the impact of material flow, efficiency from suppliers; this improves using ASN messages (Advanced Ship Notices). Whether at a plant or manufacturing cell, line works must know what item is arriving and the corresponding shipping units. Moving materials to manufacturing requires flexibility, efficiency, and speed. The increased number of SKUs makes the traditional ‘installer picks’ approach impossible or at least inefficient. Assembly is moving toward 100% picking. Supermarket picking may be one step on the way, but the increased use of warehouse automation and number of SKUs is pushing toward warehouse to manufacturing picking. Picking for manufacturing has clear advantages in speed, quality, and efficiency. ☐

A&D India | Jun-Jul 2019


D I G I T I S AT I O N | T E C H N O L O G Y

Determining automation value: The Why, When and How Most automated machinery and tools can function at the best level and also make working conditions better. Nevertheless, if not applied properly, automation can lead nowhere. The article discusses how to apply automation sustainably and make the most of it. Revamping your plants or processes with automation is a reliable way to maximise the profits on your investment. However, automation, if not implemented sustainably, leads to a negligible increase in your profit. Sometimes, it may even result in a net loss after considering the huge investment.

The Why Automation through digitisation has influenced changes in all the sectors of the industry–Design, production and sales. This change has been readily accepted not only because it is trendy, but also because of its numerous advantages. Uniform outputs, improved efficiency and reduction of production

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Milind Kulkarni Head of Business Development– Industrial Automation Siemens

time are some of the after-effects of automation. Automation maximises the performance of the process by eliminating production risks. The various production risks which industries face are: • Operational: These risks interrupt the production cycle. For example, mechanical failure, delay in supply of goods and services, power cuts, labour shortage, etc. • Technological: These risks involve the lack/malfunctioning of technical equipment • Financial: These risks depend on the changes in the financial policies of the government With automation, many unforeseen situations can be avoided and efficiency can be maximised. The reduced risks in

A&D India | Jun-Jul 2019


T E C H N O L O G Y | D I G I T I S AT I O N

If modernisation of equipment is not compatible with your existing systems, investing for features which one will not be using is unnecessary

the process improve the performance of the people along with the project. Automation is inevitable, although, only sustainable automation can lead to an increase in profits. These basic questions can help one decide the degree of automation and the methodology to implement the same, best suited for one’s modernisation project.

The When The best person to answer this question is the process manager. The answer to this question can be obtained after the analysis of various collected data and the variances of the processes. The careful evaluation of the existing process and the financial capability can help one design the automation process.

When to migrate and when to modernise Migration refers to replacing an existing legacy technology with a modern version that fulfills similar requirements and has the ability to perform similar functions like that of an existing one. Modernisation refers to planning and implementing new, upgraded technology across departments in order to create a single platform for improved communication, better collaboration, timely production schedules and thereby, creating efficiencies in an automated environment. Deciding when to migrate and when to modernise depends on the availability of resources, both technical and financial. The process manager needs to carefully evaluate the outcome of both the options by keeping in mind the ROI and the goal of the process.

A&D India | Jun-Jul 2019

• While deciding between migration or modernisation, one should consider a three to five-year investment-planning horizon when analysing one’s existing infrastructure • If one’s existing system faces issues like, intractability, reduced productivity, increase in downtime, a prolonged duration for changeovers, increase in energy consumption, issues with component availability and grey market channels being used for procurement, adequate investments need to be made to overcome these problems • After finding the root cause of these problems, one can decide between migration and modernisation • Opting for migration to reduce expenses, however, can be costly in the long run, when the entire system fails to deliver what it is aimed for. Spending on replacing an old component with the same new component might not reflect an improvement in the process if the root cause of the problem was not the component. If improved modernised components, which are compatible with your existing process, are used, they will result in the solution of the problem along with added benefits. • When one migrate to a new component, they don’t achieve any improvement in production. Modernising, on the other hand, can help one increase data collection and achieve greater productivity. Replacing parts every time might result in an emergency shutdown. Migration is useful in improving efficiencies for particular equipment or a department. • Depending on the ROI, modernisation can be embraced. However, if modernisation of equipment is not compatible with your existing systems, investing for features which one will not be using is unnecessary.

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D I G I T I S AT I O N | T E C H N O L O G Y

Take advantage of virtualisation tools to pretest and demonstrate the functional effectiveness of new system designs

• Modernisation, if implemented in planned phases, improves the ROI and makes the plant sustainable Attempting to obtain complete automation in a single shot is indeed a long shot. Instead, one should try to automatise individual processes based on priorities. This will help in managing the finances along with the productivity of the plant.

The How The humongous task of automation can be easily achieved with these steps: • Understand the process of the project on harness for migration/modernisation • Diagnose the optimisable avenues • Prioritise the automation of different systems based on their effect on overall production • Define the project scope after analysing the previously collected data and estimating the required output by predicting the changes and its effect on the process after automation • Allocate and invest money and time for each phase of implementation. Each phase is equally important. Do not compromise on important phases like, software update, because of exceeding expenses. New hardware might be useless without a proper control system. • Efficient monitoring of variances in the project will result in the best outcome—networking, wireless technology and cybersecurity and connecting devices to the Internet of Things can aid in effective monitoring A process can only be controlled as finely as it is measured. To optimise a process, the infrastructure needs three layers—control, visualisation, and business and engineering intelligence.

