IITD-AIA FSM, IIT, Hauz Khas, New Delhi

11:00 am to 01:30 pm, Friday, 11th of October 2019
Venue: Seminar Room 422, Block 2, Mechanical Engineering Department, IIT Delhi

IITD-AIA Foundation for Smart Manufacturing curated a unique event to generate fresh perspectives on the future skills, create opportunities to learn, address issues of relevance and enhance collaboration. In an exploratory meeting with Academicians from Engineering Institutes & Universities of Northern India, following shared concerns were discussed:

1. CURRENT STATUS OF EDUCATION IN INDUSTRIAL AUTOMATION

2. FUTURE TRENDS IN DIGITALISATION AND IMPACT ON INDUSTRY

3. IMPACT ON CURRICULUM AND TALENT DEVELOPMENT

4. ROAD AHEAD - CREATING A COLLABORATIVE INITIATIVE.

The keynote set by Mr. Anup Wadhwa (Director Automation Industry Association) stressed that it is crucial for engineers and teachers to be curious and SAMARTH.

Taking forward the central theme, Dr. Sunil Jha (Professor, Mechanical Dept, IIT Delhi & Director IAFSM) presented how IITD-AIA FSM (IAFSM) has strategized a way forward to Inculcate SAMARTHTA in the stakeholders involved in this transformation.

To view the Presentation, click here.

Emphasising that the key is to collaborate & build a pool of academicians who together would co-create and help in generating snowball effect, Dr. Jha shared and demystified key Industry 4.0, technologies & services that are going to form the backbone of new skills.

Mr. Ravi Agarwal (President AIA & Managing Director P+F) moderated and steered a panel discussion on an inclusive subject “CREATING TOGETHER, FOR INDIA”, and emphasised on the need to further develop similar platforms which would interest Tech-savvy millennial who otherwise get impassive. Dr. Sunil Jha present as a panelist agreed and shared his experience with students at IIT Delhi in various labs and in contrast how a new unique experiential learning methodology at FSM in IITD has become a stimulant for engineering undergraduates to be curious. Mr. Vangapandu Venkata Nagaraju (Raj) (President of Federation Of Innovation & Entrepreneurship) an Aerospace Engineer by education & young serial entrepreneur, shared how they observed lack of technological awareness or utilisation in Indian SME sector and how their Indo- European Synergized program leveraged EdTech to successfully Implement Mechatronics oriented Program In collaboration with the State Government of Andra Pradesh. He also proposed to co-create similar program in collaboration with FSM for any institute looking to strategise in this area.

Panel discussion was followed by an experiential session of Industry 4.0 technologies at FSM Cyber Physical Lab. Academicians from various technological institutes participated and could assimilate demos on key technologies of Industry 4.0 by FSM Team.

The event concluded with a session moderated by Mr. Anup where academicians shared their ideas, concerns, challenges and experiences. A consensus was built to take the initiative forward and to organise activity on their campuses to start building awareness on Industry 4.0| SAMARTH Udyog.

All nations are talking about the storm of Smart Manufacturing / IOT / Industry 4.0. Classical models of manufacturing and business are giving way too much more collaborative, self-aware, innovative and productive techniques, using data sourced directly from sensors, machines, vendors and customers. This has a direct impact on competitiveness and quality of goods and services of an enterprise. Samarth Udyog is the goal of the Indian Manufacturing Ecosystem and is achievable in a manner that works for you. To strengthen the ‘Make in India’ eco-system with adoption of smart technologies, the Automation Industry Association and IIT Delhi have created a Special Purpose Vehicle, called the Foundation for Smart Manufacturing (FSM) to take the emerging wave of Smart Technologies and adapt it with relevance to the needs of grass root manufacturing in MSME and talent incubators in Educational and Vocational Institutes. Delivering consistent quality backed by stringent norms through the production and manufacturing pipeline, right from raw material sourcing to finished product delivery for the quality conscious end user, it is essential that Indian industry aligns itself towards adopting newer and tested quality assurance practices. To facilitate, introduce and enlighten industry with an evolved genre of quality focused smart manufacturing, Quality Council of India supported by IITD-AIA Foundation for Smart Manufacturing conducted an awareness workshop with hands-on exposure in the FSM Cyber Physical Laboratory.

