AUTOMATION & DIGITISATION€¦ · Interview with Manish Walia, e 8 ools 40 g N n L 0 w . u n EM -In...

A&D - InterviewFathe Raj (F R) Singhvi,Joint Managing Director, Sansera Engineering (p. 24)

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The biggest challenge for India’s economy today is to raise the GDP growth to a sustainable 6-7% in 2020-21. The Union Budget 2020-21 is a mixed bag on this count. Largely, the Budget has addressed the need to fuel growth and development, and corporates have little reason to complain. It aims to holistically build the nation’s economy in the long-term by ensuring a progressive policy framework. The focus is clearly on boosting economic growth, with announcements of several measures for infrastructure, agriculture and rural development, setting up of data centre parks across India, simplification of taxation regime, emphasis on the manufacture of electronic items to harness export potential, easing of taxation on start-ups, rationalisation of personal income taxes, among others. The proposal to set up large solar power capacity alongside rail tracks and enabling farmers to set up solar power generation capacity on their barren lands will open up immense growth opportunity for the renewable energy sector. It’s encouraging to see the importance given to technology adoption, capacity building, higher education and skill development.

Although the industry welcomes this Budget now, the immediate impact on corporate bottomlines is not clear. The picture will only become clear as companies or individuals come to grips with the new systems. Manoeuvring the policy framework, balancing the needs of economic revival amid very limited fiscal space will be quite a challenging task for the government. It needs an immediate concrete action-plan to determine the way ahead. The outcome will be determined by effective and accurate implementation of the measures announced. Till then, let’s all contribute towards building a globally competitive and innovation-led economy!

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Building a globally competitive & innovation-led economy!

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D P V SivaramChairman - Non Executive B&R AutomationPresident - AIA

Ravi AgarwalManaging Director, Pepperl+Fuchs (Factory Automation)Vice President – AIA

Raj Singh RatheeManaging DirectorKuka Robotics India

Anup WadhwaDirector – AIA (Automation Industry Association)

Jasbir SinghVice President – Electrical & InstrumentEssar Project Management Consultants

Ganapathiraman GVice President & GM (South and South-East Asia)ARC Advisory Group

Arcot RajabahadurAutomation Consultant

Mandar PhadkeCEO, Abhisam SoftwareFormer Head – Process ControlLanxess India Pvt Ltd

Dr KLS SharmaAdvisor Automation Education & Training

Thampy MathewManaging Director, Pepperl+Fuchs India (Process Automation)

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AUTOMATION & DRIVES

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A&D - Intervi

ew

Rebecca Liebert,

President &

CEO,

Honeywell

UOP

(p.30)

VIEWPOINTCollaborative

Robots P. 32

Power & Energy P. 4

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VIEWPOINT Sensors in

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Automotive &

Machine Tools P. 42

A&D - Interview

Rolf Najork

President of Executive Board,

Bosch Rexroth AG (p.32)

A&D - Interview

Hans Bangert

Managing Director,

Bosch Rexroth India (p.32)

A&D - Interview

Marc Jarrault

Managing Director,

Lapp India (p.34)

SMART OPERATIONS

Recipe for success AUTOMATION & DIGITISATION

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Scope in the Manufacturing Industry


A&D - Interview

Akilur Rahman,Chief Technology Officer,

ABB India (p.28)

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automotive sector P. 30

Food & Beverage Processing P. 34

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OT & IT COLLABORATIONUshering new business models


A&D - InterviewIndraneel Chitale,Partner – Chitale Group

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EM - Interview

Viraj Kalyani,

Founder & Chairman

Kalyani Studio (p. 28)

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PRINCIPLES, APPLICATIONS AND DIRECTIONS

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Dr Nagahanumaiah,Director,CMTI (p. 28)

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What drives the sector

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EFFICIENT MANUFACTURINGwww.industr.com/en

EM - InterviewSanjay Chavre,Sr Development Officer, Dept

of Heavy Industry – Ministry

of Heavy Industries & Public

Enterprises, Govt of India (p. 30)

FOCUS Automotive Plastics P. 40

VIEWPOINT Industry Associations – Bringing the sector closer P. 32

DRIVES & COMPONENTSDrive technology and conveyor belts – Through terrains & populated regions

44

FOCUS MACHINE-CENTRIC ROBOTICS REVITALISING PHARMA PACKAGING

CONTENTSMARKET 12 NEWS

16 “The focus is to keep exploring new opportunities & trends”Interview with Manish Walia, Business Head – Industrial Automation Solutions, Delta Electronics India

17 “Automation is set to drive productivity in the country now”Interview with Vikas Garg, Managing Director, Rexel India

START-UP

18 “One can be a leader if he innovates faster”Ankur Jain,Founder & CEO, UdyogYantra Technologies

VIEWPOINT

30 Union budget 2020 – Impact on the manufacturing sectorThe Viewpoint section finds out how Budget 2020 will revive the economic growth in India

EVENT REPORT

47 The roadmap of digital transformation: Need and future scopeA post-event report on the recently held ‘Digital Transformation Forum’ by Rockwell Automation

50 Hannover Messe 2020: How change becomes growthA preview of the world‘s largest show on engineering technology

MANAGEMENT INTERVIEW

28 Industry 4.0 and IoT will become a necessity to run the businessFathe Raj (F R) Singhvi,Joint Managing Director, Sansera Engineering

LEADERSHIP INSIGHTS

20 “Leading the unconventional way!”Vineet NayarFormer CEO, HCL Technologies & Founder, Sampark Foundation

Expanding the field of vision

INTEGRATED MACHINE VISION More than embeddedComplete portfolio: www.br-automation.com/vision UV IR

FOCUSMachine-centric robotics revitalising pharma packaging

34

22COVER STORYOptimising asset design & operations – Pushing boundaries of performance

FOCUS MACHINE-CENTRIC ROBOTICS REVITALISING PHARMA PACKAGING

COVER STORY

22 Optimising asset design & operations – Pushing boundaries of performanceThe bigger picture of shared model design

engineering and how it can bring in

operational optimisation

FOCUS PHARMACEUTICALS & PACKAGING

34 Machine-centric robotics revitalising pharma packagingThe various ways machine-centric robotics are aiding the pharma industry process

TECHNOLOGY SOFTWARE & ENGG TOOLS

38 Acquiring centralised data analyticsHow TwinCAT Analytics makes engineering more efficient with automatically generated dashboard

DIGITALISATION

42 Digital transformation – Way forwardTrends in digital transformation and how it can be successfully achieved

DRIVES & COMPONENTS

44 Drive technology and conveyor belts – Through terrains & populated regionsTasks that came into play while building a conveyor during various projects presented to BEUMERNew Products

52 RFID enabled access permission system; Compact motor-mounted drives; Circular multi-bushing with gel technology

53 High-speed rigid exterior doors; IE3 asynchronous motors; IIoT-ready controller

54 Gear service life calculator; Universal grippers; Insulation monitoring solution

Columns07 Editorial 08 Contents 10 Guest Editorial56 Highlights – Next issue56 Company index

Advt

Expanding the field of vision

INTEGRATED MACHINE VISION More than embeddedComplete portfolio: www.br-automation.com/vision UV IR

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GUEST | ED I TOR IA L

A&D I nd i a | Fe b -Ma r 2020

The Jetsons, the popular sci-fi cartoon set in the year 2062, quickly became synonymous with the future. The future seemed promising; the nuclear family lived in a luxury smart home with a robotic housekeeper. While some elements of the Hanna-Barbera cartoon haven’t become a reality yet, easy-to-control connected homes and domestic robots are no longer figments of our imagination. Robotic vacuum cleaners, smart home appliances, AI-based voice assistants are becoming a part of our daily lives, buoyed by the continuous development of the automation industry. As per industry estimates, the global smart home automation market is expected to reach $21 billion by 2020.

Rapid progress in fields like Artificial Intelligence (AI), Machine Learning (ML) and cloud computing is paving the way for increased adoption of smart devices. In a recent report on home automation trends in India, Statista has forecasted that the number of homes with active home automation systems could move up to 5 million by 2023. With 2020 here, let us look at some of the prominent trends in the home automation world.

Voice-activated digital assistants Voice assistants are likely to

continue to their successful run this year. Modern customers prefer gadgets

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OM

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that are compatible with these voice-activated digital assistants. It’s expected that 2020 will see a growing number of devices (besides TVs and robotic vacuum cleaners) integrated with Alexa and Google Home support, offering a seamless user experience. Likewise, more manufacturers will focus on building voice-controlled smart devices with advances in ML. These voice assistants will be more capable and feature-rich, with better multi-tasking abilities.

Smart mirrorsWith smart mirrors, we can expect

impressive progress in 2020. They come with surfaces that can display social media feeds, give news and weather updates and interact independently with other smart appliances. In addition to offering a higher degree of convenience, these devices are being developed to pick up subtle health signs and detect the symptoms of diseases.

Housekeeping robots will get smarterThere are robots that can vacuum

and mop the floor and even navigate their way around obstacles. These battery-powered robotic vacuum cleaners are configured in such a way that they avoid bumping into furniture and falling down the staircase — without any human assistance. Some high-end housekeeping robots also come with the voice-controlling feature. In 2020, we will have a large scale adoption of these devices in India, even outside metro cities like Delhi, Bangalore and Mumbai.

Robust security system with automated features

It’s been observed that a majority of Indians prioritise safety when moving into a smart home. Smart locks, facial recognition-based key management system, intelligent sensors and alarms are some of the trending AI-based safety features. This year can bring further advancements. For example, a smart camera may be able to differentiate between the homeowners, neighbours and unusual visitors. This will bring down cases of home evasion and robbery. Moreover, smart sensors will be able to record any changes in the environment, such as a drastic drop in air quality. ☐

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MARKE T | NEWS


Karlsruhe Institute of Technology develops automated system for machine tool maintenanceKarlsruhe Institute of Technology recently developed a system for fully automated monitoring of ball screw drives in machine tools. A camera integrated directly into the nut of the drive generates images that Artificial Intelligence continuously monitors for signs of wear, helping to reduce machine downtime. Also, combining image data from ongoing operations with Machine Learning methods enables system users to assess directly the condition of the spindle surface. Explaining the importance of maintenance, Professor Jürgen Fleischer, Institute for Production Technology (wbk), Karlsruhe Institute of Technology (KIT), expounded, “Our approach integrates an intelligent camera system directly into the drive, which enables a user to continuously monitor the spindle status. If there is a need for action, the system informs the user automatically.” Similarly, Tobias Schlagenhauf, Institute for Production Technology (wbk), Karlsruhe Institute of Technology (KIT), asserted, “We trained our algorithm with thousands of images so that it can now confidently distinguish between spindles with defects and those without. By further evaluating the image data, we can precisely qualify and interpret wear and thus distinguish if discoloration is simply dirt or harmful pitting.”

Honeywell and Tech Mahindra team up to build ‘Factories of Future’Honeywell and Tech Mahindra recently teamed up to build ‘Factories of the Future’. Both the companies will aim to deliver world-class operations and performance management to enable manufacturing customers to expedite their growth and realise the value of Industry 4.0 technologies and solutions. Both are focused on building an ecosystem that supports collaboration. Speaking about the future of the collaboration between the two companies, Sunil Pandita, Vice President & General Manager, Honeywell Connected Industrial, asserted, "Tech Mahindra and Honeywell have enjoyed many years of successful collaboration, and this proposal is the next step as we continue pressing toward an autonomous manufacturing future for our customers. Together, we will accelerate solution adoption in the market, creating smarter, safer and more sustainable industries." Taking it further, Nilesh Auti, Global Head – Manufacturing Industry Unit, Tech Mahindra, expounded, "As part of our TechMNxt charter, we are focused on leveraging next generation technologies to address our customers' evolving and dynamic needs. Honeywell’s domain knowledge, combined with Tech Mahindra's technology expertise and global customer base, will enable our customers to increase their profitability and enhance efficiency."

IHS Markit India reports manufacturing PMI at 8-year high in JanuaryIHS Markit India recently reported that despite the downturn in the economy, Manufacturing Purchasing Managers’ Index (PMI) jumped from 52.7 in December to 55.3 in January, its highest level in just under eight years. The economy seems to be showing signs of a revival with India’s manufacturing sector activity climbing in January, driven by sharp rise in new business orders amid a rebound in demand conditions, leading to a rise in production and hiring activity. Discussing the latest report, Pollyanna de Lima, Principal Economist, IHS Markit, asserted, “The manufacturing sector growth in India continued to strengthen in January, with operating conditions improving at a pace not seen in close to eight years.” The Economic Survey 2019-20 projected India’s economy to grow in the range of 6-6.50% in the 2020-21 financial year.

Rockwell Automation opens Digital Transformation Experience Centre in IndiaRockwell Automation recently announced the launch of its first Digital Transformation Experience Centre in India, a state-of-art, collaborative hub, designed to inform and inspire Indian businesses about creative ways to spark productivity gains using automation. The Gurgaon-based centre is the first of its kind in India to fully demonstrate the integration of key technology platforms for IT-OT convergence, enabling customers to understand the benefits of the connected enterprise and the positive impact that it can have on their business. Speaking about the benefits that any business can gain from the centre, Blake Moret, CEO, Rockwell Automation, cited, “With this centre, we’re inviting businesses across the country to come and get informed and inspired about what the future could look like and how to get there.” Taking the talk further, Dilip Sawhney, MD, Rockwell Automation India, said, “Our new Digital Transformation Experience Centre enables us to show, rather than tell our customers, how our technology can help to bridge the gap between traditional plant floor technologies (OT level) and enterprise level demands (IT level).”