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Getting stakeholder buy-in for automation projects Automation, if not planned properly, acts like a black hole, which requires investment but does not have any substantial outcome. Unless the returns on the automation investment are understood, executives will not be able to justify the investment required. One needs to understand both the physical laws governing engineering and human rules of accounting. The following steps can be followed to encourage stakeholders to invest in automation projects: • Evaluate the cost of an automation investment based on its economic value to the business • Execute real-time accounting at the work-cell level, which lets you measure operator activity. Model accounting in the control system using the generally accepted accounting principles. • Establish a baseline and store the data. This will allow you to watch performance before and after each investment. • Dashboards relating to production data and financial data are powerful tools for both, operators and managers • Present your case in the language of business. Focus on productivity improvement, higher revenues, lower cost structures, risk avoidance and opportunities for growth. • Take advantage of virtualisation tools to pretest and demonstrate the functional effectiveness of new system designs. Computer simulations can be used to demonstrate the effect of automation. • Phase the automation upgrades over multiyear projects, as it will be both easier on the budget and less risky if there are transition problems Automation is not an overnight process. One should look at the bigger picture and re-envision the process. This will help in creating a sustainable automation transformation. Modernisation is leading to transformation. ☐

A&D India | Jun-Jul 2019


23 - 28 January 2020, Bangalore, India


A D V E R TO R I A L | T E C H N O L O G Y

Maximising dairy production with integrated processing plant India is one of the largest consumers of milk in the world, which leads to dairies aiming to deliver constant quality, while keeping costs low, which can be accomplished by tighter control and higher level of automation. The case study explains about one such dairy that turned to Rockwell Automation with its requirements of bringing about process optimisation, manpower reduction, and an integrated liquid milk plant. A growing middle class in India has created a growing market demand and increased consumption of dairy products. Likewise, one of Asia’s largest dairies has a processing capacity of 5000 lac litres of milk a day. With the increasing demand for quality milk throughout India, the plant is challenged to increase production for various dairy products. To meet demand, they need an integrated liquid milk plant.

The challenge The goal of the expansion was process optimisation, manpower reduction (doing more through automation) and faster time to market. The dairy also focused on maintaining low operating margins. In addition, the control systems of various plants would need

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to integrate with the systems in the dairy. The plant required greater visibility and productivity, while optimising resources including water, air, gas, electric and steam (WAGES).

The solution The goals of the plant included reducing batch cycle time to increase productivity of plant and creating a flexible storage matrix for raw materials to improve operations. Given the scope and complexity of the project, the dairy recognised they needed a single vendor to manage the design and implementation of the control system. Choosing a company with the right set of skills and experience was critical. The dairy selected Rockwell Automation due to its extensive experience in automation and global reach. With a local sales

A&D India | Jun-Jul 2019


T E C H N O L O G Y | A D V E R TO R I A L

Challenge

High-volume, low-profit margin operation requires the best from every batch

Solutions

• Seamless integration on a single EtherNet/IP network • Optimises processes by deploying controller-based modular predictive control (MPC) on the pasteuriser • Offers real-time energy monitoring, scalable engineering practices and standardisation

The results

• Reduced batch cycle time by 20 minutes using an MPC-based controller • Increased productivity from 5 to 5.5 million litres a day • Increased energy savings by reducing clean-in-place (CIP) cycles and delivering better temperature control ☐

office and distributor located close to the project site, Rockwell Automation had the required expertise and partnerships to manage the entire project from initial design through engineering and implementation. Effective solutions included seamless integration on a single EtherNet/IP network; process optimisation by deploying controller-based modular predictive control (MPC) on the pasteuriser; real-time energy monitoring; scalable engineering practices and standardisation. Rockwell Automation Global Solutions implemented a batch solution that: • Monitors and controls 50 LLPD of milk daily • Allows operators to create and run different recipes, specify daily production rates and run multiple batches in parallel via the batch production entry system. • Provides trending, alarming, & exception handling, and real-time monitoring of parameters at the refrigeration plant for energy saving. • Allows the plant manager to have complete and accurate production information at any given time, and provided different types of reports, including performance, quality and material. The solution is built on: • The PlantPAx® distributed control system using a common control engine with a common development environment to provide high performance in an easy-to-use environment. The system’s tight integration between the

A&D India | Jun-Jul 2019

programming software, controller, and I/O modules reduced development time and cost at commissioning and during normal operation. • ControlLogix® L7X controllers from various plants integrated on one EtherNet/IP plant-wide network and add-on instructions (AOI) to increase productivity and make troubleshooting easier. • E300™ electronic overload relays for better motor control, protection and predictive diagnostics.

The results The project was delivered by the Rockwell Automation Solutions Business through various OEMs including GEA Process, IDMC, Tetra Pak, Frick India and Forbes Marshall. Each of these OEMs relied on Rockwell Automation control systems to enable plant-wide visibility and real-time monitoring. The dairy is now in discussions to create real-time dashboards for production and utility data. The solution increased productivity from 5 to 5.5 million litres per day. The dairy now enjoys a significant energy savings as clean-in-place (CIP) cycles have been reduced and temperature control is more precise and much faster. Overall, the solution offers equipment OEE monitoring and real-time, role-based dashboard reporting tools for better decisionmaking. ☐ Courtesy: Rockwell Automation

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G R E E N M A N U FA C T U R I N G | A P P L I C AT I O N

Ensuring reduced carbon footprint while digitising assets Due to rapidly changing technology, the amount of e-waste has increased, which greatly impacts the environment and life on earth. Technology plays its part in industrial environment, too, with new technologies regularly being introduced in the market, thus, fuelling introduction of new products and electronics. The article explains how industries have taken note of this and brought environment as a core part of Tanay Sil their CSR, and throws light on edge architectures which help Business Development Industry B&R Industrial Automation factories reduce e-waste and also become smart. tanay.sil@br-automation.com Many organisations have increasingly put their focus on reducing e-waste with some even taking it up as a CSR activity. This is from the point of view of reducing the carbon footprint for a healthier environment. On the contrary, manufacturing setups and factories are consistently looking at upgrading their existing systems for becoming smart. However, this leads manufacturing setups and factories in a catch-22 situation. If we look at the factory perspective, both activities are extremely important, wherein one will help factories in becoming environment-friendly by reducing e-waste and the other will help them become increasingly automated and smart.