PROGRAM

PROGRAM OVERVIEW

Inaugural Theme: Global Smart Manufacturing Scenario and Implications for India - Manufacturing industry is responding to consumer and environment demands with a high degree of technological innovation that is being fuelled by the rapid convergence of Information and Automation processes. The competitive equation is no longer determined by low wages. It is being replaced by speed, flexibility and first-time right abilities.

Technical Theme - 1: Role of Sensors, Human-Machine Interaction, Precision Control in the Quality Journey - Quality assurance is largely a function of the material processing and inspection functions, whereas cost competitiveness is largely a function of idle time reduction and waste elimination. Sensors are the 24*7 watchdogs, measuring every minute aspect of operation. Information that is relevant for automated control is passed on to PLCs or Servos, whereas information to alert and guide plant personnel is presented via appropriate Human-Machine interface devices. This session was aimed at helping participants understand the various classifications of Sensors, HMIs and Control Systems used in modern machineries.

Lab Session - 1: Familiarisation with the Building Blocks of Smart Automated Machines - This session offered a practical and live demonstration of a smart machine, built for precision assembly. Lab facilitators provided a hands on opportunity to participants to experience Presence Sensors, RFID, Vision Systems, Touch-screen interactive HMIs, Process and Motion Control Systems that are deployed globally in Smart Automated Machines

Lab Session - 2: Familiarisation with Collaborative, Digital, Engineering and Asset Management Tools - This session offered a live demonstration of software tools and cloud-based services. With the help of simple case studies, participants experienced how physical components are converted into ‘digital’ format and presented for human collaboration. Among the tools demonstrated were 3D Visualisation, Augmented Reality and Real-time Analytics.

Technical Theme - 2: Demystifying the Digital Thread and ‘Anywhere’ Data - Possibilities of Cyber Physical integration are increasing rapidly because of the rapid deployment of cloud based digital platforms. It is now possible for people to collaborate sitting far away from each other. This session helped participants differentiate general IoT platforms with IIoT platforms. Covering relevant digital services for manufacturing such as deployment of Augmented Reality and Analytics.

Panel Discussion Theme: Organisation Assessment and Road Map for Samarth Udyog / Smart Factory - The indicators of ‘Samarth Udyog’ or Smart Factory presented by panelists and were discussed in an open house format. This session was aimed at providing participants an opportunity to explore a few relevant steps they can initiate in their existing roles, to prepare for the journey into Smart Manufacturing.

EXPECTED PARTICIPANT PROFILE

Reported Takeaways

Participants who attended this programme reported receiving a balanced view of the fundamental shifts taking place relevant to the Indian ecosystem.

A consequence of being exposed to the possibilities of ‘Digitalisation’ - its benefits as well as key challenges involved.

Enlightened with a basic framework of readiness for Industry 4.0.

While participants who had their internal systems and budgets already set for improving quality and transparency were guided by experts and encouraged towards identifying teams, technologies and detailed engineering needs for conducting proof-of-concept activity.

Smart Manufacturing

The “Digital” storm and the manufacturing world is agog with the rapid changes that are transforming the international manufacturing scenario. Technology is forcing huge disruptions in the classical models of global commerce. India being one of the biggest markets in the world with an equally strong bedrock of potential in manufacturing, cannot stay aloof from these winds of change which are forcing readjustment of the sails elsewhere.

Samarth Udyog is an initiative by the Government of India that bridges the awareness and actual technology gap to enable Indian companies to participate and play an important role on the global stage of manufacturing. To strengthen the ‘Make in India’  eco-system with adoption of smart technologies, Industry and IIT Delhi have created a Special Purpose Vehicle, called the Foundation for Smart Manufacturing (FSM) to take the emerging wave of Smart Technologies and adapt it with relevance to the needs of grass root manufacturing in MSME and talent incubators in Educational and Vocational Institutes.

IIT Delhi, a pioneer institute leading excellence in engineering education & research organized the annual Industry Day, inviting Industry, Technologists, Consultants, Researchers and alike for interface with the best in Industry and Education

This years’ theme was “Smart Manufacturing”, with Live Demos those of Smart Factory Modules assembled / developed at
“FSM” IITD-AIA Foundation for Smart Manufacturing

Some of the marquee Industry participants were
TCS, IBM, JCB, Ansys, AMAT, Tata Chemicals, UTStar, Maruti Suzuki, TEVA & others
Chief Guest : Mr. R. C. Bhargava, Chairman, Maruti Suzuki

PROGRAMME SCHEDULE

For more Information write to us at info@iafsm.in

Mr Dilip Sawhney, delivered the keynote address on the theme,  'India Specific Challenges'.

