Announcing Foundation for Smart Manufacturing (FSM)

IITD and AIA have launched the ‘Foundation for Smart Manufacturing’, a fully integrated smart manufacturing and learning facility for discrete and hybrid manufacturing segments such as automotive, machine tools, consumer durables and processed food, and others. The Government of India has approved this project as a Common Engineering Facility Centre (CEFC) under the Samarth Udyog Mission

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What is Foundation for Smart Manufacturing (FSM)?

Indian Institute of Technology Delhi (IITD) and Automation Industry Association (AIA) joined hands in May 2017 to set up a center under auspices of Samarth Udyog - a project of the Department of Heavy Industries (DHI). is center is called Foundation for Smart Manufacturing (FSM), and it helps, supports and develops technologies for right understanding and implementation of concepts of smart manufacturing.

FSM is a demo-cum-experience facility in North India, vests in extensive skill building, MSME consultancy, multi-academia partnerships and research which will give a huge fillip to the technology aided competitiveness of Indian manufacturing. The project will imbibe technologies from Europe, Japan, USA, and India.

‘Producing Smarter’ with Technologies

FSM has been launched specially for implementation of smart manufacturing in India which it undertakes to do effectively by:

  • Awareness Building

  • Prototype, Simulation and Testing Services
  • Consulting Services
  • Site Integration Services
  • Education and Training
  • Skills Certification
  • Job Work
  • Research

CEFC is proposed to comprise of a Cyber-Physical Factory at the Sonepat campus of IITD (30,000 sq. .) and a research laboratory at the Hauz Khas campus of IITD (1,500 sq. .) with state-of-the-art infrastructure, automation so ware and machines.

    Realising Dreams with CEFC

    Expertise and Excellence

    AIA in its quest to set up a Common Engineering Facility Centre (CEFC) at IIT Delhi has brought together experts from various industries in the sector of automation. These experts are looking forward to working together and use their industrial experience along various verticals to initiate smart manufacturing in India. The firms that have agreed to come together to set up the CEFC comprise of partners pertaining to technology & investment, simulation, integration and machinery, as highlighted below.

    AIA also signed an MoU with the Automotive Component Manufacturers Association (ACMA) to extend the bene ts of the CEFC to its member companies.

    The collaboration is aimed to provide multiple services to Indian industries, from ideation to implementation, and also to develop a national educational curriculum and skill building programme through a vibrant incubation and administrative environment.

    Mandated Guidelines

    • Awareness campaigns on Industry 4.0
    • Training for master trainers
    • Active participation provisions for start-up / incubators
    • Hand-holding of SMEs to plan and implement relevant Industry 4.0 projects to be done through consultancy services on a chargeable basis
    • Collaborating with neighborhood universities for student training/internship programmes
    • Involving industry in SPV membership model for sustainability
    • Participating in a Government-formed platform for Industry 4.0
    • To make adequate provisions for e-waste management
    • Involving as many clusters of ‘capital goods’ as possible

    Repertoire of Technologies

    Industrial IoT and Cyber Physical Systems

    Manufacturing is a process that converts raw materials into physical products in factories by managing resources with best automation practices available.

    Today, drivers such as technology, sustainability, optimization and the need to meet customer demands have once again encouraged the transformation of the manufacturing industry to become adaptive, fully connected and aware of its own potential. One of the most significant trends in manufacturing is of improved information technology solutions involving the union of conventional automation with information technology.

    Advanced Simulation and Digital Twin

    The digital factory concept offers an integrated approach to enhance product and production engineering processes, and simulation is a key technology within this concept.

    Simulation helps to create digital models of products, production systems, and logistic systems so that one can explore a system’s characteristics and optimize its performance. These digital models have the ability to run experiments and what- if scenarios without disturbing existing production systems or - when used in the planning process - long before the real production systems are installed. Extensive analysis tools, such as bottleneck analysis, statistics and charts give us an opportunity to evaluate different manufacturing scenarios.