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Smarter machines and factories In order to stay competitive and ahead in competition, machines and factories need to focus on technology. As the world is moving in the direction of Industry 4.0, digitisation, and industrial IoT, the amount of focus on technology & incorporating new products for smarter operations has drastically increased. These new technologies focus not only on automating processes but also on efficient, optimised operations. This helps factories save millions from operation costs. Thus, incorporation of these technologies in machines and factories is also a topmost priority.

A&D India | Jun-Jul 2019


A P P L I C AT I O N | G R E E N M A N U FA C T U R I N G

Edge Embedded and Edge Controller can also be equipped with energy and condition monitoring tools

Ensuring higher machine availability reduces downtime, ensuring higher productivity. Incorporating predictive maintenance ensures reduction in unplanned downtimes leading to reduced wastage of raw materials and products. Monitoring energy in different forms helps factories save energy and thus, reduce operation costs. For machine builders incorporating virtualisation means reducing the time to market for new machines and avoiding rework. This saves them time and effort, which eventually helps them avoid waste. Gathering data from machines and lines enables factories to analyse the performance in real-time, enabling them to avoid human errors in data entry with making decisions spontaneously. These are just a few examples of the various benefits technology brings to machines and factories.

Smarter yet cleaner This is a dilemma machines and factories face in making their operations smart yet be cleaner for the sake of the environment and health of life. Factories need to find a way not only to benefit from smart manufacturing concepts but also to care for the environment. B&R Industrial Automation takes both aspects seriously with providing next generation smart automation solutions to machines and factories yet helping them in their endeavour of reducing e-waste. It offers machine builders advanced automation technology and solutions for incorporating them in the new machines for becoming ready for the future and becoming innovative. In addition, it provides brownfield factories with solutions via edge architectures, which allows them to keep using the legacy systems yet be able to incorporate the new technologies. Thus, any factory using the edge architectures from B&R will be able to leverage benefits the new technologies bring in. With addition to edge architectures, factories reduce e-waste as well as become smart.

Edge architectures Factories are looking at ways to gather data from machines as

A&D India | Jun-Jul 2019

well as lines and send it to IT systems for analytics. With intelligence becoming more and more decentralised & a growing volume and variety of machine and line data becoming available for analytics, the need for edge computing is on the rise. Edge architectures help collect data from sensors, actuators, machines, lines and plants and move it to IT systems for analytics and longterm storage. Edge architectures make life easy for factory operators & plant owners by providing a variety of options tailored to their requirements. These are add-on systems keeping the existing OT infrastructure untouched, thus, eliminating the need of generating e-waste for adding new technology. Edge Connect allows them to gather data directly from sensors and actuators in the field, which can then be shared securely with any cloud platform using the open-source OPC UA protocol – making it the easiest way to collect data from the field. Edge Embedded provides basic intelligence, trends, reporting, data aggregation, and the possibility of viewing data locally on the shop floor before moving it to the cloud. With Edge Embedded, factories can divide computation between the cloud and on-site controllers. Edge Controller provides factories with comprehensive onsite analytics, business intelligence and machine learning – giving them full control of their data. Edge Embedded and Edge Controller can also be equipped with energy and condition monitoring tools. Edge architectures are the perfect way to begin the transformation toward the smart, connected factories of the future.

Reducing carbon footprint The industry understands the value and potential of digital transformation, which has opened the door for significant step change improvements. Edge architectures will continue to play a vital role in helping factories reduce their carbon footprint in their endeavour to become smart. B&R is a global automation provider with ground-breaking motion control, machine operation and control solutions for helping machine builders, factories and manufacturing units on their path of digitisation. �

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EVENT | REPORT

Productivity through digital transformation With the evolution of digitalisation through the past years, there has been a major change from understanding the necessity, significance and benefits of digitalisation to now understanding how to be a part of the growing digitalisation, without affecting one’s business & manufacturing infrastructure. In this context, Rockwell Automation recently held a conference on ‘Digital Transformation Driving Business Outcome’ in Hyderabad, which aimed at helping the manufacturing industry learn about the technology enablers and get insights about the best practices for manufacturers keen to Anvita Pillai Sub-Editor & Correspondent implement change across their organisation. A post-event report… anvita.pillai@publish-industry.net The significance of digital transformation for a business that companies, and how the right mindset is needed to adopt it. wants to remain pertinent in its forte can't be overlooked. The first session of the day was by Rajkumar Paira, Senior However, if people do not have the right mindset to change Analyst – ARC Advisory Group, who gave an in-depth view on while adapting to it, then the transformation only tends to the ‘dynamics of digital transformation and its impact on Indian magnify existing blemishes in organisational practices. Keeping manufacturing from a consultant’s perspective’. He explained this in mind, Rockwell Automation recently held a conference how digital transformation requires comprehensive planning on ‘Digital Transformation Driving Business Outcome’ in and disciplined management to achieve various benefits, like Hyderabad, which gave a close view on what digitalisation is higher customer satisfaction, optimised operations, safer really all about, bringing about digital transformation in working environment and more.