Manufacturing is acknowledged as a developing country's stable engine for economic growth. For the economy to grow, manufacturing vision must be fuelled by innovative and creative leaders, said DrKalam, at a recent forum of Automation industry leaders.

Manufacturing companies looking for sustainable competitive solutions can draw inspiration from that vision. In an era where reduced budgets limit the scope for trials and error, Automation Tech 2013 served a timely reminder for manufacturing leaders to be future ready. On Friday, the 18th October, the link between Manufacturing Competitiveness and Automation was explored at the Automation Tech Conclave, organised by AIA in Pune.

In his opening address, keynote speaker Mr K Nandakumar, President, Automation Industry Association drew an analogy from America’s School for War, saying “It’s a world of VUCA (volatility, uncertainty, complexity, ambiguity). To sustain the VUCA world, we must be conscious of how we Manufacture. Feed into the Global Grid, shape Consumer demand, reform Governance and Price our Planet. Presenting an appropriate definition for Automation, he said, “It is the Industrial Infrastructure that delivers ultimate customer experience making positive difference in the Community.”

Padmashri Dr Vijay Bhatkar, Chairman, Board of Governors, IIT Delhi, and known for his path breaking pursuits in Government, Industry, R&D and Academia, was the chief guest. “In Automotive we have transformed from total backwardness.  Ability to add value in manufacturing is important for manufacturing industry to thrive. Whenever we have had a challenge or have been denied anything we have responded. The present time offers an opportunity to create intelligently designed machines to add intelligence on the matter and the energy we process. In the future we may be able to think and control. I would like to see Automation peaking in the city of Pune, which is also the Engineering Capital of India.”

Sanjay Kachre, Head Operations at Kimberly Clark shared how automation strategies impact all manufacturing, because complexity of operations continues to increase. To make the transition to Sustainable Manufacturing, Kachare said “the increasing need for energy efficiency, emissions monitoring, regulatory tracking, process changes, packaging changes, asset upgrades, and new controls and metering places greater demands on Design and Engineering teams to collaborate in bringing new functionality and enhanced visibility to Manufacturing Operations.”

Vishwas Chitale, Director & CTO Chitale Dairy emphasised that holistic use of automation across the entire business process is warranted. He shared how his business is managed with dynamic Business Intelligence Dashboards that provide drill down capability to view and analyze cost and production information coming in from real-time data collectors. “It’s not all over yet,” declares Mr Chitale, “we aim to connect the cows to the cloud.”

Nidamaluri Nagesh, a recipient of the prestigious Boss Kettering Award for Innovation on Collaborative Robots and currently Sr GM with Mahindra Vehicles, dealt with Automation Game Changers, Connected Manufacturing and Disruptive technology. Quoting a Gartner report, Nagesh emphasized "Over 50% of internet connections in the PLANT are THINGS. Manufacturers need a fully connected enterprise to compete in today’s global economy. They need to connect their manufacturing operations and business systems while sharing performance data with machine builders and tier suppliers to improve processes, increase production and reduce risk.

At Autom@tion 2013, global technology giants like Microsoft, Rockwell Automation and Siemens also pitched in with their sneak previews of future automation technologies.  To sum up, Autom@tion Tech really showed how Automation is a hidden value amplifier and how manufacturing businesses can unlock profit potential with real-time decision power. AIA also launched its news magazine, Automation India, introduced as an open and collaborative forum to share unique experiences and challenges.

Program Details

In the current market scenario, automotive manufacturers and their supply chain partners, are experiencing swings in market demand, that pose a special challenge for sustainable growth. Manufacturers envision a flexible setup that is cost competitive, yet capable of rapid multi model adjustments.

This strategy translates into 4 specific goals that manufacturing engineers, production engineers, shop floor staff and automation engineers can collectively pursue.

• Innovation for flexible manufacturing that can cater to changing model demands from the market & also should be easily adaptable to manufacture new models & variants.
• Innovation for sustainable process improvements based on real-time tracking & tracing to achieve manufacturing transparency & reduce waste in manufacturing.
• Innovation for sustainable Energy Efficiency and recycling, in manufacturing processes.
• Innovation for improving the Safety & Environment standards that motivates a new generation workforce.

Based on the innovation strengths of in-house teams, we receive small to mid-sized projects the Industry. This year the AIA team received nearly 40 cases which were evaluated, All leaders selected for felicitation will also be supported by AIA and its member companies in pursuing further experimentation and innovation.