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NEWS | MARKET


Automotive industry leading in smart factory adoption - Capgemini reportCapgemini Research Institute recently reported that the smart factory adoption rate is highest in the automotive industry and is set to increase its investment by over 60% in the next three years, which could result in productivity gains up to $167 billion. The report said that the auto industry plans to make 44% of its factories smart in the next five years. It also pointed out that three out of ten automotive factories have been made smart in the past 1.5 – 2 years. However, it warned that companies must also invest in skills and systems to take full advantage. Its findings showed that the cloud computing, 5G, advanced automation are considered as the enablers of digital transformation for auto manufacturers. Other technologies used in the factory include virtual assembly technology, autonomous ground vehicle, driverless floor conveyor, remote maintenance portal, metal 3D Printing centre, collaborative robots and drones, etc.

Frost & Sullivan’s analysis on‘Impact of IIoT on global water & wastewater industry’Frost & Sullivan recently analysed the water solution that aids in smart asset management to maximise economic and environmental sustainability under ‘Impact of IIoT in the global water & wastewater industry’. The analysis examined the application potential of digital transformation and IoT in the water sector. It analysed the current trends and recommended strategies for long-term growth across regions. The study covered IIoT in water & wastewater utilities and networks, customer demand management & treatment.

Discussing the key requirement for ensuring regulatory compliance and economic sustainability, a sustainability analyst from Frost & Sullivan said, “Water and wastewater utilities are widely adopting data analytics platforms as analytics-driven intelligence is gradually becoming a key requirement for ensuring regulatory compliance and economic sustainability. By combining Artificial Intelligence (AI) with data analytics, technology companies have developed solutions that can learn from various events and provide customised preventive measures. The predictive and prescriptive intelligence not only improves the resilience of the infrastructure but also minimises the damage to the environment.”

The analyst further noted, “Utilities that are embracing IIoT-based digital transformation are likely to adopt a modular approach that can be scaled over a period to cover the entire asset. As every utility has a unique set of challenges, smart solutions need to be first customised and then integrated into a single platform. Eventually, there will be a continual focus on upgrading software solutions and expanding their capabilities to include even climatic factors and climate change goals.” In addition to investing in advanced IIoT sensors and data analytics platforms, smart water treatment or management product/solution providers will find growth opportunities by:• Modifying their product lines to suit conventional infrastructure instead of merely focusing on new build/installation projects• Modularising their offerings and providing asset management and business intelligence as separate customised modules. This will allow them to focus on

providing value to maintain and maximise the data generated by their product/solution. • Partnering with holistic data analytics solutions providers, which can effectively maximise the asset management and intelligence capabilities• Engaging in M&A with large engineering, procurement and construction (EPC) and operation & maintenance (O&M) companies, which can help with market

penetration in both the new build and existing project baseImpact of IIoT on the global water & wastewater industry is part of Frost & Sullivan’s global Environment & Water Growth Partnership Service programme.

EtherCAT Technology Group provides new educational tool for developersEtherCAT Technology Group (ETG) recently offered manufacturers, developers and users comprehensive support services for EtherCAT technology. The EtherCAT Device Protocol Poster is an additional tool that specifically helps developers of EtherCAT devices successfully navigate the EtherCAT world. The poster deals with the basics of EtherCAT technology, the EtherCAT Device Protocol (EDP) and provides a visual overview of EtherCAT. It describes the basic functional principles of EtherCAT, the structure of the frame and its processing in the EtherCAT Slave Controller (ESC). Additionally, it provides further information on the registers used by the ESC, the object model and references to relevant specification documents. Discussing his goal, Stephan Köhnen, the EtherCAT Expert responsible for the EtherCAT Device Protocol Poster project, ETG, explained, “My goal for the poster was to provide EtherCAT device developers a visual basis for a deeper understanding of EtherCAT technology. Comparable to a geographic map, the poster helps to orientate oneself in the EtherCAT world.”

14

MARKE T | NEWS


B&R organises sixth ‘Innovation day’ themed ‘Partnering for smart factory’B&R recently organised its sixth ‘Innovation Day’ in Pune, which catered to the theme ‘Partnering for smart factory’ and witnessed informative workshops, presentations, panel discussions and demos. During the keynote speech, Jhankar Dutta, MD, B&R India, elucidated, "New technologies are continuously changing the manufacturing landscape, and B&R takes pride in being a preferred automation partner for OEMs and factories. Our integrated, future-ready automation solutions enable machine builders and factories to become globally competent, highly productive, efficient and profitable." Providing a roadmap for Indian machine builders, David Hemetsberger, Strategy Manager – India, B&R, informed, "Globally, machine builders face similar challenges. It is important for manufacturers to take that first step towards implementing the latest technology. Innovators and early adopters are more likely to experience better business outcomes, lead the technology race and become trend setters – ultimately improving their revenue and market position."

Presenting the topic ‘Changing customer landscape in packaging industry’, Vishwanath Joshi, Head — NPD & Application, Nichrome India, spoke on changing customer requirements, including the increasing variety of products, higher filling precision, international standards and compliances, different materials, faster machine delivery and the benefits of a one-stop solution. In order to respond to these demands, Joshi pointed out the need for a transition from automation vendor to automation partner. Later, Nikhil Baste, Director, Technoshell Automations, addressed the importance of advanced technologies to build cutting-edge machines in order to maintain and improve global competitiveness. He further mentioned that the manufacturing industry is undergoing change with new technology, automation and digitalisation being the key drivers for success. "We have been working with B&R for over 15 years and they have always helped us achieve higher machine performance and flexibility, manage SKU proliferation and deliver higher OEE and reliability. It has helped us maintain our leading position in the printing and packaging industry and deliver best-in-class machines to our global customers," he said.

Samir Limaye, Business Head, Wimco and Committee Member, The Institute of Packaging Machinery Manufacturers of India (IPMMI), spoke on the topic of ‘Economy Industry & IPMMI Association’. Limaye explained the important role industry associations can play in helping OEMs adopt latest technology. Another highlight of the event was a success story presented by Mayuresh Pimpalkar, CEO, Kokban Automation. He spoke briefly on the Industrial IoT and how an edge controller can be deployed in infrastructure automation projects to acquire, evaluate and process data for unprecedented levels of efficiency and productivity, making flexible manufacturing a reality.

The event also witnessed a panel discussion on the topic ‘Making flexible manufacturing a reality’, moderated by Pooja Patil, Corporate Communications, B&R India. The prominent panellists included Atul Patwardhan, Functional Head - Corporate Engineering, PARI; Mayur Raut, Production Manager, L'Oréal India; Ramesh Chauhan, VP, Sandhar Technologies; Subrata Karmakar, President, ABB Robotics; Tanay Sil, Business Development – Industry, B&R India. The discussion initiated with importance of batch size one and mass customisation in manufacturing, from consumer goods to F&B to automotive ancillary. It has been observed that consumers prefer individualised products and are willing to pay a premium for them. This has placed a demand on factories to be able to manufacture variants based on consumer needs and requests. This has provided a paradigm shift in manufacturing lines in order to optimize production as well as be competitive in the market.

The panellists highlighted today's connected users and their rapidly changing demands. Meeting them requires a flexible, scalable production line that is able to accommodate small batches of different products, which at times could be down to batches of one. Flexible manufacturing lines enable factories to produce smaller batches economically. In such next-generation factories, machines, devices and systems can be reconfigured quickly and inexpensively to changeover, without hampering the production process. This allows mass-customisation and enables quick responses to market changes. The panellists also presented case studies illustrating how flexible manufacturing enables manufacturing companies to meet market demands for increased efficiency, throughput, availability and product quality. Innovation Day 2020 offered thought-provoking discussions, presentations and interactive sessions with B&R industry experts as well as live demos and hands-on technical workshops.

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16

MARKE T | I N TER V I EW


Delta is coming up with a new state-of-the-art manufacturing unit in South India. Could you tell us a bit about it?Delta India has a manufacturing unit in Hosur, Rudrapur and Gurgaon. Going ahead, we are establishing another unit in Krishnagiri, Tamil Nadu. The upcoming plant will have domestic production as well as exports. We will be having variable range of products which will be manufactured in the plant and as per the market needs, will have the products manufactured globally to be made in India. This will reinforce our commitment in supporting with government’s initiatives such as Make in India, e-mobility mission, smart city mission and profoundly investing in India to create best in terms of technology, provide end-to-end solutions & create more job opportunities.

What work is Delta currently doing in the area of energy efficiency? We offer a diversified cutting-edge technology with a portfolio of energy-efficient solutions, strengthening the industrial automation infrastructure. Our focus is also to provide a complete range of solutions that can deliver the industry best technology to support the growing ecosystem with a vision of powering green automation. We are constantly developing technology to strengthen our offerings in machine, factory and process automation, where the objective is to provide variable applications and solutions that can support the growing industry demand and are sustainable.

How is Delta dealing with the current slowdown? How are you ensuring that the year beginning is of positive growth numbers for Delta?The focus is to keep exploring new opportunities, where we can use our expertise and deep root engineering in being a catalyst for India’s smart manufacturing era. The last few months have been critical for the sector, but we have managed very well for our focus is not restricted to a specific industry. If we talk about Industrial Automation, we have diversified products and solutions for wide range of industry segments.

We are still moving ahead with positive growth along with numbers and see immense opportunities. Delivering the same

commitment recently, we have been ranked third in Low Power AC Motor Drives in the country, strongly indicates as to how we are evolving with our global expertise in the industrial automation domain.

Could you throw some light on how Delta is educating its customers on the potential of IoT and Industry 4.0?We already offer products that are IoT and Industry 4.0

compliant. In industrial automation, our diversified cutting-edge technology of efficient energy portfolio includes a range of connectivity solutions. But currently, the adoption of the technology is at nascent stages in India and the majority of customers are yet to explore its benefits and understand the process of its implementation.

In our endeavour to strengthen the market with these trends, we are doing our part in educating the customers to understand the potential of the technologies. Using various marketing platforms, our teams are showcasing what Delta can offer to this new domain and educating our associates. The progress is slow, but the future of Indian manufacturing is

about executing the production with smart technologies where the automation sector will have a key role to play.

What are Delta's future plans in the industrial automation business?We have a growth objective of 20% year-on-year for the next five years and we are quite optimistic about this target. Moving ahead, our vision is to support the market with our full potential, where the emphasis will be to keep innovating technologies that will enhance our offerings. We have also scaled up further to meet the additional demand with our upcoming new plant in Krishnagiri.

One of our major focus is on our global expertise i.e. machine automation, but at the same time, exploring new opportunities in process automation. We have also been venturing, recently, the most into the water segment – we are working to provide a complete range of solutions for effluent treatment, sewage treatment, clean water and a host of other applications. ☐

“The focus is to keep exploring new opportunities & trends”

… says Manish Walia, Business Head – Industrial Automation Solutions, Delta Electronics India, in this interaction with Juili Eklahare. He discusses how the company is strongly active in industrial automation business and helping its customers to understand the potential for new-age technologies

like IoT and Industry 4.0. He also gives his view on how 2020 will be a better year. Excerpts…

17

MARKET | I NTERV IEW


The government’s Make in India initiative has been taking every industry by storm. How is Rexel India doing their bit to ensure they align with this agenda of the government?We are a technical automation distributor. We contribute indirectly to the Make in India initiative by supplying quality products, services and technical solutions to the end-user customers to expand their plants and get to the latest technology for them to increase productivity and quality. Under the Make in India initiative, specific to the process industry, we are helping them conceive all the products and services that are made locally.

Rexel has been providing a broad range of innovative products and services in the field of industrial automation, energy management, supply chain consolidation and electrical supplies. Where do you see the maximum growth coming from? What are the key drivers of growth?We see growth happening across all our industrial segments, but I feel that the maximum growth would be coming from automation. The reason being, automation is set to drive productivity in the country now, which means, IoT, Industry 4.0 and digitisation are going to help business become productive. For example, manufacturing plants cannot afford to waste a full-day due to a machine breakdown. With automation and digitisation, we are now making the machines smart. One can take control of the machines on the cloud and resolve problems, even from a remote location. As the complexity and competitiveness increases, there is no option other than digitising to ensure one doesn’t lose on productivity. Automation and digitisation are going to be the key drivers of growth, even for us.

Your organisation has been on a drive to create ‘A world of energy’. Can you tell us more about this mission and how you plan on harnessing the same in the Indian industrial space?We are trying to reduce the energy consumption and increase the green footprint at our company. We have taken certain initiatives, like, there are a lot of projects we are doing to make

a shift from conventional lights to LEDs, which saves over 50-60% energy. For this, we have our technical team, who are experts on lighting, go to the customer’s site, do the audit and undertake projects to change from conventional lights to LED. In the process, if customers want, we offer them OPEX mode; wherein, we do the full investment and the customers can pay us back from the savings they make.

To harness the same in industrial spaces, we are working in alignment with industries, especially the tyre industry,

because it is heavily dependent on good level of lumens. So, we are focusing on replacing lights comprising sodium vapour/mercury high day light and providing highly efficient LED lights.

Artificial Intelligence and digitalisation have started seeping in the automation space. How do you plan on providing innovative, sustainable solutions that abide by the future technologies? We’ve created our own business plan for IoT. We are offering our customers a buffet of services and software, with which we are making machines smart. We have brought in modular software solutions that make

machines interface with the cloud and help the end-users to integrate their business needs with the process. We help them integrate the plant information with business information, which is needed today to reduce downtime and increase productivity.