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A&D India | Jun-Jul 2019


REPORT | EVENT

Smart & connected Next, Madan Kumar, End User Business Leader – South, Rockwell Automation, took over to speak about ‘How one can accelerate high performance operations through the connected enterprise’. This was followed by a session on ‘smart devices for smart manufacturing’ by Rajendran Menon, Product Manager - Smart Devices, Rockwell Automation. He spoke about the various business drivers and challenges, smart devices in connected enterprises and various aspects of what makes devices smart. Moving on, Shibasis Patro, Manager – Equipments, Signode India, hosted a session on ‘Enabling digital transformation through smart machines & equipment’, discussing various aspects of technology, like smart technology machines & equipment, integrated safety solutions, OEE solutions, and realtime diagnostics. Next, T D Dhanu, Technical Consultant – South, Rockwell Automation, presented a session on ‘How one can improve their operational efficiency through advanced analytics’. This session majorly discussed industry trends, an overview of analytics offered, and the walk through and story behind the development of Rockwell Automation Global Energy Drink (RAGE).

Digital transformation driving business outcome The event further delved into the panel discussion, which was on the topic ‘Digital transformation driving business outcome’. Moderated by Shekhar Jitkar, Chief Editor, A&D India, the discussion was aimed at the business outcome and future trends of digitalisation, and how other advanced technologies, like AI, AM or cloud computing can be utilised in a successful digital transformation journey. The panellists were Sandeep Redkar, Business Manager, Process Solution, Rockwell Automation; Subba Rao, Director, Aztec Consulting; Ramprasad Nori, Associate Vice President, Greenco Energy; Ravi Maknikar, National Head, Zenith Technologies; and Avinash Tote, Executive Director, Logicon Techno solutions. Considering digitalisation not needing any in-depth introduction, Jitkar started off by the question on technological adoption levels for digitalisation in the Indian industry and how close Indian factories are to adopt advanced technology concept.

A&D India | Jun-Jul 2019

Sharing his views on this, Redkar responded, “We have been associated with our customers in this journey for almost five years now. Some organisations, especially the global manufacturing conglomerates, have been the first ones to make advancements in the applications of the technologies in their own plants operating in India. What’s more interesting is that the public sector and the government-owned units are showing an extremely aggressive trend of adoption.” Throwing light on the pharma side of it, Maknikar asserted that, today, the buzzword is data integrity. “Companies cannot achieve data integrity without the necessary digital transformation,” he explained and continued, “So, to achieve data integrity, various pharma companies are implementing MES, which is proving to be an effective solution. There is willingness, but there is also a certain lag in the supporting infrastructure, which needs to be addressed first.” Giving his opinion in this context as well, Rao said that the meaning of data integrity is very different to a small and mid-scale pharma company, compared to a largescale pharma company. For a small and mid-scale company, digitalisation is majorly about improvement in quality, while for large scale companies, it is majorly about data integrity and ROI. According to Nori, firstly, it is important to have commitment from the management. Secondly, people who are going to implement digitalisation, need to have the required mindset and should adapt to the change of technology. “In India, the new generation has that kind of a mindset, thanks to the kind of exposure they are getting,” he implied and continued, “For any business, if the survival becomes the question, they would go for the solution immediately. As for our company, we have almost all our assets digitally connected. We are reaping benefits of digitalisation now. Today, data is the oxygen for business and analytics is the food.” Being from a solution providing company, Tote gave a brief insight on the challenges faced during digitisation. “When we started off with a digitalisation project in 2011, we faced a lot of challenges during the period, as the hardware and network infrastructure weren’t well developed back in 2011 and also because there was less resistance from operators because of the fear of getting exposed. This made us re-design the solutions with the help of our customer and gave us a great learning, making our job easy today.”

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EVENT | REPORT

Rockwell Automation created a platform for technology enablers to get insights about the best practices for manufacturers keen to implement change across their organisation

The discussion then turned to security of data, which has been a question of importance even in top global companies. Maknikar shared his views, where he cited that a lot of work is going on into providing adequate cyber security to the booming digitalisation. “We are trying to conduct trainings on cyber security in India for awareness generation,” he informed and continued, “Everyone is concerned by cyber-attacks, from solution providers to end-users. And, I believe that we should talk about it as an important topic while going about in the journey of digital development.” Speaking on the criteria and parameters while approaching a solution provider and the expectations from solution providers and systems integrators, Nori asserted, “Eighty per cent of failures are predominantly because requirements have not been specified properly. Even major companies are not able to articulate, understand and convert what a customer is expecting into a solution, making the result zero. Everybody has to be equally updated as solutions are not readily available because they are all customised.” Redkar further added, “As providers of technology and solution, we have tried to come up with solutions in our own way. What we have noticed is that currently there are three aspects in which the investments are happening by customers. First is improving productivity, second is consistent quality, and third is to reduce maintenance. The solution to these will vary based on what your company focus is and what industry you belong to. We create a kind of document that becomes our guiding document for the rest of the implementation as well as the first implementation that we may want to take up. Obviously, there is an awareness gap that exists, but we can’t wait for that gap to be filled by somebody else. So, we make our own attempt in terms of filling it up.”