Participants will return home:

• inspired with new ideas for optimizing their plant operations
• with ideas for potential upgrading of their equipment
• with a valuable network on a managerial level

Special Session - Sustaining Good Performance with Grassroot Innovation( At Seminar Area, Hall No. 3)

• 03:00 pm - 04:00 pm  : Theme address and Panel Discussion
• 04:00 pm - 05:15 pm  : Case discussions and facilitation
• 05:15 pm - 06:00 pm  : Felicitation and award of Innovation Trophy

Eminent experts from the Automation Industry have shared their success stories, insights and inspiration with leaders in the Manufacturing Industry. The conference was held as a concurrent event of the India Manufacturing Show .

The manufacturing industry, as the backbone that defined India’s growth in the 1980-90s. While India gained global prominence due to the rapid growth of the service Industry, the manufacturing industry has all the qualities to further enhance the economic development of the country. In fact, it is this sector that is fueling growth, employment and enhancing the other industries such as agriculture and service. To accelerate the efficiency and competitive performance of the manufacturing industry, it is essential to modernise their infrastructure. Now more than ever before, industrial enterprises and utilities rely on their control systems to improve their reliability and efficiency.

Automated, Flexible, Synchronised and Efficient Production Systems are in demand to execute innovative business strategies and sustainable operational practices in manufacturing and improve value for the ecosystem. Industrial Automation is the emerging technology infrastructure for a robust and sustainable economy.

The themes were discussed at the Conference:

The AIA President delivered the keynote address at the ARC Forum on July 6, at Hyderabad on the theme, 'Transforming Industry and Infrastructure'.

In today’s competitive market, the company that stands out is the one which has been able to use technology in a creative and innovative way. This event was an effort, recognized how automotive middle-level management equivalent of plant managers and general managers created excellence through innovation in their plants.

In keeping with the overall theme of “Manufacturing Excellence”, on Day-2, this sub-event was aimed to celebrate the achievements and experience of plant managers using Automation creatively in their manufacturing processes.

This event had provided a forum where seasoned automotive specialists can engage in an exchange of ideas with each other; aknowledge sharing opportunity. Managers from across the automotive manufacturing spectrum have had the opportunity for their hard work and creative passion recognized and celebrated. Format- These managers had presented their experiences in Quality, Safety, Energy Efficiency, Environment Protection, Productivity and Value Improvement etc and illustrated with examples how they have creatively used Automation in true-life situations or have overcome some specific challenges with technical creativity enhancing plant performance and efficiency.

The cases were reviewed and judged by eminent jury members

Mr. Mukund V. Mavalankar
Director Technical
Bharat Forge Ltd

Mr. Dilip Sawhney
Regional Director, Rockwell Automation India Pvt. Ltd. 
Executive Council Member, Automation Industry Association

Mr. Sandeep Balooja
Group President Business Development, Anand Group
Chairman, ACMA - Western Region

Prof. Sudhir Agashe
Head - Dept. of Instrumentation & Control
College of Engineering, Pune

Dr. Mohan M. Godse
Vice President, Product Development - Casting
Endurance Technologies Pvt. Ltd.

About 100 attendees from the region’s major user groups - OEM, Tier 1 vendors, system integrators, and machine builders were there, making it a great place for networking, sharing ideas, celebrating success, building relationships and learning about developing initiatives. The program’s collaborative nature enabled the participants also to learn from one another. 

It aimed to create a motivating environment and built credibility and profile.

Participants returned home:

… inspired with new ideas for optimizing their plant operations

… with ideas for potential upgrading of their equipment

… with a valuable network on a managerial level

Awardees Receive

Boost your profile – The program is an excellent means of raising individual as well as company profiles. Awardees and winners receive widespread media coverage about their achievements.

Establish credibility – This is the chance to prove that you and your company are worthy of competing on the world stage.

The AIA President, Mr V. V. Paranjape delivered the keynote address at the ARC Forum on August 2nd, at Pune, addressing the theme 'Gaining Sustainable Competitiveness and Achieving Operational Excellence.', Mr Paranjape focussed on the Digital Manufacturing Vision, its impact and challenges.