How has the progress for your company been in the last financial year? What are your growth plans for the year 2020?In the last six to seven months, we have seen a lot of news regarding the slowdown in the industry business. Despite this, I am happy to share, we have grown over 30% in the last year alone in all the segments that we cater to. Even for this financial year, we are confident of achieving more than 30-35% growth over the last year. For this, we have drawn our business on five core segments – industrial automation, IoT, LED-fication, solar and transportation and would be focusing on growing in these segments. ☐

“Automation is set to drive productivity in the country now”

… mentions Vikas Garg, Managing Director, Rexel India, in his conversation with Anvita Pillai. Herein, he details on the Make in India initiative, the key growth drivers,

increasing the green footprint and more. Excerpts…

18

START- UP | I N TER V I EW


What was the idea behind starting UdyogYantra Technologies?I had worked for a European semiconductor major & an American industrial automation multinational, which helped me closely see the impacts of industrial revolutions on technology development and adoption across markets, experience Industry 3.0 indepth and understand the socio-political-cultural variables that correlated economies with industrial revolutions. The realisation that we are standing at two inflection points, one being Industry 3.0 and Industry 4.0, and the other one being India transitioning into a developed economy, was the birth of UdyogYantra.

Choosing the food-tech industry for your start-up was a smart strategy, soon leading to the company bringing in revenue. What made you realise that this strategy would work? We, in India, are particularly fascinated by food and India is also rapidly developing. The engines of this growth are millennials who are spending a major part of the week adding to India’s GDP, but not being able to spend the hours to prepare and consume the meals the way they love. This is a huge opportunity in the food-tech Industry. So, UdyogYantra is perfectly placed to develop products which make the processes in the food-tech industry efficient and smart.

One of your products that is being developed is the Smart Microwave for Cloud Kitchens. Can you tell us the objective of this product? What is being done to make sure it functions without flaw? We have developed a Smart Microwave IoT panel, which can be connected to any commercial off-the-shelf microwave and make it a network connected and controlled device. Independent of the microwave OEM, UdyogYantra IoT panel would give the same interface to all the present and future workforce and locations of the food chain. The panel has a number for each recipe of the food brand and these recipe settings can directly be updated by the central operations. The operator has to just press a number against a food type and the desired heating will be

done. The logs of how this panel was operated or if the heating cycle was cut short, etc will be available to central operations. The heating is not based on duration, but precise temperature sense-based control, so that accurate heating can be achieved, independent of magnetron power differences across OEMs, ambient food temperature differences across locations or operator skill / process issues.

The hardware and software have been designed and thoroughly tested using latest design and test methodologies in our labs and is being deployed with our lead customers for further feedback to

be followed by mass manufacturing.

Can you tell us about your collaboration with National Instruments? We are a National Instruments Alliance Partner in India, empowered by the NI platform called LabVIEW, which offers seamless integration with third-party analytics packages, databases and cloud platforms. One of the products we have applied for a patent is designed with LabVIEW. This association also takes us to a lot of manufacturing shop floors, where we solve their existing test challenges while learning how to make their manufacturing process smarter and efficient.

What's your plan on achieving your long-term vision to be a leader in making Industry 4.0 solutions and make the factories more connected with each other?UdyogYantra will focus on manufacturing process innovations which will help us consistently come up with innovative Industry 4.0 products. One can be a leader if he innovates faster and executes at the fastest speed. We plan to have a strong focus on our IT+OT = IoT approach to consistently get meaningful data for intelligence in the process to develop. The amount of data we are going to generate by these connected manufacturing processes can only be processed by machines (Machine Learning) and this process is called Artificial Intelligence. Investing in these right technologies for Industry 4.0 are the fundamental steps to become a leader in the future and we are committed to it. ☐

“One can be a leader if he innovates faster”... says Ankur Jain, Founder & CEO, UdyogYantra Technologies, in this interview with Juili Eklahare. He talks about how the start-up found an opportunity in the food-tech industry, its collaboration with

National Instruments and long-term vision to become a leader in the future. Excerpts…

20

LEADERSH IP I NS IGHTS


Vineet Nayar, a leader, author and a philanthropist, is not only a management visionary but also a radical thinker who transformed HCL from a $0.7 billion company to a soaring $4.7 billion global technology service company. His disruptive leadership tactics, after navigating through fair and unfair share of opinions, has brought in unmatchable growth at HCL.

During his joining days at HCL, Nayar and other new joiners were hired with a make-belief that they were employed to be the change-makers in the company. Nayar, who took this task to heart, was almost fired during the first 30 days due to his candid thoughts on where he disagreed to the management. But around the same time, many employees had started resigning from HCL’s Bombay division because of which they refrained from sacking him. Instead, to challenge him, Nayar was sent to Bombay, where employees were thoroughly demotivated due to the sapping and steady losing of deals to rivals. Shifting from the ordinary tactics, the philanthropist brought in 50 condolence cards in his office and told his employees that every time they bag a deal, they would

send a condolence card to the salesperson from the competing company. The task to send out 50 cards within a year became a challenge that the employees sportingly took on. The negative energy of losing a deal got converted into a motivation in no time, and the office soon started winning one out of every two deals they bid on.

The former CEO staunchly believes a leader can only lead if his people want to be led; and people will accept the leadership only if they believe their leader has an idea to which they can align. Until people don’t believe their passion aligns with their leaders’, they wouldn’t instil their trust in them leader and wouldn’t want to be led. Nayar deems, a leader should have a deep-rooted conviction in his ideologies and his stand on something. He cites, “Leadership is about being passionate about an idea.” To him, whoever said work with your feet on

the ground is wrong. Instead, he suggests on having one foot firmly planted on the ground and simultaneously experiment with the other.

Nayar has been a constant advocate for change. With a mission in mind to have an ‘innovation-led large-scale social change’, he co-founded Sampark Foundation. It has enabled transformation by educating over seven million children throughout India. Nayar is an absolute exemplary of how unconventional methods and speaking one’s mind out can bring about positive transformation in the organisation. And like he propagates, “Unless the company becomes obsessed with constant change for the better, gradual change for the worse usually goes unnoticed.”

LEADERSHIP IS ABOUT BEING PASSIONATE

ABOUT AN IDEA

Vineet NayarFORMER CEO, HCL TECHNOLOGIES &FOUNDER, SAMPARK FOUNDATION

Leading the unconventional way!

Anvita PillaiSUB-EDITOR & CORRESPONDENT

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22

COVER STO RY | T ECHNOLOG Y


– Pushing boundaries of performanceOPTIMISING ASSET DESIGN & OPERATIONS

For organisations, it is essential to cultivate an environment of continuous innovation while integrating with operations, planning, scheduling and manufacturing. Most companies create a collaborative environment to ensure maximum operational efficiency with optimisation. The cover story analyses the bigger picture of shared model design engineering and how it can induce a reduced CAPEX & OPEX, and bring in operational optimisation.

Vikas Dhole, Vice President Engineering Product Management, Aspen Technology


22 A&D I nd i a | Fe b -Ma r 2020

23

TECHNOLOGY | COVER STORY


To realise the maximum potential for optimisation, process plants must simultaneously address multiple dimensions and factors. Most successful organisations bring together people from across the business to optimise design and operations through process improvements. There are multiple groups involved in this optimisation; they need to build on each other’s contributions rather than working in isolation or at odds. Cross-disciplinary teamwork that takes a big-picture, integrates the approach to optimisation, delivering superior business result – including reduced CAPEX and OPEX, faster time to market, greater energy efficiency and higher profit margins. For example, a project that addresses capital and energy concerns can’t ignore safety, environmental issues, controllability and yields. Advances in engineering tools help organisations improve collaboration and integration to deliver comprehensive asset optimisation strategies that yield significant financial returns.

Technology alone is not the answer. However, digital transformation enables best practices that drive significant value. These best practices call for organisations to rethink the way they operate and the tools they use to make decisions. More relevant than ever, these approaches help companies succeed in today’s market as they contend with changing market conditions, constraints of aging equipment, a shifting workforce and increasingly strict environmental and safety regulations.

New possibilities drive performance

Performance engineering is about pushing the boundaries of existing concepts, designs and asset constraints to create new, higher performing designs and operations. Using asset models consistently across the CAPEX and OPEX cycle multiplies the value delivered. Shared models support conceptual engineering, Front End Engineering Design (FEED) and economic

evaluation, safety, sustainability and operation optimisation, driving performance improvements at all stages. Explore some of the best practices that can deliver value at all stages of plant design and operation.

Conceptual engineering

Develop optimal processOrganisations in the process industry, particularly specialty

chemical producers, must overcome technical challenges to introduce new products that meet the market demands and create clear differentiation, quickly evaluating process development options, understanding how operational changes will impact product quality and accelerating scale-up calls for collaboration across sites and functional groups.

Process models that enable modelling and optimisation of batch and continuous operations, involving both solid and fluid operations, offer a way to fast-track innovation. Process development staff can evaluate different processes and equipment configurations to design fewer and more targeted lab experiments and reduce investments in experimental and pilot plant facilities. Process simulations allow teams to find the optimal process and assets in hours instead of weeks. Combining modelling exercises, that traditionally took place across several tools, reduces engineering time by consolidating information and streamlining collaboration between research and engineering.

Design optimisation with concurrent conceptual engineering

Typically, process plant conceptual designs go through numerous iterations in a time-consuming, sequential path. A process engineer develops a process alternative using simulation,

Shared models support conceptual engineering, Front

End Engineering Design (FEED) and economic evaluation,

safety, sustainability and operation optimisation, driving

performance improvements at all stages

24



then shares that information with an equipment expert who sizes the equipment and finally, shares the information with an estimator. By the time the estimate for the proposed design comes back to the process engineer, weeks have passed.

Due to time constraints, organisations typically evaluate only a few alternatives and settle for a feasible design rather than the optimal one. Moving from this sequential approach to concurrent engineering, where different tasks involved in the process design cycle are performed simultaneously, allows companies to evaluate myriad design options from different perspectives in a short time.

Concurrent conceptual engineering tools allow firms to quickly analyse an asset for energy, economics and equipment while optimising for maximum yield and ensuring process safety and environmental compliance.

Front End Engineering Design (FEED)

Accelerating multidisciplinary collaboration Performance engineering can automate the handover from

conceptual engineering to front-end design, delivering greater efficiency. In addition, capturing updates in real time and cascading them to everyone who needs the information enables global engineering teams to work concurrently, with automated handoffs around the clock. Providing a single source of truth for FEED collaborators reduces manual data re-entry and improves accuracy, which can translate into as much as a 30% reduction in the FEED time.

Taking a data-centric approach means the entire team has up-to-date information and no one wastes time waiting for the latest project iteration. Using a single asset data model improves accuracy as well and allows teams to share best practices and reuse designs. The latest basic engineering capabilities also enable faster hand-off to mechanical and detailed engineering.

Driving collaboration between process engineering, mechanical engineering, estimators and other groups to optimise assets maximises the potential benefits plants can achieve in terms of CAPEX, OPEX and energy savings.

Economic evaluation

Improving efficiency and reducing riskMany engineering and construction firms struggle to

create accurate estimates based on limited information at an early phase in the lifecycle. Providing reliable quotes is especially critical for markets where the Lump Sum Turnkey (LSTK) contracting model prevails. Today’s model-based estimation tools can quickly generate conceptual estimates from the process simulation, and then continue to develop detailed cost estimates for equipment and associated plant bulks, as well as indirect costs.

Using volumetric models that are regularly updated on the cost basis derived, from five well-established regions paired with historical data from completed projects, allows EPCs to calibrate for greater accuracy. Costs like labour, materials, bulks and equipment can be adjusted based on specific project information. Increased estimate accuracy, reduced man-hours and less rework mean significant savings for engineering firms. For owner-operators capital cost estimation, including risk analysis, enables collaboration with EPCs and minimises chances of project overruns.

Safety and sustainability

Developing safe design and operationsSafety is a top priority for owner-operators and EPC

companies. Analysing assets for safety across lifecycles help

Feasibility Studies

Conceptual Deisgn

FEED & BasicEngineering

DetailedDesign

Construction & Startup

Debottleneck & Revamp

Operations & Turnaround

Conceptual Design

Equipment Design & Rating

BasicEngineering Third Party

Detailed Engineering

Economic Evalution

Safety, Environmental and Dynamic Analysis, Energy Management Operator Training

Planning Update

Debottlenecking

Operations Improvement

Revamp

Enterprise Visualization &

Workflow

Performance Engineering for Engineering, Procurement & Construction

Performance engineering for engineering, procurement & construction

25

TECHNOLOGY | COVER STORY


minimise risk to staff, reduces downtime and protects process equipment. While firms want to ensure they operate as safely as possible, an overdesigned safety system can increase project costs or delay already constrained projects.

Performance engineering enables complete overpressure protection safety analysis starting from equipment to flare system including relief and blowdown. Using integrated steady state and dynamic simulation, including safety analysis, helps identify asset designs that can support current demands while accommodating capacity growth, extending asset life and safety.

Optimising energy for supply and demand

While both process engineers and utility engineers focus on improving energy consumption, they’re examining the problem from different sides. Process engineers typically look at a process’ energy consumption and assume the utility system as given; utility engineers consider the process as given and optimise the utility system. The greatest savings occur when both aspects are considered simultaneously – optimising processes to minimise the utility demand and the utility system for maximum efficiency.

Achieving the maximum potential in energy management calls for both, design and operations improvements. Design improvements typically provide the maximum impact but require capital investment. Operational improvements, such as planning and scheduling the utility system and optimising processes also delivers additional savings. Combining design and operational opportunities holistically can save 10% to 20% for the asset.