Going further on digitalisation Post the panel discussion, Redkar took over and gave a

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presentation on ‘What to Expect from a Modern DCS in Digital era’, which focused on the benefits of enabling IoT for better connected enterprises and customer outcomes, how digital technologies enabled by Rockwell Automation can help manufacturing organisations, life of an IIoT project, and DCS of today and tomorrow benefitting the industry. It is important for an industrialist to understand the security trends and its implementation in the industry to attain complete data protection. Ankur Pancholi, Product Manager- Large Controllers & Networks, in his session ‘Secure Network Architecture for The Digital Plant’ spoke about the industrial security trends that are being followed, series of standards that define procedures for implementing electronically secure (IACS), security design for all Rockwell Automation products, guidelines to achieve a secure network infrastructure and procedures for its configuration to meet personal system requirement, and user access control and authorisation. The event came to an end with the final presentation of the day by T Venugopal, Power Control Manager-South, Rockwell Automation India on ‘Rethinking Motor Control in A Digital Age’. The session highlighted various motor control technologies, like across-the-line starters, soft starters, servo drivers and more. Venugopal also divulged into evolution of communication and the two layers of digital communication. He further went on to speak about the intelligent motor controls from single network and its benefits, the value delivered, implementations and benefits of premier integration and Allen Bradley PowerFlex portfolio.

Creating a clear roadmap Rockwell Automation created a platform for technology enablers to get insights about the best practices for manufacturers keen to implement change across their organisation. The conference culminated to be a journey that would create longterm benefits, guiding dynamic manufacturing professionals for the staged approach with a clear roadmap. ☐

A&D India | Jun-Jul 2019


2019

INTERNATIONAL AUTOMOTIVE MANUFACTURING SUMMIT

Manufacturing Excellence with Technology Innovations 16-17 July 2019, Hyatt Regency, Pune, Maharashtra, India

Organised by

Knowledge Partner

Association Partner

Meet our expert panel of speakers The only event designed to keep automotive manufacturing professionals at the forefront of a fast evolving technology landscape in a digital era. The International Automotive Manufacturing Summit will bring together manufacturing leaders, technology experts to jointly pursue the necessary developments for the entire automobile and auto-components manufacturing process chain. Key Highlights Visit to Mahindra & Mahindra Automotive Plant, Chakan, near Pune – a state-ofthe-art eco-friendly manufacturing facility, that integrates the best in technology, operational excellence, & green practices. A dedicated session on E-mobility – Advanced Manufacturing Technology Key Takeaways • CONNECT with the automotive business community • INTERACT with the industry experts & leaders • LEARN from the informative discussions • COLLABORATE for information exchange • EXPLORE best manufacturing practices

M M Singh

Raju B Ketkale*

Vijay Kalra

Kaushik Madhavan

Director, Maruti Center of Excellence, Maruti Suzuki India

Senior Vice President & Director - Product Design & Development Toyota Kirloskar Motor

CEO, Mahindra Vehicle Manufacturers & Chief Manufacturing Operations, Mahindra & Mahindra

Vice President, Mobility, Frost & Sullivan

Sudhir Gurtoo

Dr Ravi Damodaran

Viraj Kalyani

Rajib Kumar Jena

Krishna Bhojkar

Managing Director & CEO, Leadec India (Voith Industrial Services India)

Chief Technology Officer, Greaves Cotton

Founder & Chairman, Kalyani Studio

General Manager, Bajaj Auto

Head, Manufacturing Engineering, Volkswagen India

Pramod Khot

Dr Pradeep Chatterjee

Ammar Master

Sajid Mubashir

Rajiv Bajaj

Vice President, Powertrain Manufacturing Head, Fiat India Automobile

Head, Digital Transformation & Change Management, Tata Motors

Senior Manager, Asia Pacific Vehicle Forecasts, LMC Automotive

Scientist G, Dept of Science & Technology, Govt of India

Managing Director, India and SEA, Stratasys India

COMPETENCE PARTNERS / SPONSORS

For registration, contact: Ananya Choudhary Tel: +91 7410009436; email: ananya.choudhary@publish-industry.net

REGISTER FA ST!!! Early Bird Offe r ending on 10th July, 2019


TECHNOLOGY | NEWS

Industrial robot arm Maxon Motors recently introduced a compact industrial robot arm, Meca500. This is an arm with six degrees of freedom and only half the size of a regular industrial robot. It weighs only 5 kilograms, with a base about the size of a human palm. Nevertheless, it has a load capacity of 500 grams. The operations are simplified, and the space is saved as the controller is integrated. Meca500 can be programmed and oper-ated with the help of a 24V power supply, a computer, and an ethernet cable. The challenge to fit all the components into a small space is overcome with the help of the brushless flat motors from the company, keeping the drivers sufficiently small, while still being powerful and complaint with high quality standards. In the Meca500, the DC motors, that are compact in design and high in torque, are combined with zero-backlash gearheads and high-resolution encoders for precise movements. The robot arm has a repeatability of 0.005 millimetres, which is twenty times less than the Meca500 thickness of a sheet of printing paper.