Operational excellence is an ongoing process even in the best of times and in today’s integrated and turbulent world, the need for companies to pursue continuous improvements is even greater. How companies design, engineer, source, make, and distribute products, and manage their assets, ultimately determines their success. Playing a crucial role are the people and processes, well supported by enabling technologies

India’s automotive, auto components, and machinery industries, which are poised to post robust growths in the years to come, have opportunities to emerge as best-in-class. While domestic demand drives industries’ growth, their challenge is protecting their margins and gaining global competitiveness. The entire Design-Operate-Maintain cycle will need to be continuously addressed to discover newer ways to delight consumers and gain competitiveness. There is a constant need to channel investments into systems and solutions and adopt best global industry practices in order that greater operational performance levels are achieved.

Shortening design and engineering cycle times is critical to reducing manufacturing costs, which essentially means reduced iterative actions necessary to design, manufacture, and deliver products to consumers. Manufacturers will need to invest in technologies and solutions leveraging digital manufacturing, third-party product engineering services, and collaborative production management (CPM/MES) systems, backed up by state-of-the-art factory automation, and supply chain and product life cycle management systems. OEMs must have state-of-the-art plant-floor automation systems and integrate them with enterprise and other decision support systems.

AIA Working Group for Automotive

Besides its own events and Round Tables, AIA supports many initiatives such as the ARC Forum, the Automotive Engineering Show and the AIEC - AIA Skills Enhancement Centre. We have.constituted a Working Group to advise and lead Automation related initiatives specially tailored for the Automotive segment. The group members are listed below

‘SME India Outlook 2011’ has disclosed the opportunities that Small & Medium Enterprises (SMEs) in India can leverage for operational excellence, through smart IT & Automation technologies.

AIA was a knowledge partner for this event. AIA members serving the SME sector were invited to participate and showcase best fit technologies and solutions.

Achieving Operational Excellence in Manufacturing
by V Srinivasan
Managing Director, India
Invensys India Pvt. Ltd.

K Nandakumar
Vice President,
Chemtrols Industries Ltd

D Hambardikar
Messung Systems Pvt. Ltd.

Milind Kulkarni
A&D Division, Siemens Limited

A Thought Leadership Discussion was held on 17th May 2010, the concluding day of the Automotive Engineering Show at Chennai. The panel comprised Manish Ramakrishnan, Sr. Manager, Ashok Leyland, Satish Ansingkar, Vice President Sales, B&R Industrial Automation, Jitendrakumar Kataria, MD, Beckhoff Automation Pvt Ltd and Sudhir Bachloo, Sr. Manager Automotive (Business Development) Siemens Ltd. The discussion was moderated by Anup Wadhwa, Director, AIA.

Excerpts from the discussion:

Anup Wadhwa

The evolution of Automation technologies has gained considerable momentum over the last decade, giving rise to a host of new hardware and software features. Is India’s Automotive Industry at par with the developed world, in the deployment of Automation?

It seems both sides are not satisfied with the current gaps in the engagement process. Are we stuck with an entrenched practice or is there an alternate approach to look at?

Jitendrakumar Kataria

The adaptation in India is slower. There is fear about being able to deploy fast changing technologies. People training is yet to become a high priority, so the necessary ground work needs to be laid at the college level itself.

Manish Ramakrishnan

Real-time Factory Automation is yet to emerge as a full-blooded engineering discipline. There are a very large number of automation vendors coming to meet us; which is a good sign, but what they are selling is technology in isolation. We would like to see sales teams sit with us at the design level and show us exact deployment.

Satish Ansingkar

There are independent hardware suppliers, machine builders and integrators They respond to unconnected specifications and acceptance procedures. Very often the different entities within a supply chain operate completely independent of the main OEM while determining the specifications of Automation investment. We welcome more discussions on application needs before the commercial dialogue.

Manish Ramakrishnan

The wish list for us would be to maintain our assets in good shape for achieving High Line Throughput, Multiple Model Flexibility, Total Cost Reduction, Technology absorption and skill upgrade. If we can do all this we get to be very competitive. Better visualisation is useful. Safety integrated into controllers are very important. RFID applications are being used in axle and engine making lines for automated tool selections. But RFID based tracking in assembly operations is still under evaluation.

Sudhir Bachloo

Wireless and mobile HMIs are going to increasing operator convenience. And if genealogy is to be captured with read / write operations, or if tagged items have to pass through high temperature zones, RFID is increasingly becoming relevant.

Automation Industry Association (AIA) worked as the knowledge partner for a Workshop on Process Control Instrumentation and Process Optimization in Fertiliser Industry