Operations improvement

Updating planning models based on actual performanceAccurate refinery planning tools are critical for sustaining

profits. Unfortunately, these tools depend on models that can easily become outdated when there are changes in crude slate, operating conditions, equipment or catalysts.

Updating planning models using simulation models tuned to actual operational conditions allows for better decision-making, ensuring production meets or exceeds the plan. Automating the planning model update workflow reduces the planning update time from months to just weeks, giving refineries more accurate plans and a means to improve margins. Most importantly, this tool enables refineries to update the models themselves, in-house, without costly third-party consultants. Companies using Aspen HYSYS reactor modelling for operating advice, unit monitoring and planning model updates, report benefits ranging from $8 million to $36 million per reactor unit.Digital twins driving operational excellence

Process engineers work with many teams in plant operations to help optimise an asset. Typically, operations staff bring a problem to the process engineer’s attention. The process engineer will analyse the problem using a simulation model and make a recommendation. The more time passes, the more opportunity is lost, causing delays in optimising operations, ultimately losing margins.

A simulation model tuned to current operations results in a digital twin of the asset mirroring the performance of the asset in both, offline and real time modes. This digital twin can quickly identify the opportunities for improvements, accelerating collaboration between process engineers and operations team, resulting in faster decision-making and increased margins, taking a holistic, collaborative approach and leveraging the digital twin technology to quickly evaluate the different operational scenarios, including revamps & speeds optimisation, within a broader business context.

Performance engineering enables complete

overpressure protection safety analysis

starting from equipment to flare system

26



Digital acceleration driving profits & productivity

For peak performance and profitability, organisations must simultaneously optimise design and operations across multiple dimensions through strong collaboration between disciplines. Technologies that enable collaboration across disciplines can help teams combine their strengths to deliver the maximum potential from optimisation. Time and time again, we’ve seen that collaboration across engineering, planning, scheduling and plant operations deliver unparalleled results.

Performance engineering provides a concurrent engineering environment that EPCs, upstream companies, refiners and chemical companies can use to optimise equipment, plants and assets based on consistent models throughout the asset lifecycle. This not only enables optimisation across the CAPEX and OPEX cycles but also drives collaboration between process engineering and other groups to capture a wide array of benefits, including safer, greener, more profitable operations. Implementing any of the best practices outlined here will deliver value; saving capital and energy, reducing environmental impact with an inherently safe operation, which will maximise the Return on Investment (ROI).

Choosing tools that drive asset lifecycle

Only one technology company has a proven track record for creating value across the entire performance engineering spectrum. AspenTech delivers billions of dollars in value annually across verticals and regions, from R&D and conceptual engineering to FEED, economics, safety, sustainability and operations optimisation. Continuous innovation in engineering tools that integrate with operations, planning, scheduling and manufacturing execution drives unparalleled value for asset-intensive companies working to digitalise and ultimately, digitally transform. ☐

Training operators reducing risk and accelerating time to production

Operator training simulators have been proven effective in preparing operators to manage start-ups, shutdowns, complex operational changes and respond to equipment malfunctions in ways that reduce risks while improving safety. When operator training simulations reuse the dynamic models created for engineering, owner-operators save time on training development and can start preparing engineers and operations staff sooner.

Plants can confidently prevent safety incidents and improve sustainability with more rigorous training scenarios, based on their unique equipment and operating conditions. Post start-up, companies can update models to reflect changes to start-up and shutdown procedures, new operating conditions or equipment updates and revamps, thereby extending the value from the investment in an operator training system. This best practice of lifecycle dynamic modelling improves operator effectiveness as well as the safety and reliability of the asset across its lifecycle.Accelerate Advanced Process Control (APC)

To roll out a new Advanced Process Controller (APC) or re-tune an existing one, most plants conduct step tests on the actual asset. This usually involves introducing a disturbance to see how the plant responds and then using the data to define initial tuning parameters for the controller. Using the actual asset for testing requires high levels of engineering and operations expertise – this approach can introduce operational risks and may impact production.

Performing step-tests on a digital twin reduces production losses and saves time implementing APC. Control engineers can collaborate with process engineers to leverage existing simulation models, based on actual operating conditions, leading to faster deployment for new APC units, reduced operational risks and less impact on production.

Plants can confidently prevent

safety incidents and improve

sustainability with more rigorous

training scenarios

MANAGE ME N T | I N TER V I EW

28 A&D I nd i a | Fe b -Ma r 2020

“Industry 4.0 and IoT will become a necessity to run the business”

… mentions Fathe Raj (F R) Singhvi, Joint Managing Director, Sansera Engineering, in his conversation with Anvita Pillai. He discusses how Sansera is moving forward by incorporating digitalisation in its daily operations, their

initiatives in integrating digitalisation, its benefits, how the company is aligning itself with the industry requirements, his perspective on the readiness of Indian factories to adopt Industry 4.0, the anticipated challenges and more. Excerpts…

the nature of the production system. This helps us to identify the bottlenecks, optimal manpower planning, maintaining optimal inventory, production, planning, line balancing, etc. We also use process simulate – a time-based simulation software – which helps us to validate automation system design, perform virtual commissioning of automation systems, perform ergonomics analysis and safety of the operators, before carrying out the physical implementation.

Some of the key initiatives at our company are the implementation of real-time data on CNC machines for calculating the OEE (availability, performance and quality), use of robots in the area of machining and forging, automated inspection of parts through robots and sensors capturing the live data. AGV is the latest implementation at one of our plants.

How has workplace automation been integrated into daily volumes of work in your organisation? How has this helped in increasing labour efficiency whilst cutting net cost and improving product quality?Workplace automation has substantially reduced the need for additional manpower and has reduced human errors. This has also given a safe working environment in critical operations like forging and surface treatment process. Less human intervention has resulted in controlling the rejections due to human error.

The forging industry in India is not much developed in terms of advanced technology adoption. But your company has fully automated the forging processes. Can you brief us more about that?Our organisation has fully automated and integrated the forging process with the necessary automation technology and controls, right from raw material lifting and cutting

With digitalisation/Industry 4.0 integrating into the manufacturing industry, how is Sansera ensuring implementation of latest digitalisation tools with a focus on quality and customer requirements at each stage? What are the initiatives in this area?Sansera started its journey of digitalisation about 10 years ago, anticipating the need for it. Latest digitalisation tools adopted in our company include IoT, analytics – mainly for SCM, sensors, robotics, gantries and automation. The process of capturing the data manually leads to a lot of errors and delay in corrective actions, resulting in loss of time and money, affecting the performance of the plant. Therefore, it is apparent to capture the real-time data in order to

review the process without loss of time. We have implemented capturing real-time data from its

recently installed machines, which gives the production data and also works on capturing the live quality parameters, to automatically generate the SPC charts. With the above, live status of the production and quality can be obtained. The areas covered are machine production monitoring, paperless shop

floor, work order management, inspection data capturing – with interface

to external SPC through automation for

high volumes, traceability and conf igurat ion management.

Using plant simulation, we simulate the production lines to understand

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to heating, pre-forming to final forging and subsequently finishing the operations. We have used many robots, sensors and thermocouples in the forging automation for a seamless flow and assured quality, which also includes controlling the temperatures and weight of each forging. The acceptance and rejection at every stage is monitored and automated.

Aerospace is another integral focus sector for your company. How is Sansera preparing itself for the developments in this sector, aligning with the industry requirements? Sansera has progressed well in the aerospace sector in the last five years, supplying detailed parts to OEMs, tier-I and tier-II companies. Some of the main challenges we face are - • Global competition: Despite sourcing imported raw materials

and consumables, we still need to provide substantial cost savings to our customer

• Human challenges: Skill development & team building, and retention of skilled manpower or superior knowledge pose as a problem

• Building a complete eco-system: Availability of RM / customer approvals on special processes causes a hinderance

• Inventory & logistics costs are very high

Some of the key initiatives taken by us are -• Skill Olympiad is Sansera’s way to develop skill-sets functional

wise by in-house and external training• Monthly rejection display and group analysis• Machine wise rejection / plant wise rejection / rework

monitoring system• Motivate the team by awarding for zero rejections and for

continual improvements

• Implementation of Industry 4.0 • Application of QCC and Kaizen• Execution of Zero Defect Plan (ZDP)

Our approach:• Build a strong culture and system to meet customer requirements

& company objectives• Systematic, risk-based thinking approach

for all the processes and monitor mitigation actions periodically. No short cuts/escapes.

• Effective daily management to monitor, control and meet the company’s objectives (OTD and Zero PPM)

• Thoroughly understand and consume all customer requirements

• Evaluate skill levels, conduct trainings and improve competency

Do you think Indian factories are equipped enough to adapt to advanced technologies, for example Industry 4.0, IIoT, etc? What are the challenges anticipated?Not many factories have started working on the implementation of Industry 4.0, but the awareness on this is increasing. Many service providers are developing the software to meet the Industry 4.0 requirements. In the days to come, a lot more companies will adopt Industry 4.0 and IoT to make the whole system more efficient and fool-proof.

One of our biggest challenges is customising the customers’ requirements. There is no single solution which is readily available to meet them. The solution provider and the end-user have to work together to achieve the expected results. Industry 4.0 and IoT will become a necessity to run the business. Many of the new generation machines and tools have incorporated many features of Industry 4.0 and the software is compiled with features to assist in digitisation. ☐

LESS HUMAN INTERVENTION HAS RESULTED IN CONTROLLING THE

REJECTIONS DUE TO HUMAN ERROR

‘‘

Fathe Raj (F R) Singhvi is presently the Joint Managing Director of Sansera Engineering. He has previously served as the Chairman of HR & IR, Aerospace and before the current change, he was the Chairman of Skill Committee. Aside from managing a company with a turnover of ₹945 cr, he also manages Sansera Foundation which is involved in improving the lives of over 5000 children studying in 28 government schools and 10 private-run schools.

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Impact on the manufacturing sector

VIEWPO IN T | MA RK ET

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With the Budget 2020-21 declared, there has been a lot of deliberation on its impact on the manufacturing sector. It has taken big steps in several elements, from enhancing the MSME sector & start-ups, to an improvement in electronics manufacturing, to a rise in cost of electric CBU and CKD vehicles. The idea is, undoubtedly, to revive economic development. The Viewpoint section finds out if the Budget can revive economic growth in the country, its short-term and long-term gains and what are the opportunities it brings.

Kailash Desai,Managing Director,Endress+Hauser India

“It is time for rural India to get smarter”The budget 2020-21 has introduced more tax slabs and offers higher limits, provided the

taxpayer is ready to forego all the existing exemptions. Also, it looks to me that the Government has plans to introduce a policy that would boost the private sector and guide them through building data centre parks throughout the country. Since the last couple of years, we have been working tirelessly on various ‘smart city‘ projects and technology enhancement that would make a huge difference in the lives of Indians. The Government had in the earlier budget introduced technology enhancements in tier II and tier III cities and this time around an allocation of ₹6000 cr for BharatNet is appreciated. As cities are getting smarter, it is time for rural India to get smarter as well. To bring the Indian economy on the fast track and achieve the Modi Government’s target of $5 trillion economy, the budget has a major focus on three themes – aspirational India, caring society and Indian economic development, by taking into consideration the Indian technology sector, Artificial Intelligence initiatives and start-ups. For over five years, an amount of ₹80 billion ($1.13 billion) will be provided for quantum technologies and applications, and this truly will create job opportunities, help tech start-ups and boost the economy.

Juili EklahareFeatures [email protected]

2020UNION

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Jhankar Dutta,Managing Director,B&R Industrial Automation

“Budget 2020 proposes an array of measures for start-ups”With the announcement of the Union Finance Budget for the year 2020-21, it is seemingly

clear that the government is upbeat on consolidating its existing financial measures. One of the major highlights for manufacturing in recent times has been the proliferation of start-ups. Budget 2020 proposes an array of measures for start-ups, SMEs and MSMEs, mainly focusing on business growth. The introduction of ‘Assemble in India’ is expected to facilitate India to manufacture networked products to make it part of the global value chain. There is certainly a cost advantage in electronics manufacturing in the country other than its immense potential to create huge employment. Budget 2020 targets a boost in incomes and enhances purchasing power with reduced tax burden. With improved purchasing power of the common people, manufacturing, including EVs and the automotive segment, might witness better sales. The Union Budget this year mainly focuses on many important aspects like the social well-being of the economy by increasing infrastructure and agriculture budget, to mention a few, but only time will decide the fulfillment of short-term and long-term strategies.

Similar to earlier budgets, Budget 2020 too offers something for all, with a hope of reviving the economic slowdown. With several macro challenges and the target of reaching $5 trillion by 2024, the budget does promise some impetus to manufacturing but definitely, there is scope for more. We are making an effort to become a global manufacturing hub, the scope of the model spans across all sectors of manufacturing and service industry, with a special focus on micro, small and medium enterprises – some of the engines of Indian economic growth. Thus, there is hope for growth in the ever-challenging volatile market.

Ramani Iyer,District Vice-President – Asia Pacific District 14,International Society of Automation (ISA)

“What boosts manufacturing will boost the economy”The Union Budget 2020-2021 , following the earlier big-bullet reduction of corporate tax to

15% , will have a very salutary impact on the automation sector. This ‘sun rise’ high technology sector is already poised to make a huge contribution to the manufacturing and services segment of the economy. Every 2% increase in investment in this sector is estimated to contribute to a whopping 5% increase in the GDP. The measures to boost the MSME segment are also very significant; over 50,000 MSMEs have already availed the benefits of restructuring of debt permitted by RBI in 2019-2020. This scheme has been extended in the current budget. Plus, waiving the dividend tax is a huge gain for MSMEs. Reducing the compliance burden on the segment, the budget has proposed that the ceiling on mandatory financial audit be raised to ₹5 cr from the current one crore.