    Wireless Instrumentation

    Wireless products have fundamentally changed our lives - and they are also playing an increasingly important role in the industrial environment. Here too, the enormous potential of wireless technology opens up totally new perspectives.

    In the new connected world of smart manufacturing, industrial wireless instrumentation is rapidly becoming the technology of choice for a growing class of applications. It is quickly gaining relevance in automation applications. In some applications, it is not the amount of data that poses challenges, but the distances to be bridged. Whenever the plant architecture does not allow conventional wiring, values are only accessible through frequent visits to the field. Wireless instrumentation can be a solution to one such problem.

    Rapid Prototyping and Tooling

    A key component in making Industry 4.0 a reality are machines that can produce the desired components faster, more flexibly and more precisely than ever before. Also, consumers want products that reflect their individuality.

    Moving away from traditional brand loyalty, they prefer loose relationships with multiple suppliers who can provide increasing levels of product personalization, from fashion and apparel to homeware and furniture, from automobiles to fast-moving consumer goods. To drive this interaction, consumers are accessing ever more intuitive websites to move back along the supply chain, becoming part of the product design function of a business and providing design intent for products that have yet to be manufactured.

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    Collaborative Robots

    Until now, industrial robots always worked separately from humans in specially safeguarded protected spaces. Improved safety technologies have broken down this barrier with a new generation of collaborative industrial robots.

    Collaborative robots sometimes also known as ‘cobots’ for short, are the robots that are capable of human-robot collaboration (HRC) and work hand in hand with their human colleagues. Human-robot collaboration is thus combining the best of two worlds: humans with their superior creativity and cognitive abilities and the robot with its greater repeatability, strength, and precision.

    Smart Sensors, Actuators, and Controllers

    Networked production and control processes in complex machine environments determine the industrial future and make Industry 4.0 possible in the first place. Smart sensors already today support dynamic, real-time-optimized, and self-organized industry processes.

    They record real operational statuses, turn these into digital data and share them automatically with the process controller. e added value of sensor communication depends significantly on the quality and reliability of the delivered data.

    Augmented Reality

    Augmented reality (AR) is the integration of digital information with the user’s environment in real time. Unlike virtual reality, which creates a totally artificial environment, augmented reality uses the existing environment and overlays new information on top of it.

    AR is taking information that is found in a variety of applications, such as maintenance records, inspection, and repair manuals and engineering specifications, compiling it and displaying it on the physical features of the thing or machine. Moving the smartphone or tablet around the object to show different views reveals new information related to the object’s features.

    Analytics and Manufacturing Operations Management

    The core idea of Industry 4.0 is being connected with intelligent products that communicate with users or other products, enabling new digital business models that shall harness collected data to o er additional services which will lead to the formation of a fully digital value chain.

    The digital universe is expected to grow to around 40 zettabytes (40 trillion gigabytes) by 2020. Embedded systems data in the Internet of Things is expected to grow from just two percent of the digital universe in 2013 to 10 percent in 2020. e sheer volume of data created within the Internet of Things is so enormous in scale that it cannot be comprehensibly processed in conventional databases. Detailed and complex nature of data captured by intelligent devices demands advance analysis to derive value out of it.

    Cyber Security and Mobility

    The ongoing development of the automation landscape with Industry 4.0 means that companies are faced with new security challenges. Smart manufacturing involves a tremendous amount of data, demanding a significant IT commitment to securely manage it all.

    Moving to an in-house smart network as the backbone of an entire business operation raises alarm bells about security - the network must be impenetrable at all times and at all costs. In fact, network security is considered as today’s leading point of discussion about a wholesale adaptation of Industry 4.0.

    Industrial Safety

    The world of automation is merging with the IT world. Safety and security is an important prerequisite for the function of Industry 4.0 systems, which in contrast to traditional production plants have interfaces to their environment.

    In future, Industry 4.0 systems will be reconfigured and optimized autonomously - i.e. by the system itself during operation - so this requires a reassessment of safety and security during runtime. It must also be ensured that no unacceptably high safety risks will arise as a result of residual security vulnerabilities. Ultimately, confidence building on this issue should be supported among small and medium-sized enterprises, as the crucial basis for production in ad-hoc networks. Transparency, participation and open communication are important prerequisites in this regard.