The Meca500 is only the starting point for a whole line of robots. The company is trying to offer the smallest and most precise robots for industrial users to pave the way of new products, applications and discoveries. The company is also working on a gripper for the arm. Customers receive firmware updates as soon as they become available. With these updates, the Meca500 will soon be able to function as a collaborative robot, with a function to prevent collisions and a zero-gravity mode. Many other applications are possible, for example, in medical technology, to assist surgery or in automation systems. However, the robot arm is also able to perform pick-andplace or inspection tasks. Mecademic handles the production of robot arms in-house to ensure quality. They machine the aluminum parts of the robot arm on precision equipment and assemble the components inhouse. On request, the Meca500 can be shipped neatly pack-aged in a case. Maxon precision motor India | Bengaluru Email: info.in@maxonmotor.com | Tel: +91-80-41734132

Safety for machine building

Diagnostic system for vibration sensors

Phoenix Contact recently offered a portfolio of products and services for machine building that are cost-effective, good quality, flexible which improve the machine performance. When the machine requires safety functions and logical links are to be implemented, PSR safety can be utilised. Similarly, the FL MGUARD security CLIPLINE routers and firewalls protect the machine and the network against unauthorised access by people or malware. The QUINT POWER with SFB technology trips circuit breakers magnetically and quickly with six times the nominal current. Also, the VARIOFACE system cabling connects the controller to the field - easy and error-free. Plus, the HEAVYCON EVO plug connector system features a standardised mount for cable glands from size M20 to size M40 while the Toolfox tool program offers excellent hand tools and machines for cutting, stripping, crimping, screwing and testing. Also, with the help of CLIPLINE complete, user can choose the connection technology. The available options are amongst screw, push-in, spring-cage, quick, bolt or plug connection.

ifm recently introduced VSE150, which is 6-channel VSE type diagnostic system with an interface to exchange data with a PLC via Profinet IO for the evaluation of dynamic signals, such as, acceleration or force and analogue signals. The signals from the connected sensors are continuously processed in the VSE150 to calculate the characteristic values for condition monitoring defined in a parameter set. The results are compared with limits and thus, become information about the condition of the process and machine. A deterioration in quality VSE150 is recognised early, avoiding rejects and expensive damage. Using the fieldbus connection measured values can be directly indicated in the controller and monitoring can be perfectly adapted to the operating states and processes of the machine. Further benefits of VSE150 includes two digital switching outputs (response time ≤ 1 ms) for time-critical alarms, 3 Ethernet ports (for a separate office and machine network) and a large internal history memory with real-time clock and counter. The auxiliary parameters of condition monitoring can be directly transmitted via the fieldbus and no longer need to be exchanged via analogue and digital signals.

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Phoenix Contact India | New Delhi

ifm electronic India | Kolhapur

Email: response@phoenixcontact.co.in | Tel: +91-11-30262700

Email: info.india@ifm.com | Tel: +91-231-2672770

A&D India | Jun-Jul 2019


NEWS | TECHNOLOGY

Chainflex cables

Controller with integrated switch

igus recently introduced the chainflex cables with a predictable service life to make a decisive contribution to the safe operation of moving applications. It also fulfils the "Restriction of Hazardous Substances" (RoHs) II specifications for the safety of humans and the environment. This applies to the entire chainflex product range of the motion cables specialist. The chainflex motor cable CF30 has been tested in test 5191 with 25 CF30 million cycles and the RoHs II conformity confirmed. Since the mid-1990s, throughout Europe, there have been restrictions on the use of environmentally hazardous substances for electrical and electronic equipment and their components. These ever-stricter guidelines set limits for the use of industrially essential but potentially harmful substances such as chromium, lead, mercury or bromine and other hazardous substances, including phthalates. The plasticisers are preferably used when plastics need to be very supple, soft and elastic in use. The company meets these requirements for highly flexible chainflex cables even without the use of these toxic phthalates, which is an important criterion for recycling or disposal.

B&R recently added a compact controller with an integrated switch, which enables daisy-chain cabling between network stations, to its Compact-S series. The X20CP0420 is extremely compact, i.e. a width of only 37.5 mm including the power supply. The controller achieves cycle times down to 4 ms and is equipped with 128 MB RAM and 256 MB internal flash memory. Also, the controller offers plenty of communication options in X20CP0420 regards of ethernet, USB and RS232. Besides, an optional CAN bus interface is also available. Moreover, this controller is maintenance free, as it has no fans or batteries. The X20 I/O modules can be connected directly to the controller, where they can be lined up seamlessly. The entire system saves a large amount of space in the control cabinet because of the compact design of the controller. Above all, even with its narrow dimensions, the controller has a built-in power supply for itself and the connected I/O modules. Hence, there is no need for a separate power supply module.

igus India | Bengaluru Email: vinayak@igus.in | Tel: +91-9341136381

Industrial gear unit

Clamping device for mounted points

NORD recently added a new industrial gear unit series, MAXXDRIVE XT, to the MAXXDRIVE industrial gear units’ range that provide high output torques and are ideal for use in heavy duty applications such as agitators, belt drives, mixers, mills, drums or crushers. The new series optimises the proven modular system for applications with high thermal limit powers. The output torques of the new series range between 15 and 75 kNm with speed ratios of 6.3 to MAXXDRIVE® XT 22.4. These industrial gear units are available in seven sizes for powers from 50 to 1500 kW. Due to the increased surface and the air guide covers, the cooling air flow is optimised and a very high thermal limiting power is achieved. All the solutions by the company are planned for individual customers according to the modular principle. With the matched modular system, attractive solutions can also be provided for price-sensitive industries. Predictive maintenance concepts for heavy industrial gear units are also available. The networked drive units, via the frequency inverter, communicate their status data via the control system or communicate directly into a secure cloud. ®