Lowering the threshold for availing an invoice credit by uploading on the Trade Receivables Discounting Scheme will boost these companies. The cumulative turnover of such platforms is poised to increase to ₹1 trillion in the next 18 months. A ₹1000 cr scheme anchored in EXIM Bank and SIDBI is aimed at technology upgradation, research and development and business strategy, particularly to assist exports.

Today, automation technology is the major component of manufacturing and financial services sector. By enabling the MSME segment of this sector to grow with vigour, the budget will enable the economy to grow at a faster pace. Over 40% of the turnovers in this sector is contributed by the MSME components of the ‘brick & mortar’ automation technology industry, IT and IT-enabled sectors. What boosts manufacturing will boost the economy.

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Sameer Gandhi,Managing Director,OMRON Automation India

“The budget has in store positive measures for the MSME & start-up sectors”The budget is expected to have a positive impact on manufacturing activities, mainly owing

to the rearrangement in IT rates, which will act as a boost for the FMCG, white goods and two-wheeler automotive manufacturing segments. Also, I feel the announcement regarding ‘Assemble in India’ should act as a catalyst in expansion of the electronics hubs base in India. Eventually, this will lead to an increase in volumes which will motivate machine makers to start building machines in India rather than getting them imported. This will also lead to an increase in manufacturing activities. Another sector which is going to gain growth in manufacturing is the textile sector, with the announcement of reversal of $16 billion imports in by the National Technical Textile Mission. The budget also has in store positive measures for the MSME and the manufacturing start-up sectors. With tax reliefs and rebates being announced, both sectors are expected to become more robust and conducive to drive the growth of the manufacturing sector. Plus, notable buoyancy is expected to be felt in terms of electric vehicles as well as the mobile parts phased manufacturing because of this revision. But the retention of existing duty on EV batteries is a slight dampener. It will not work towards bringing the prices of EV vehicles down which will act as a hindrance against the mass adoption of EVs. Also, the overall automotive sector, which has been feeling the downturn, has not received significant relief or measures.

Sanjay Sudhakaran,VP – Digital Energy, Greater India Zone, Schneider Electric

“The Digital India initiative will see a new wave”As per the Union Budget 2020, the allocation of ₹6000 cr for BharatNet to digitise one

lakh gram panchayats is a step towards making India digitally more connected. These new initiatives will help improve telecom and internet services in the rural and remote regions of India. The Digital India initiative will see a new wave as citizens in deeper pockets will gain further access to services like e-governance, e-health, e-education and e-banking amongst others. In addition, the announcement of allowing private sector set up data centre parks across the country will help in data localisation and protection. We welcome the government’s decision in announcing additional smart cities in building a robust digital infrastructure. This also aligns with the Internet of Things (IoT) taking over as automation has made lives simpler and buildings smarter.

Vartul Jain,SVP and CFO,GreyOrange

“We laud the government’s focus on improving the supply chain economy”It is heartening to see how this year’s Union Budget focuses on promoting India as an

investment and innovation hub. Focus on entrepreneurship, skill development and supply chain economy and a thrust on technology are important for the growth of the government’s Digital India and Make in India programmes. Measures such as an Investment Clearance Cell, early stage fund and multiple tax rebates and relaxations for start-ups will help widen their scope and provide more opportunities. From a business perspective, the government continues to extend its support to MSMEs and bolster their growth by allowing for debt restricting, all of which will help boost the entrepreneur ecosystem. We also laud the government’s focus on improving the supply chain economy. Measures such as geo-tag warehouses and establishment of efficient facilities at the block level, will be key in ensuring zero wastage and optimised resource allocation. We are now excited to witness how the industry makes the most of these initiatives for entrepreneurship and drive innovation to further the spirit of India Vision 2025.

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Robots, an icon of Industry 4.0, are considered to relieve humans of repetitive and laborious work. As the intelligence and capability of robots increase, we look for more innovative designs to boost their value. One of the main accusations levied against intelligent robots is that they are actually, well, stupid. This means that there is no awareness of context or surroundings. Machine-centric robotics addresses this issue by close integration of robot with the machine. As a result, the robot is perceived to become suddenly more sensible.

Importance of packaging for pharma

The pharmaceutical industry requires safe and secure packaging to maintain identification and stability of drugs. The packaging must provide proper protection and reduce the risk

of contamination. Pharmaceutical packaging is important as it protects the product from physical, chemical and microbiological invasion. It is also a medium to present useful details to the consumer and influence their choice; a good packaging assures the consumer of good quality.

Labelling of products is important in pharma applications as it provides vital information like composition and expiry date of the product. It also provides data needed for tracking and tracing, such as a batch number. And of course, it is the packaging which carries the labelling.

Pharma packaging continues to face challenges arising out of regulatory regimes, competitive landscape leading to faster time-to-market, informed customers and globalisation. The challenges are nearly the same for both, OTC and prescription drugs. Brands still need to build physician awareness and trust through product-

Machine-centric robotics revitalising pharma packagingWith the fast-paced robotic revolution, there is a significant cost, error and time reduction that is expected to come into pharma packaging. The article offers a detailed study on how machine-centric robotics has made robots sensible and the various ways it’s aiding the pharma industry process.

Sivaram PV, Chairman Non-Executive, B&R Industrial Automation

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centred information. But to win with empowered consumers, they must also provide brand-centred relevance, based on insight into consumer behaviours, perceptions and preferences.

Variety in packaging possibilities are infinite and are broadly classified into primary, secondary and tertiary. Primary packaging is the packaging in direct contact with the product itself and is sometimes referred to as consumer or retail packaging. The main purpose of primary packaging is to protect and/or preserve, contain and inform the consumer. Secondary packaging’s main purpose is for branding display and logistical purposes. They are also used for protecting and collating individual units during storage and are often used by the F&B sector, cosmetic sectors and also the pharma industry for displaying primary packs on shelves and are sometimes also referred to as grouped or display packaging. Tertiary packaging facilitates the protection, handling and transportation of a series of sales units or secondary packaging in order to group everything into unit loads during transit. This type of packaging is rarely seen by the consumer.

Standard robotic operations in pharma-packaging

Robots are mostly seen at work in the packaging lines, either alongside operational lines or at the end-of-line. Packaging robots are designed to open, fill, transport, palletise, seal, code and/or label product packaging.

Robotic systems provide various benefits to pharmaceutical manufacturing such as lesser space utilisation, reduced production downtime, no labour turnover, enhanced health and safety, better waste management, increased production flexibility, improved production output and product quality and lower operating costs. With the growing pharmaceutical industry and the various benefits offered by robotic automation, adoption of robots is likely to increase in the coming years.

Packaging processes, like other pharmaceutical operations, benefit from the speed and repeatability that automation brings. Robotics in particular provide flexibility and accuracy. In some packaging applications, such as carton loading, robotics also performs more efficiently than dedicated machines. Pharmaceutical packaging machines are often custom designed to handle specific product configurations, such as vials.

In contrast to packaging machines, that automatically stop, if too much product accumulates at the discharge, robotic loaders and unloaders meet or exceed the in feed and discharge rates that packaging machines require. This ability allows the robot to keep the packaging process running at full production capacity.

Advantages of robotic automation in packaging

Speed - Robots work efficiently, without wasting movement or

time. Without breaks or hesitation, robots are able to alter productivity by increasing throughput.Flexibility - Robots can be easily reprogrammed for the packaging applications that vary. Changes in their End of Arm Tooling (EOAT) developments and vision technology have expanded the application-specific abilities of packaging robots.

Highlight features of integrated robotics

Integrated robotics is defined as the single line or cell controller controlling the robot, which can reduce the need for a dedicated robot controller and associated hardware components, such as servo motors, drives, teach pendant and I/O. In this way, a single controller can be used to control multiple robots and it can simplify integration and increase operational efficiency.

The concept of integrating robots into the process enables synchronised execution of robotic operations parallel to the machine operations or transport of the product. Such tight integration of robots and machine components offer the ideal foundation for implementing Industry 4.0 concepts and has a positive effect on the performance of the entire machine. The improvements are seen in the operation of the machine. The increased efficiency starting at the design stage of each operation, each machine and of the entire line all add up.

What does machine-centric robotics mean?

The question arises that - what are the differences between a machine, an industrial robot and a machine-centric robot? Mostly, it’s the difference in the tasks they perform. Machines are designed to perform one particular task such as filling, bottling, gluing, printing or stamping. Machines perform specific tasks which require periodic human intervention e.g. for operating the machine, feeding products, packing finished product, etc.

Robots perform more versatile tasks, which do not require constant human intervention to a great extent, until and unless new operations are to be performed. Robots can perform a task which is completely impossible to be performed by humans, such as carrying melted metal for the forging industry. They can work in hazardous as well as highly hygienic areas, such as medical/pharma, where even during packing and filling of a particular medicine human breath can contaminate. Industrial robots, such as a palletiser, works standalone and performs serially with reference to main operation.

Machine-centric robots, such as FlexiPicker (Delta/tripod), Scara, 6–axis serial kinamatics (Camau Racer), work in coordination and synchronisation with various machines such as packaging machine. Palletiser picks filled boxes of biscuit/bottle cartons and place it in stationary pallets whereas machine-centric robots pick syringes/ampules and place it in pocketed

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chain of running machine. Purpose of the articulated arms in machine-centric robotics is to manipulate products while the machine continues to process them, bringing about an increase in the throughput.

Why is this integration now possible?

Over the years, we see a great improvement in performance capabilities of PLC controllers. In many cases, manufacturers are relabelling their PLC as a PAC to underline the improved performance. Some companies like B&R are able to install real time operating system into an automation PC and make the PC function as a PLC controller. This brings a rapid performance increase in the PC systems’ ASO into real time control. Thus, it is possible to execute PLC logic as well as robotic kinematics in same controller without affecting performance or safety of either. The second limitation of storage size is also now totally removed. Controllers are able to accommodate huge amounts of program and data.

One can ask, when we try to promote distributed processing and distributed intelligence, how integration can be justified. The answer is that when we look for tight integration – for example between line operation, like filling and robotic operation like pick-and-place — a very close integration brings a boost in throughput. The tightest integration is, of course, when both functions reside in one and the same controller.

Performance benefits out of machine-centricity

When there are two or more controllers involved, there is an overhead of communication. In every such peer-to-peer communication, there needs to be a protocol. All these operations

bring in a computational overhead. But much more, there is going to be a communication latency. Several benchmark demonstrations show a performance improvement by 50% and more. As a bonus, there are significant savings in cost as well.

Going beyond just cost savings, there are huge benefits in efficiency of design process. The legacy solution had been to take a regular PLC application, take a standard robot and find some ways to coordinate the two. The common solution had been to use some digital input/output signals to coordinate the operations. This led to complex programming & commissioning and made the future modifications and flexibility a challenge.

Benefits for machine builder and plant designer

When machine builders need a delta or articulated arm robot for a new machine or plant, their first instinct is to turn to one of the big names in the robotics industry. They offer a large selection of universally applicable industrial robots, specialty solutions (such as for welding, gluing or dosing applications), dedicated robot controllers and accessories. Usually, there is no way to order the robot mechanics separately from the robot controller.

More and more machine and plant builders, however, do not want to buy mechanics and controllers in a bundle and are looking for alternatives. The reason is simple – having separate controllers for robotics and machine control adds time and cost throughout engineering, commissioning and maintenance, as well as spare parts storage. In addition, latency times at the interface between robot and machine controller can make it more difficult to synchronise robot movements with machine processes, such as the movement of a conveyor belt. Modifications in SW of machine controller may need a second modification in robot programming. ☐

The newly developed integrated solution supports machine builders, enhances processes and future-proofs automation investments. Since the machine builder no longer needs to use separate hardware, communication networks and applications, one is able to achieve much tighter synchronisation between the robot and other machine components

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The aim of TwinCAT Analytics is the machine-oriented, centralised analysis of data from one or more simultaneously running machines or systems (Figure 1). This is achieved with optimally coordinated and integrated tools that operate in a consistent workflow, ranging from the acquisition of data to its communication, analysis and visualisation in an analysis dashboard. The engineering tools involved combine a high degree of flexibility with easy and intuitive operation.

The analytics workflow begins as early as in the engineering process for the machine application. As is customary in TwinCAT engineering, all tools are integrated into Microsoft Visual Studio®, and since the TwinCAT

Analytics Logger is already embedded into each TwinCAT project, no external configuration tool is required. The logger makes it easy to pick data simply by checking the appropriate box in order to transfer it to a message broker via MQTT or store it locally as a file on the control system. No complex programming is needed. Only the logger’s options, such as IP address and authentication of Transport Layer Security (TLS), must be configured in order to enable communication once a machine project has been activated. In addition to being ideal for high-resolution data, the real time logger can also be started and stopped with PLC calls via the control program.

Acquiring centralised data analyticsAs data becomes more important for machine builders down the line, it has also become necessary for them to provide their services through engineering that is not complexed. The article talks about how TwinCAT Analytics makes engineering more efficient with automatically generated dashboard, how users can access live data from the machine as well as historical data supplied by the TwinCAT Analytics Storage Provider and how automatic dashboard generation saves substantial time.

Pascal Dresselhaus,Product Manager – TwinCAT, Beckhoff Automation

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Data analytics easily incorporated into IoT concepts

An Internet of Things (IoT) infrastructure can be easily implemented with TwinCAT Analytics to ensure that the various applications are decoupled. All MQTT clients need to connect only to the message broker and not to each other. It doesn’t matter whether the message broker is on the local network or, for example, on the cloud. The outbound client-to-broker connections simplify the IT setup.