    Remote Maintenance

    Before the advent of Industry 4.0, the service technicians used to drive to customers to maintain or repair machinery and equipment while o en following a route that is dependent on a de ned preventive maintenance schedule.

    The prevalence of Industry 4.0 in manufacturing and production could possibly change that as it allows setting up secure remote access to distributed assets. is can help machine and equipment manufacturers to effectively optimize maintenance while offering the best possible maintenance support. Instead of having to drive to the customer’s premises when after-sales services are required, the service technician can access the customer’s machinery remotely in order to diagnose the source of the problem or to support the customer during installation and maintenance. In both cases, the customer benefits from a quicker response and completion times for services and problem-solving.


    Client Services

    Technology and Cloud Licensing

    High-end computing facility is available for users to install their cloud applications at nominal charges.

    Consulting

    The domain of smart manufacturing is expected to open up a new opportunity in industrial consulting, especially with regards to identification and removal of bottlenecks in current operations. e CEFC multi-disciplinary teams will undertake feasibility surveys, ROI analysis and process improvement studies for clients, prior to implementation and also post-implementation.

    Skill Certification

    It is expected that skill councils such as Automotive Skill Council, Capital Goods Skill Council, Industrial Automation Skill Council and Tool Rooms will be creating their unique set of role-based competencies.

    The CEFC will offer them and their training partners, a gap filling option for theory and practical, and a brand-agnostic independent certification.

    Testing

    The testing service will enable clients to test and debug problems before installing the solution at the site.

    Education and Training

    Short-term education and training courses will be offered along with online learning and assessment tools to educators and users on a chargeable basis. All the 12 technology streams will be covered.

    Simulation

    The CPS facility and the associated technologies will provide a one-stop shop for users whose needs cut across multiple disciplines and who wants to witness a comprehensive digital transformation before taking up for actual implementation. is will enable clients to experiment and innovate with an appropriate mix of standard and customized solutions.

    Site Integration

    Many times, clients wish to test out the ‘proof-of-concept’ on their actual production lines. The CEFC team assigned to the client during concept formulation will undertake such site activities with a pool of industry

    Prototyping

    The research team will help users to bring in uniqueness into their solution while providing adequate safeguards for IP protection. Users can sponsor prototyping or R&D projects as per their need.

    Research

    Fundamental and applied research on various technologies associated with the implementation of smart technology-enabled manufacturing will be carried out in the CEFC, enabling easy penetrating of the state-of-the-art technologies to the industries.

    Awareness Building

    The initial period will be utilized for demonstrations, surveys and sensitization of various stakeholders to the possibilities of adapting the proposed solutions to the immediate needs of users. 


    How How does the manufacturing and commercial landscape change in India due to I4.0/IIoT?

    The actual enabling and game-changing opportunity lies with the international producers, domestic producers and domestic consumers in India and therefore has a direct impact on our landscape for production and consumption.

    All the cost and pain to build and sustain the classic existing models of production and consumption can be circumvented, given the huge demand on all kinds of resources in our country.

    I4.0 and IIoT can build a better country, market, decentralise opportunities for the betterment of our populace.

    How can we embrace or implement I4.0 or IIoT in India? 

    It is very important to dispel that I4.0/IIoT are some distant e actual enabling and game-changing opportunity products or compliances.

    They are opportunities wherein current and future-to-be products, technologies, goods and information are so networked in ingenious ways so as to render our products and services to be better.

    This has to evolve from the very ground where such services and products would be produced and consumed.

    We can learn, understand, modify and create through our own ingenious ways and means to meet out the changes.

    There needs to be a good amount of learning, discourse, joining of hands, experimentation and participation from all walks of life to make it happen in India.

    How can you be a part of this initiative?

    If you are an individual or an institution who is interested in benefiting from the services of the Foundation for Smart Manufacturing or contribute to the Inian growth story through smart manufacturing, simply write to us at info@iafsm.in

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