A&D India | Jun-Jul 2019

B&R Industrial Automation | Pune Email: office.in@br-automation.com | Tel: +91-20-4147-8999

Schunk recently expanded the high-precision clamping technology as standard to mounted point clamping. The Schunk TRIBOS mounted point holders permanently ensure excellent run-out and repeat accuracies < 0.01 mm. Its rotationally symmetric design enables maximum speeds of up to 90,000 rpm, which means that even the most demanding shape and position tolerances are reliably achieved during internal cylindrical grinding and jig grinding. At the same time, the grinding wheels are evenly worn-off, the service lives of the mounted points increase, and the mounted point costs decrease accordingly. Also, the TRIBOS polygonal clamping technology has several advantages compared to conventional toolholders for mounted points. Hence, the TRIBOS mounted point holders are suitable for all common grinding machines and TRIBOS mounted point holders grinding spindles. As a first step, the company offers the precision holders for the interface HJND 50 with clamping diameters 3 mm and 4 mm in the slim version TRIBOS mini, as well as clamping diameters with 6 mm, 7 mm and 8 mm in the robust version of the TRIBOS-RM.

Nord Drivesystems | Pune

Schunk Intec India | Bengaluru

Email: india@nord.com | Tel: +91-20-39801200

Email: info@in.schunk.com | Tel: +91-80-405-38999

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TECHNOLOGY | NEWS

Emerging trends in testing & measuring solutions Almost every industry requires the measurement of certain parameters to keep the processes running and the market throughout had always relied on conventional methods of measurements. The engineer/contractor needs to physically take the measuring instrument at the location to get the realtime values, again for report generation, must carry the instrument back to the workstation, connect it to his system to download the measurement readings which furthermore add to the difficulties. The latest trends and advancements from the digitisation of the working system, along with the increasing application necessities, are calling for solutions that are intuitive and smart. Testo has brought transformational change in the T&M industry with an entirely new range of smart measuring products for multiple applications. World of measuring instruments The electrical instruments provided by the company can be used to inspect the electrical components and circuit failure threats. Along with that, they ensure longevity and efficiency of various power electronic components that control and regulate the flow of electrical energy. The unique clamp meters and multi meters are intuitive, can measure several parameters in a single component and even have patent feature. The thermal imagers with smartphone integration, which is designed to deliver networked thermography, are mostly used for predictive and preventive maintenance in the electrical and power sector. These electric Testo 440 instruments & thermal imagers are good for trouble shooting in the power sector. Similarly, for improving energy efficiency, energy conservation and optimising operation costs, a range of electronic refrigeration manifolds/ analysers, that not only help to measure pressure but also accurately calculate the sub-cooling and superheating temperatures, based on the refrigerants selected, are available. In addition to that, digital vacuum measuring instruments like, the testo 552 - Testo Saveris 2 evacuation of refrigeration/air conditioning systems and heat pumps and the testo 316 - electronic leakage detector for refrigerants, hence been introduced. In-line with Industry 4.0 Industry 4.0, to a great extent, deals with smart operational framework and consists of automated set ups and equipment with an increasing inclination towards IoT, cloud storage, machine learning and smart technology, there is a complete transition of processes. As the operations that are carried out are much advanced, intuitive, seamless and the

industry is sure to witness the next level growth, the necessity for data monitoring & parameter measurements becomes a mandate which should be totally in line with the existing set-up. Hence, the company brings out its latest testing & measuring solutions such as the Smart Probes, which equip the users with smart and easy measurement techniques using the smartphone interface. These can be wirelessly & intuitively operated by smartphone via a free App. The Testo 420 air capture hood, for measuring the air volume flow has made the measurements easier even at the turbulent inlets/outlets. With only 2.9 kg and ergonomic handles, measurements, can be carried out comfortably, without inducing fatigue. The testo Saveris 2 WiFi data logger system is the simple, flexible and reliable solution to humidity and temperature monitoring in store rooms, cold storage area and work rooms, as well as during workflow processes. With a secure online storage of all readings in Testo Cloud the data can be managed and analysed online by the user via smartphone, tablet or PC anywhere and anytime. In case of crises and deviations, it is provided with an alarm by e-mail, or optionally by SMS. Testo Saveris 2 has replaced timeconsuming manual data monitoring and documentation system. Multifunction instruments The availability of products that can carry out measurements of multiple parameters in a single instrument not only reduces the cost of procurement of different instruments but also reduces the painpoints of the engineer. The company has now revolutionised the measurement technology with products like testo 440, intuitive air velocity & IEQ measuring instrument which can carry out measuring tasks on air conditioning and ventilation systems reliably under control with just one versatile instrument and multiple range of wired & Bluetooth probes. Even if one probe needs service, the instrument is still functional & can carry out remaining measurements. As the latest contribution to the industry, the company brings in the new generation of IEQ measurement technology: The new testo 400, which is the universal measuring instrument for all air flow and IEQ applications, impresses with smart technology, fast readiness and convenient application. The product is equipped to serve multiple applications in several industries. Wireless operation, with the ease of saving and transferring data over networks makes the instrument more user friendly, interactive and cost effective. Testo India | Pune Email: info@testo.in | Tel: +91-20-25920000

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A&D India | Jun-Jul 2019


H I G H L I G H T S | C O M PA N Y I N D E X | I M P R I N T

Highlights – Aug-Sep 2019 IMPRINT

Automation & Drives

Publisher / Chief Editor ShekharManufacturing Jitkar Efficient

shekhar.jitkar@publish-industry.net Features Writer Juili Eklahare juili.eklahare@publish-industry.net Anvita Pillai Sub-editor & Correspondent anvita.pillai@publish-industry.net Content Developer (Online & Print) Namrata Singhania namrata.singhania@publish-industry.net

» Artificial Intelligence Artificial Intelligence, digitalisation, analytics and automation are reshaping the future of the manufacturing industry. Digitalisation relies heavily on Artificial Intelligence to make automation intelligent. The forth coming issue analyses operational benefits, opportunities for businesses and how Artificial Intelligence is bringing about transformation and increasing efficiency, manufacturing quality, and more.