This is also reflected in the system’s use. For example, a service technician can use the TwinCAT Analytics Service Tool to log onto the message broker and analyse machine data from anywhere as an MQTT client. Users can access live data from the machine as well as historical data supplied by the TwinCAT Analytics Storage Provider. For the analysis itself, TwinCAT Analytics provides many algorithms in the form of modules. These include simple flank counters with and without hysteresis, logical operators, as well as a wide variety of classifiers and comparators.

The service technician can then use these algorithms in the TwinCAT Analytics project within Visual Studio®, without having to leave the familiar TwinCAT environment. Operation is graphical and intuitive. Especially useful is the automatic TwinCAT Scope configuration, which can be generated by clicking a button. While the proven charting tool from the TwinCAT world can be individually supplemented, it already contains all important variables of the configured analysis. With the link thus created, results from the analysis can be dragged and dropped into the TwinCAT Scope View tool to easily visualise them and highlight significant events in the data stream.

Services as a new business model

This is where the engineering process ends for the service

technician or the person commissioning the system, who can also access the machine data via the ADS communication protocol. If a machine builder or system integrator wants to offer their customers additional services, the engineering process enters another phase. This approach also offers significant potential for new business models that can be monetised with a one-time payment or a subscription. In return, customers receive a customised visualisation interface, i.e. a dashboard that perfectly meets their specific information needs. It is crucial for this business model that such a dashboard be implemented as easily and cost-effectively as possible.

To maximise the customer benefit, the goal is to deliver a 24/7 application that runs for the entire lifecycle of the machine and analyses machine data non-stop. The best conditions for such a permanent application are provided by the PLC, which is designed exactly for scenarios with a focus on continuity and longevity. The only thing that’s complex in such a scenario is the programming of mathematical algorithms, which are often easier to realise in script languages or in graphical configurators, albeit with a different focus: Instead of analysing a stream of live data, they often look at historical data within the engineering process. But since the end-customer does not want to and is often not able to work within an engineering tool, the goal is to combine the simplicity of data analysis with the PLC.

Workbench reduces engineering complexity

This combination is delivered by the TwinCAT Analytics Workbench, which supplements the functions of the service tool. Like the service technician, the data analyst, who is often the application engineer, uses the Analytics Configurator in Visual Studio® for data analysis, providing the ability to create complex analyses graphically, broken down into various networks that represent machines, machine components and machine tasks. The algorithms can also be combined with each other, which further increases complexity.

Figure 1: The aim of TwinCAT Analytics is the machine-oriented, centralised analysis

of data from one or more simultaneously running machines or systems

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The Workbench’s key function in reducing complexity is, therefore, the complete and automatic conversion of the configuration into readable and executable PLC code with the simple click of a button. This includes connectivity options as well as all network and/or algorithm names. At the same time, a complete HTML-5-based analysis dashboard – the so-called one-click dashboard – is generated and loaded into the selected analytics runtime program. When the code and dashboard generation is completed, users receive the corresponding network address at which they can access the dashboard via a web browser, without having to write a single line of code or design any graphics.

Automatic dashboard generation saves significant time

Simple dashboard generation saves a substantial amount of time within the engineering process. The functionality is based on TwinCAT 3 HMI and for each TwinCAT Analytics algorithm offers a separate HMI control that is based on modern web standards and features a modern tile design. The available controls can be selected within the respective algorithm properties, with a corresponding control preview. Combining multiple algorithms in a single control element is also possible.

Automatic dashboard generation can take many individual user requirements into account. One can specify header colours and logos or optionally display a world map on the start page that shows the locations of all machines being analysed. In addition, several languages are available for the controls. The application designer can also select from various layouts and themes and the user – whether the end-customer or the machine builder’s service technician – has an overview of the entire

machine status at all times (Figure 2). Depending on the surrounding conditions, the user can even switch between light and dark themes. In addition, the reset methods for the algorithms are linked automatically in the dashboard.

Despite its high degree of flexibility, the automatic dashboard generation will not always be able to meet all needs directly, which is why the system integrates as a rule the complete Analytics PLC project and TwinCAT 3 HMI project in Visual Studio®. That way, the application engineer can freely modify the generated dashboard in the graphical editor and add standard or custom controls. Even when the dashboard is customised to a great extent subsequently, this approach still saves more than a thousand clicks and thus, considerable time and costs. In addition, individually designed HMI controls can be integrated into the Analytics workflow and also into the one-click dashboard.

Synergising customised world of analytics

Easy, proven and familiar engineering as well as a complete workflow for the ad-hoc and/or continuous analysis of machine data are the outstanding attributes of TwinCAT Analytics. Many automatic functions make the machine builder’s or system integrator’s work quick and easy while maintaining the flexibility of TwinCAT. Everything from the analysis PLC to the analysis dashboard can be customised. While the end-customer is able to enter the new world of the IoT and service-based business models, the application designer can operate in the familiar world of TwinCAT engineering and make use of its many synergies. There is no way to access new business models and machine options that are based on data analytics with greater ease and cost-effectiveness. ☐

Figure 2: The user – whether the end-customer or the machine builder’s service technician – has an overview of the entire machine status at all times

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As per the ARC definition, digital transformation is the transformation of industrial products, operations, value chains and aftermarket services that are enabled through the augmentation of people and knowledge, through the expanded use of sensors, data and analytics, automated and crowdsourced.

Digital transformation on the move and the next several years will bring this in manufacturing industries. This transformation will be widespread and far-reaching. Information Technology (IT), Operational Technology (OT), Engineering Technology (ET), supply chain, asset management, services and customer-facing systems will all be impacted. Discrete manufacturing, process industries, utilities, energy, infrastructure and more are already beginning the transformation.

Digital transformation trends

It will surely take many years to fully realise digital transformation, but it is already happening faster than many expected. Some of the key digital transformation trends are -

• Artificial Intelligence• Advanced analytics• Augmented Reality• Virtual Reality• Operations performance management• Asset integrity management• Digital twin and digital thread• IT/OT Convergence.

Digital transformation – Way forwardThe Indian manufacturing industry is a promising one, which assures to be one of the most established sectors in the following years. With this, digitalisation is one of the main elements that will help the sector move forward and change it for the better. The article discusses the various trends in digital transformation, challenges and opportunities encountered and how successful digital transformation can be achieved.

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Rajkumar Paira,Senior Analyst,ARC Advisory Group, India

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Primary operational challenges for the industry

Also, while organisations are finding it exceedingly difficult to answer simple questions, lots of operational challenges are faced, such as -

• New projects are larger and more complex• Situational awareness• Eliminating unplanned downtime/incidents• Migration and modernisation• Stranded diagnostics

Top hurdles to overcome

Despite a great deal of industry activity, some real progress and growing comfort with the cloud, issues related to cybersecurity, data security & privacy and confidentiality still lead the list of hurdles to be overcome.

Another group of leading hurdles or obstacles relate to technology issues arising from the fact that today’s plants aren’t highly connected yet. It’s a big part of the digitisation work to be done. These include -

• Lack of strategy for dealing with legacy systems & equipment• Limited availability of machine health data• Complexity of potential solution space: where to focus?

The other leading hurdles are not about technology but are normal business issues, as follows -

• Lack of industry standards (over 41%)• Lack of budget (over 38%)• ROI or business case for digital transformation (over 38%)

Digital transformation opportunities

• Business transformationAccording to a survey by ARC, over half of the respondents

see creating new markets as one of the important aspects to start with the digital transformation journey. Over 40% of respondents also see growing existing markets, opportunities for improving business responsiveness and agility, new services based on smart connected products and opportunities for new business models and revenue streams as very important aspects. ARC frequently sees this expressed as ‘moving closer to the customer’. It is sometimes realised through new service offerings based on connected products or other customer needs. For example, in the paints and coatings market, companies have begun offering online design services to help customers select and visualise colour

schemes in advance. An element of creativity and innovation is needed to bring about a business transformation. • Performance improvement

It is useful to examine the expected performance improvement opportunities from the perspective of the respondent. If we look at the top performance improvement opportunities identified by those whose focus is either business, supply chain, operations or engineering and maintenance, from a business perspective, plant operating performance tops the list, but inventory optimisation, demand forecasting, sustainability & compliance and warehouse operating performance are also important.

Towards successful digital transformation

For successful digital transformation, one must abide by the following -

• Make honest assessments: One must be realistic about the organisation’s readiness to support digital transformation – both willingness and ability

• Account for the human element: Organisations need to lead workforce and culture change. The focus on human-centered questions should start in the initial phase.

• Have a cohesive strategy: Projects should be connected in scale and ROI. Issues arise if planning is too technology-centric or when not considering changing processes and job roles.

• Connect strategy and reality: One must make sure that strategy accounts for reality and reality doesn’t hold back strategy. There should be rationalised decision-making processes at all three phases, from strategy through execution.

• Be flexible: One should be willing to change philosophies to data management and cybersecurity. As organisational gaps are uncovered and initiatives are prioritised, the organisation should evaluate the benefits.

• Measure success: One should identify the metrics to measure success, including time and cost budgets and clarify accountability.

Making the manufacturing industry future ready

While digital transformation has a different meaning for different people, India will have to embrace it, simultaneously with the rest of the world. Digital transformation is influencing businesses and reducing the typical ways of functioning, clearly making it the way forward for the Indian manufacturing industry. ☐

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DR IVES & CO MP O N E N T S | T E CH N OL OG Y


A traditional Chinese proverb says that the roads in Sichuan are hard; harder than climbing to heaven. Depending on the destination, there are rivers and valleys to be crossed and mountains to overcome. The southwestern Chinese province of Sichuan is the source of the majority of different ores in the country, such as titan, lithium and silver, and it plays a major role economically. The electronics, mechanical engineering, metallurgical, chemical, medical, food and building material industries are all pillars of the economy. One of the cement manufacturers in the region is Sichuan Yadong Cement located near Chengdu, the capital of Sichuan. The company is a member of the Asia Cement Group, headquartered in Taipeh, Taiwan.

In 2004, the company decided to build a new cement plant in Sichuan. During the development phase, Asia Cement Group received approval from the Chinese government to use an abandoned railway to transport the limestone. Halfway through finishing the plant however, the government decided to build a new dam. The area intended for the transport was to be flooded, which would have changed the project conditions considerably – roads would be flooded and the trucks would have to take significant detours. Asia Cement Group was also planning on building two additional kiln lines at this location. It was determined, as a time and cost efficient alternative, to install a troughed belt conveyor able to navigate horizontal

Drive technology and conveyor belts – Through terrains & populated regionsSichuan Yadong Cement in Pengzhou, China, has been relying on a 12.5 km overland conveyor from BEUMER Group in order to convey limestones from their quarry silos, which runs through hilly terrain and nature reserves, over streams and unstable ground. The case study analyses the task that came into play while building the conveyor across inhabited areas during the various projects presented to BEUMER by Asia Cement Group, which Sichuan Yadong Cement is a member of, while following the government guidelines.

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TECHNOLOGY | DR I VES & COMPONENTS


and vertical curves. For this, the company turned to BEUMER Group. For many years now, Asia Cement has been relying on the system supplier’s expertise and are currently operating several of its bucket elevators.

Knowing what the customer wants

BEUMER Group took over the mechanical and electrical engineering and supplied the core components for the overland conveyor and monitored and commissioned its installation. The advantage: The Chinese subsidiary BEUMER Machinery, Shanghai, can be reached easily and deployed quickly to site.

“Our colleagues were able to work closely with the customer. They know the specific local customs, speak the language and are familiar with the particular market and customer requirements,” reports Dr Andreas Echelmeyer, Director of Conveying and Loading Systems, BEUMER Group.

In May 2006, Asia Cement Group awarded the contract for the 12.5 km long system. The overland conveyor can reach a mass flow of 1,500 tons per hour and a conveying speed of 4 m/s.

“Compared to other conveying solutions, the open troughed belt conveyors are suitable for higher throughputs. Horizontal as well as vertical curve radii are possible,” explains Dr Echelmeyer. They can be adapted to the specific task and topography. Using BEUMER calculation programs, we can precisely calculate the static and dynamic tractive forces of the belt during the development phase of the system. This is a prerequisite for the safe dimensioning of horizontal curves. The type of drive technology and conveyor belts needed are based on these calculations. This ensures longevity of the entire system.

Mountains, soft grounds and extreme heights

The terrain is hilly and covered with dense bamboo forest, parts of which are listed as nature reserve. For this reason, the government did not approve a service route nor deforestation. The ground also presented a major challenge for the BEUMER Group engineers. “The ground is unstable due to previous coal mining. In other areas, the ground consists mostly of granite that could only be partially removed,” explains Dr Echelmeyer. Another section of 1.5 km had to be guided across a river. These framework conditions contributed to the fact that 90% of the system was installed manually on site. As it was impossible for trucks to transport the components, they were carried by mules, one part at a time, to the place of installation.

The route of the overland conveyor was coordinated between BEUMER Group and the cement manufacturer. The system supplier calculated the tractive forces of the belt considering the eight horizontal curves with radii of 1000 – 5000 m. The routing was checked for its feasibility on site. The complete route was checked by employees on foot, passing through rough terrain, in order to reliably check the predefined positions for the 460 supports for their suitability directly on site. Whenever technically possible, the routing of the conveyor was adapted to the topography. Height differences of up to 100 m had to be overcome within shortest distances, so several sections were equipped with bridges of up to 55 m. One section was realised with a 130 m long tunnel.

In close cooperation with the customer, the company designed the overland conveyor and the bridges. The system supplier developed, built and supplied the core components for

The overland conveyor can reach a mass flow of 1,500 tons per hour and a conveying

speed of 4 m/s

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DR IVES & CO MP O N E N T S | T E CH N OL OG Y


the drive and take-up station as well as the belt of an overall length of 25 km, the idlers and the drive technology. Since February 2009, the overland conveyor has been transporting bulk material from the quarry to the bulk loading system. Since commissioning of the first section, the mass flow of the conveyor was increased in two steps. Today, the system conveys a mass flow of 2200 tons per hour at a conveying speed of 4.5 m/s.

Longest belt conveyor in company history

In July 2013, Asia Cement contracted BEUMER Group again for an additional, efficient overland conveyor to replace the trucks transporting the limestone from the bulk loading system to the cement plant. A mass flow of 2200 tons of limestone per hour was necessary to meet the plant’s requirements. For this project, the first conveyor was to be customised to these requirements. “We were planning a second troughed belt conveyor with an overall length of 13.7 km,” says Dr Echelmeyer. This is the longest system in the history of BEUMER.

Projects of that size are often unpredictable, so flexibility was needed from the engineers. During the planning phase, the cement manufacturer acquired another plant in Lanfeng, approximately ten kilometres away. “Now we had to design the system so that both plants could be supplied with limestone,” explains Dr Echelmeyer. The team had to divide the overland conveyor in two parts. After 5.4 km, an additional conveyor can be added to be fed to Lanfeng in the future. In February 2015, the system supplier started with the installation of the conveyor frame.

Both overland conveyors have four horizontal curves with radii of 1200, 1500 and 1800 m. “We provided the engineering and the individual parts such as pulleys, motors, drive and control technology and the entire automation,” describes Dr Echelmeyer. The installation was monitored by a BEUMER Group supervisor and the wiring of the system was supported by the company’s electrical engineer. The system supplier was also in charge of the commissioning in May 2016. The troughed belt conveyor is now supplying three kiln lines, a fourth line is planned.

Reaching the destination - No longer through rough terrain

The requirements were different for the two projects. The challenges for the first project were the hilly terrain, instable grounds and crossing through conservation areas and over waterways, for the second project the system had to be built crossing through populated areas. The Chinese government has set out exact regulations on the noise emission levels so that the residents would not be impacted. The system supplier took several constructive measures in order to reduce the noise emissions. “We used noise-reducing idlers and customised protective covers on the drive stations,” explains Dr Echelmeyer. In collaboration with the operator, the company optimised the conveyor frame and the completely enclosed conveyor bridge. For the whole project, BEUMER Group was able to ensure that the limestone is transported safely and quietly, without disturbing the residents or disrupting the surrounding nature. ☐Courtesy: BEUMER Group GmbH

View of the enclosed conveyor flight in the area of the bridge

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REPORT | EVENT


Digitalisation is the reason for extensive transformations across several elements of businesses, opening them up to substantial opportunities. In this context, Rockwell Automation recently organised ‘Digital Transformation Forum’ in Pune, India, which highlighted how digital is the way for the industry to go ahead, the challenges at an organisational level and how digitalisation is about more than just technology.

The event kick-started with Arvind Kakru, Country Head-End User & EPC Business, Rockwell Automation India, giving the welcome address and opening remarks. He took the

audience through the agenda of the event, briefing on the topics that will be discussed. Next, Sunit Mukherji, Associate Director

– Plant & Transformation Lead, Induri, Mondelez India Foods, gave the keynote address on ‘Why businesses need to digitally transform – your future is here’.

Having a solid strategy

“We have to embrace digital, as that is the way for the industry to go ahead. Plus, digital success can only happen when one has

The roadmap of digital transformation: Need and future scopeIt is no news that digitalisation has been bringing about humungous disruptions in the manufacturing industry. Keeping this in mind, Rockwell Automation recently organised ‘Digital Transformation Forum’ in Pune, India, which stressed upon how India cannot copy the West in Industry 4.0, how digitalisation can be brought together with ‘a roadmap’ and how digital transformation needs to be customised. A post-event report…

Juili EklahareFeatures [email protected]

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EVENT | R EP ORT


a solid strategy in business,” he said. Mukherji further added that blockchain has helped a lot in international logistics because international logistics has a lot of documentation.

Can’t copy the West

Moving forward, Himanshu Jadhav, CEO, Jendamark India, threw light on ‘Digitalisation influencing manufacturing’. “It is important to create a platform and not own everything that is needed by the customer,” he elucidated. Jadhav also explained that India’s social economic background is completely different from that of Europe. Therefore, India cannot copy them in Industry 4.0.

This was followed by Arup Ghosh, Head Information Solutions Business – India, Rockwell Automation India, highlighting the topic ‘Enhancing asset management & maintenance through strategic use of data’. He said, “By implementing digitalisation, we have seen inventory days from 120 days to 82 days. What’s more, lead times have reduced by 50% and there has been a 40% improvement in quality.”

Roadmap of digitalisation

Up next, Sandeep Bhutani, Associate Director, Cognizant, took over and spoke on ‘Roadmap to implement digitalisation in manufacturing’. “The roadmap to implement digitalisation in manufacturing is to envision, build and apply,” Bhutani asserted and continued, “We interact with the end customer on where they stand right now and how they can get ahead in the Industry 4.0 journey with their end goal.”

Communication from the whole ecosystem

It was then time for the panel discussion, which revolved around the theme ‘Maximising business outcome through Industry 4.0’. The discussion was moderated by Shekhar Jitkar, Publisher & Chief Editor, A&D India magazine and the revered panellists were Ruchi Mathur, Head – Marketing, Rockwell Automation India; Kakru; Jadhav; Dr Pradeep Chatterjee, Head – Digital Transformation & Change Management, Tata Motors; Virbus Mirche, Automation Manager, Alfa Level India and Bhutani. The discussion began with Jitkar addressing the audience, saying that while implementing digitalisation, there

needs to be a proper understanding of the technology, solutions and the outcomes that are required.

Jitkar then put his first question to Kakru, asking him the challenges faced with customers when adopting digitalisation and the overall approach towards it. To this, Kakru responded,

“One should identify what would be the outcome of a project; many projects are not successful when they don’t have outcomes identified very clearly. There are different types of people with a different set of expectations, expertise, etc, while some people might still be testing the waters. So, there needs to be more communication from the whole ecosystem.”

The amalgamation of 'jugaad' and digitalisation

Moving forward, Jitkar then turned to Jadhav, popping the very curious question – while the term ‘jugaad’ comes up very strongly, how can one make a smart combination of jugaad and digitalisation technology? Throwing some light on this, Jadhav returned, “What we call jugaad, is what the Europeans call innovation. Explaining through an example, Jadhav cited, “A problem was thrown at us once, where when a machine goes into breakdown, everyone starts asking when was the last time it was oiled, etc. So, the maintenance person made a diary and wrote down points of what he is doing every day. Taking this ‘jugaad’ solution, we came up with a tool maintenance app, which is given to several maintenance people, who log in, select the machine, get 10 checks to do, can take pictures, report to the manager and solve the problem. This is easier to implement and assures the manager that he gets the record of the 100 odd machines which were checked.”

Challenges at an organisation level

Furthermore, Mirche was questioned from the manpower and skill training point of view across different countries, pressing on how he handles the change in mindset of businesses while implementing new projects. He answered that there certainly is resistance when a business does something new, not because people don’t want to do it, but because it’s something they don’t realise. “And to make them realise it, there is a process,” he expounded and continued, “We experience some things when we start looking into new emerging businesses, where we need to make sure that businesses realise that digitalisation is meant for

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REPORT | EVENT


them to be successful and it will not lead to job loss. We need to change our mindset and way of working.”

Tata Motors is one of the significant companies that has taken a lot of initiatives with digitalisation. Undoubtedly, Chatterjee had quite a bit to say about his experience. “At an organisation level, a couple of things come in the way while using digital technologies,” he revealed and went on, “These include multi stakeholder management, compliance related things and IT security. All of these delay the process of digitalisation. So, we need to find the problem we are trying to solve and the best technology to solve it instead of vice-versa.”

With Chatterjee’s response, Mathur threw light on what infrastructure can be brought in to the customers, similar to such challenges. “People like us would want to create infrastructure where we can come up with some proof points, so that they can understand the outcome they are trying to derive,” she affirmed and continued, “So, when we create infrastructures for people to come and visit, it opens up their minds. Some people are already a step ahead in the maturity curve, but others may have to start their journey or accelerate it

– the intent of these infrastructures should be to simplify and accelerate the roadmap rather than beating around the bush.”

Jobs won’t be lost

Jitkar further went on to ask Bhutani, how does one recommend the kind of approach to have while proposing digitalisation. To this, Bhutani stated that we first need to be very clear that we cannot replace the current infrastructure in the plant. “We need to think how we can leverage the maximum from the existing infrastructure and also educate the industry – jobs won’t be lost, only the profile will change,” he asserted.

The panel discussion soon came to a close, with Jitkar concluding that while there has been an industry slowdown, but there hasn’t been any slowing down in technology change and we need to be a part of that change.

This was followed by a presentation on ‘Redefining industrial automation & predictive anayses’ by Ankur Pancholi, Manager Consultant, Rockwell Automation India. “To properly maintain assets, you need to keep track of many parts in your system,” he averred. Giving an example of using predictive maintenance to monitor heat sink fans, he explained the application factors to be determined before configuration, such as ambient temperature, vibration and early notification.

Cybercrime is getting worse

Subsequently, Sabyasachi Goswami, Connected Services Commercial Leader – AP, Rockwell Automation India, spoke on the topic ‘A robust & secure OT network infrastructure is critical to digitisation’. Highlighting cybercrime, he explained how it’s only getting worse. “Most industrial automation environments are poorly inventoried. If you do not know what is connected in the environment, you cannot secure it,” he clarified.

More than just technology

The final presentation of the day was by Mirche, on ‘A case study of implementation of digitalisation and its impact’.

“Digital transformation is about more than just technology,” he cited and continued, “Don’t go alone and make sure your partners go with you. Plus, there are no limitations in technology; it’s about using combinations together effectively.”

The event wrapped up with Sadashiv Lad, Country Head – OEM Business, Rockwell Automation India, taking the audience through a short briefing on all that was discussed throughout the event. The forum made it crystal clear that businesses that do not act fast to form a broad digital action-plan will lag behind. India’s digital backbone continues to develop and we will have to mandatorily make it a part of our businesses to provide every customer with an experience that is distinguished. ☐

Connected services booth at the event

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EVENT | P R EV I EW


Digitalisation, individualisation, climate protection and demographic change, are the four megatrends changing the world. Hannover Messe shows the global industry a way forward. "The way we live, produce things and work is undergoing extremely rapid changes," said Dr Jochen Köckler, CEO, Deutsche Messe and added, "The manufacturing industry is in the driver's seat. The challenge is to take the wheel and shape the change. At Hannover Messe 2020, to be held on April 20-24, some 5500 exhibiting companies will show how transformation can be positive and how change can spark growth and progress."

Data: Source of efficiency and prerequisite for Machine Learning

In today's world, growth is built on data, and thanks to digitalisation, the volume of data generated in industrial production processes is growing exponentially. Our ability to extract meaning from these data and turn them into profit is also growing. Today's industrial technology solutions are interconnected. Machines and systems communicate and share information with each other autonomously, while software takes care of the documentation, monitoring and simulation.

Hannover Messe 2020: How change becomes growthThe manufacturing industry worldwide is grappling with the twin challenges of technological change and economic and political uncertainty. With its keynote theme of ‘Industrial Transformation’, Hannover Messe 2020 focuses on the opportunities presented by innovative technologies, steadily growing and ever more readily available amounts of data and a growing awareness of climate protection. A preview of what one is set to witness…

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PREV I EW | EVENT


This data revolution is driving efficiency and is the prerequisite for Machine Learning and Artificial Intelligence.

Köckler mentioned, "At Hannover Messe, we show how machines, production plants and intralogistics processes can be transitioned to the digital world. If you don't make this transition, then sooner or later you will be left behind by your competitors." Against this background, Hannover Messe will feature presentations of software solutions for flexible manufacturing and B2B platforms for industry by big-name companies like Amazon Web Services, Cisco, Google, HUAWEI, IBM, Intel, Kaspersky, Microsoft, SAP, Siemens PLM and Software AG.

5G for industry

This year's Hannover Messe will see the return of the 5G testbed infrastructure that premiered last year. Network equipment providers and users will use the testbed to demonstrate the kinds of functionality that the new mobile telephony standard will be able to deliver. Köckler accentuated,

"The ability to transfer large volumes of data in real time while maintaining high standards of data security is absolutely fundamental to the digital integration of the industry. So, in Halls 3 and 21, we are setting up a real, working 5G network." Numerous individual showcases in these halls will be networked via 5G. "Nowhere else in the world will you find such a diverse array of 5G industrial use examples in a real, working 5G network, all under one roof," remarked Köckler.

The convergence of production and logistics

Digitalisation is already a major driver of change in all areas of intralogistics. This includes automated warehouses, where processes are controlled by software programs, and where automated guided vehicle systems tour the halls at all hours of the day and night, delivering the right goods and materials in the right quantities to the right place at exactly the right time. Another key aspect is that production and logistics processes are converging and becoming increasingly interconnected, thereby making production more efficient, flexible & cost-effective. This year's Hannover Messe will hold a mirror to these developments by prominently featuring logistics and intralogistics solutions.