» Automotive & Machine Tools With the increasing solutions in the field of software and automation, there have been collaborative ways in which machines and people interact. With the growing industrial sector, digitisation is a pre-requisite for the fast-paced industrial sector, commoditisation, and price demands. The upcoming issue investigates the key drivers in automotive and machine tool manufacturing that will increase the speed and quality of new machine tools and process technologies.

» Wireless Automation With the manufacturing industry working its way towards entering “Industry 4.0” it is embarking itself into a journey to automate production, to make machines wireless, and to make operations smarter. The installed base of wireless IoT devices in industrial automation is resulting in intelligent manufacturing. The upcoming issue discusses the recent trends, advancement benefitting the industry, and future of wireless automation in the manufacturing industry.

Advertising Sales & Marketing Sagar Tamhane (General Manager – North & East) Contact: +91 9820692293 sagar.tamhane@publish-industry.net Dhiraj Bhalerao (General Manager – West & South) Contact: +91 9820211816 dhiraj.bhalerao@publish-industry.net Alok Kumar (Sr Manager – South) Bangalore Contact: +91 8861009443 alok.kumar@publish-industry.net Advertising Sales (Germany) Caroline Häfner (+49 - 89 - 500 383 - 53) sales@publish-industry.net Overseas Partner Ringier Trade Media Ltd China, Taiwan & South-East Asia Tel: +852 2369 - 8788 mchhay@ringier.com.hk Design & Layout Tarun Kumar Pyne Design Head (Print & Web) Editorial & Business Office publish-industry India Pvt Ltd 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001, Maharashtra, India Tel: +91-7410006435/36 Board of Directors Kilian Müller (CEO – Worldwide) Hanno Hardt (Head – Marketing & Business Development) Frank Wiegand (COO – Worldwide) Shekhar Jitkar (Publisher / Chief Editor)

COMPANY INDEX Name . . . . . . . . . . . . . . . . . . . . . . . . . Page ABB India . . . . . . . . . . . . . . . . . . . . . . . . . 30 B&R Industrial Automation . . . . . . . .Cover, 6, 7, 36, 54, 61 Balluff Automation (India) . . . . . . . . . . . . . . . 23 Bentley Systems . . . . . . . . . . . . . . . . . . . . . 10 Birlasoft . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Boston Consulting Group . . . . . . . . . . . . . . . 28 Contrinex Automation . . . . . . . . . . . . . . . 8, 39 Dassault Systèmes . . . . . . . . . . . . . . . . 11, 24 Delta India . . . . . . . . . . . . . . . . . . . . . . . . . . 3 HARTING Technology Group . . . . . . . . . . . . . 40 Hindustan Platinum . . . . . . . . . . . . . . . . . . . 10 HMS Industrial Networks . . . . . . . . . . . . . . . 33 Hummel Connector Systems . . . . . . Back Cover

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Name . . . . . . . . . . . . . . . . . . . . . . . . . Page IBM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Ifm electronic India . . . . . . 60, Back Inside Cover igus . . . . . . . . . . . . . . . . . . . . . . . . 2, 11, 61 IMTMA . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Industrial Cart FTF Revolution . . . . . . . . . . . . 44 Innovista Sensors India . . . . . . . . . . . . . . . . 15 Intech DMLS . . . . . . . . . . . . . . . . . . . . . . . 12 Kubler Automation . . . . . . . . . . . . . . . . . . . 47 LANXESS . . . . . . . . . . . . . . . . . . . . . . . . . 10 Maxon precision motor India . . . . . . . . . . . . 60 Mitsubishi Electric . . . . . . . . . . . . . . . . . . . . . 1 MurrElectronik India . . . . . . . . . . . . . . . . . . 29 Nord Drivesystems . . . . . . . . . . . . . . . . . 9, 61 Objectify Technologies . . . . . . . . . . . . . . . . . 14

Name . . . . . . . . . . . . . . . . . . . . . . . . . Page Phoenix Contact . . . . . . . . . . . . . . . . . . 17, 60 Pilz India . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Rittal India . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Rockwell Automation . . . . . . . . . . . . . . . 52, 56 Schunk Intec India . . . . . . Front Inside Cover, 61 SEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Sick India . . . . . . . . . . . . . . . . . . . . . . . . . 43 Siemens Digital Industries Software . . . . . . . . 10 Siemens . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Testo India . . . . . . . . . . . . . . . . . . . . . 41, 62 Topper Industrial . . . . . . . . . . . . . . . . . . . . . 44 Zenith Technologies . . . . . . . . . . . . . . . . . . 18

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A&D India | Jun-Jul 19


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A&D Jun-Jul 19  

With rapidly evolving automation technology that is increasingly becoming an absolute necessity than luxury, service providers are looking t...

A&D Jun-Jul 19  

With rapidly evolving automation technology that is increasingly becoming an absolute necessity than luxury, service providers are looking t...

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