Climate protection through innovation: The road to carbon-neutral production

Industrial production is energy intensive. That is why resource efficiency, energy efficiency, and carbon-neutrality have been on the industry agenda for many years. The climate

debate, that is currently taking place in the society, is helping with this by adding further momentum to the development of sustainable advanced technologies and carbon-neutral business models. Whatever form these technologies and business models take – whether smart solutions for energy, circular economy models or lightweight design – the resulting gains in terms of resource conservation, energy efficiency and process optimisation will do more than merely counter climate change; they will be good for business as well. That is why one of the key messages of Hannover Messe 2020 is that climate protection and forward-looking industrial policies are two inseparable sides of the same coin.

Energy in transition: Hydrogen as a motor for industry

Hydrogen and fuel cell technologies span both infrastructure and industrial applications and are steadily gaining ground in the alternative energy mix. For many years at Hannover Messe, the international ‘Hydrogen + Fuel Cells Europe’ showcase has been a key driver of growth in the hydrogen economy. This year the group exhibit boasts record participation, with more than 200 exhibiting companies from around the world. Visitors gain a comprehensive overview of energy generation and use, transport and mobility, and the interrelationships between the building-systems, manufacturing, transport and energy sectors.

E-mobility infrastructure and related technologies everything from transportation systems and charging technology to electricity network infrastructure and stationary energy storage technologies shall be discussed Hannover: Exhibitors show.

Young guns: Tech start-ups shaking up the industrial sector

One important effect of digitalisation is that it empowers small companies to achieve things that were once the exclusive preserve of the big industrial players. Start-ups are now able to punch above their weight with disruptive ideas and technologies that really make a mark. Tech start-ups from all around the world are rising to the challenge and helping to shape the transformation of industry in all kinds of ways, whether in the form of AI-powered software, virtual reality applications, sensor technologies, smart materials or intelligent energy solutions.

Not only young disrupters present pioneering visions of the future of industry, the show also profiles Indonesia's impressive roadmap for the future. Hannover Messe's official Partner Country for 2020 is taking decisive steps towards the realisation of Industry 4.0. ☐

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TECHN O LO GY | NEWS


Pilz recently launched a modular operating mode selection and access

permission system called PITmode fusion, which enables efficient operation

mode selection and access permission

management, that covers both safety and

security specifications. The new PITmode fusion

consists of a reader unit PITreader with RFID

technology, an integrated web server and a Safe

Evaluation Unit (SEU). Its modular design allows

PITmode fusion to be integrated individually into

the design of existing control consoles. The

existing pushbuttons can be used to enable

better operation for the user. PITmode devices

are used in plants and machineries through

which one can switch between range of control

sequences and operating modes. Authorised users receive an enabled

machine suited to their individual task on a coded RFID transponder key.

One can define up to five safe operating modes, such as automatic mode,

manual intervention under restricted conditions or service mode. Once the

key is inserted into the control console, the SEU detects the specified

operating mode and the PITreader ensures functionally safe switching. So

accidents, misuse and manipulation are prevented.

PITmode fusion with integrated RFID technology

Email: [email protected] | Tel: +91-20-4922 1100

To increase protection against manipulation, the RFID keys can be coded

with company specific programmed PITreaders, i.e. the keys include a

password-protected signature. In addition, RFID

keys and the PITreader can be used to implement a

group-based permission management. In this case,

the various enables are transferred to the whole

group with the same access permissions instead of

an individual person. Open for further tasks, one

can use PITmode fusion to implement a wide range

of functions beyond access permission and

operation mode selection. On top of that, a complex

hierarchical permission matrix with various groups

and permissions, can be created in the free user

area. These functions are bundled on the RFID key,

replacing additional mechanical keys or access cards.

Two other versions of the PITmode are available in addition to the modular

version. The reader unit, PITreader, can be used to control access permissions

and is particularly flexible as a standalone device or in conjunction with a Pilz

controller, such as the configurable small controller PNOZmulti or the

automation system PSS 4000. PITmode and PITmode fusion offer functionally

safe operating mode selection and access permission up to PL d.

Pilz India | India

RFID enabled access permission system

Compact motor-mounted drives

B&R recently introduced two compact motor-mounted drives. The two

new additions to the ACOPOSmotor series facilitate development of

modular plants and machinery.

They reduce installation costs and

save cabinet space. The new

devices cover a power range up to

0.35 kW, and the smallest version

measures 60 mm x 90 mm. Despite

their compact dimensions, they

have a full-fledged integrated servo

drive that enables control loops as

fast as 50 µs. They are optionally available with an integrated gearbox

and brake. The devices have two connections for hybrid cables, so only a

single cable is required to connect to the control cabinet. The hybrid cable

transmits both the power supply and POWERLINK communication.

Additional ACOPOSmotor units are easily added on via daisy-chain

cabling. The unique 300° swivel connections also facilitate easy

installation. The new variants have a wide voltage range of 24 to 60 VDC.

It is also possible to feed regenerative braking energy back into the DC

bus. This can reduce energy consumption by up to 30%. The STO safety

function comes standard on motor-mounted drives.

Circular multi-bushing with gel technology

Lapp India recently developed the Skintop Multi-M with metric connection

thread which has highly elastic gel technology, making it possible to insert

cables with variable outside diameters of

2-6 mm into entry point. The Skintop

Multi-M offers the connection of both, by

enabling the insertion of a large number

of cables in a round cable gland with

metric connection thread. The gel is

firmly connected to a plastic outer shell

which defines the possible feed-through

points. As the gel has high elasticity, the

conductors can be routed directly

without having to pierce the gel beforehand. The gel adapts optimally to the

cable diameter and thus, guarantees a high IP protection class (IP 68). At the

same time the gel technology ensures that unused entry points remain

securely sealed against the ingress of foreign bodies, but they can also be

used directly for insertion if cabling is subsequently required. This makes the

round Skintop Multi-M multiple entry system with metric connection thread

particularly suitable for feeding through unassembled cables and conductors

as well as media-conducting hoses. This ensures quick and easy installation

of the cables even with the highest packing density.

Email: [email protected] | Tel: +91-20-4147 8999 Email: [email protected] | Tel: +91-80-4740 5222

Lapp India | BengaluruB&R Industrial Automation | Pune

Compact motor-mounted drives

Skintop Multi-M

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NEWS | TECHNOLOGY


Gandhi Automations recently launched high-speed metallic doors that are

ideal for commercial and high security applications where speed is

important, looks are critical, traffic is frequent and door safety concerns are

paramount. The door panels are constructed with low profile anodised

double walled aluminium, with durable EPDM rubber weather seal between

slats that can withstand wind pressure.

Using ultra-high-speed operation and

unique spiral technology, the prime metallic

door is fast and extremely quiet. Top-to-

bottom, full-width window slats provide extra

safety and a high-tech look to promote an

enviable image of cutting-edge operations.

This door is ideal for modern production

and commercial environments, such as

automotive dealerships, government, parking

and security applications.

The patent pending no metal-to-metal contact design provides

whisper quiet operation and reduces wear. The structural finishes and

stainless-steel screws make them perfect for narrow spaces where there

is an intense flow of traffic. The curtain of the door comes in a wide range

of colours, which include three different shades of blue, two shades of

Prime mettalic high speed rigid door

Email: [email protected] | Tel: +91-22-6672 0200/300

grey, orange, white, ivory, yellow, red, green and black, chosen according

to the design of the area where the door will be installed. They are also

compatible with the company's accessories, such as the microwave

sensor, safety photocells and the presence and movement sensor, which

help enhance the natural advantages of this model.

Its simple, patented design ensures

hundreds of thousands of maintenance-free

cycles. Its ‘full view’ panels, made of clear

polycarbonate glass and supported by

aluminium frames, provide natural light and

create a quality environment for employees

and customers alike. The bold, eye-catching

design includes performance features that

add value and ensure safety and protection

for employees and equipment.

Improved sealing around the perimeter of

the door limits air leakage and helps support an increased U-value. It will

quickly seal the building, reducing temperature loss to achieve maximum

energy savings. The outstanding engineering makes the doors extremely

fast, safe, robust and guarantees an extremely long service life, with low

maintenance needs.

Gandhi Automations | Mumbai

High-speed rigid exterior doors

IE3 asynchronous motors

Nord Drivesystems recently optimised the design of its IE3 asynchronous

motors with numerous details that achieve a better assembly and cooling.

The facelift of the IE3

asynchronous motors involves

no change of electrical data and

outer dimensions. It can be

seamlessly used without

adjustments in any existing

application with IE3 motors. The

optimised cooling fin shape, an

assembly-optimised fan and a

new modern fan cowl, enable a

better heat dissipation and

assembly. The fan cowl can be simply assembled in case a motor-

mounted frequency inverter is used. The new cooling fins design enables

an unhindered airflow around the terminal box. The revised terminal box

is without sharp edges and corners and has reinforced feet for a better

motor stability. Another important detail is the optimised incremental

encoder mounting. Due to the fan cowl, the encoder is fully shock-

resistant and not within the airflow, which further improves the cooling

power. Retrofit mounting is also possible due to a plug-on shaft.

IIoT-ready controller

Schneider Electric recently announced the launch of a solution, the new

Modicon M262 controller, which is IIoT-ready for logic and motion applications.

It offers intuitive, scalable and reliable

machine integration into Industry 4.0

environment, machine to device, machine to

human, machine to machine, machine to

plant or machine directly to cloud.

Additionally, the controller embeds cyber

security features and encryption protocols to

provide direct cloud connectivity and digital

services through two ready-to-work and

independent embedded Ethernet ports. Few

of the key benefits of the controller includes connectivity, efficiency, flexibility &

protection. The Modicon M262 Controller is IIoT-ready, designed and delivered

with intuitive direct cloud connectivity. No gateways are required, which

enables OEMs to maximise profitability and optimise their time, from the design

of performance demanding applications to the commissioning of the machine.

This controller is an integral part of the company’s EcoStruxureTM Machine, a

complete architecture that brings powerful capabilities to smart machines.

Modicon M262 can be easily connected to EcoStruxure Machine Advisor, which

allows OEMs to enable asset monitoring and predictive maintenance.

Email: [email protected] | Tel: +91-20-39801200 Email: [email protected] | Tel: +91-80-4554 0000

Schneider Electric India | BengaluruNord Drivesystems | Pune

Optimised design for IE3

asynchronous motors

Modicon M262

54

TECHN O LO GY | NEWS


igus recently developed the gear service life calculator for its 3D printed

gears made of the laser sintering high-performance plastic iglidur I3.

With the new online tool, the user

receives a concrete statement in a few

seconds about the service life of the

wear-resistant part. By uploading the

file in the igus 3D printing

service (www.igus.in/3Dprintservice),

the configured gear made from the

iglidur I3 can be ordered immediately

from the company. So that the customer

can also determine the service life of

his wear-resistant gear, igus has now

developed the gear service life

calculator. By means of this, the user

receives in just three steps a concrete

statement about the service life and the

application limits of his gear pairing.

Get the precise service life in just three steps

In step 1, the user must first enter the number of teeth, the width and the

The service life of wear-resistant 3D printed gears

Email: [email protected] | Tel: +91-93411 36381

tooth module of the gear pairing again. Here the customer can choose

between iglidur I3 gears, a metal or another plastic. In step 2, the tool

asks for the speed and torque of the

large or small gear, depending on the

which gear's values are available. Step 3

is to determine the duty cycle of the

printed gear, the mode of operation, the

ambient temperature and the safety

factor. Based on the specified

parameters, the new online tool can

determine the service life of the 3D

printed gear in seconds. This makes

maintenance predictable in advance.

Here, the gear made of iglidur I3

took on a POM injection-moulded gear

and a POM machined gear in a pivot test

at 1440°C at a speed of 0.1 m/s and a

torque of 2.2 Nm. All gears had 30 teeth

and a width of 16mm. While the injection-moulded gear made of POM

failed after just 4,000 cycles and the machined POM gear broke down

after 12,500 cycles, the iglidur I3 gear withstood almost 20,000 cycles.

igus India | Bengaluru

Gear service life calculator

Universal grippers

Schunk Intec recently expanded its range of PGN-plus-P universal

grippers with all sizes of the PGN-plus-P, which are now available as

ATEX version for the use in potentially explosive

areas. Also, all sizes are available in dust-proof

version as part of the catalogue range along with

corresponding retrofit kits for existing grippers. The

new design minimises wear and increases life span,

even under normal loads. In addition, circumferential

lubricant pockets on the multi-tooth guidance ensure

permanent lubrication of the sliding surfaces and the

grippers operate maintenance-free under clean

operating conditions for their entire life span. Tests

in the company’s own product torture chamber show

that the new modules have a significant edge over other products on the

market, especially with respect to life span. Achieving cycle times in the

middle seven-digit range with the PGN-plus-P are not uncommon. But

what is even more important from the user's point of view, is the high

process reliability of the modules, which is important for ensuring

trouble-free plant operations. The company has integrated possibilities

for screw connections, supports or centring as standard. The sensor

program is also impressive.

Insulation monitoring solution

DOLD Electric India recently developed an intelligent solution for

insulation monitoring, especially for DC charging stations, the RN

5897/020 of the VARIMETER IMD

family. The RN 5897/020 is used

especially for DC charging stations,

according to the IEC/EN 61851-23

standard, and monitors the charging

process from the charging station into

the vehicle. The device is characterised

by the short response delay of ≤ 1s, a

nominal voltage up to DC 1000 V with

an additional coupling device and the

detection of asymmetrical as well as

symmetrical insulation faults. The

integrated voltage measurement ensures reliable determination of the

insulation resistance in the IT system. The insulation monitor also has a

self-test. This takes place automatically after power-on and after every

full operating hour. In addition to monitoring DC charging stations, the

insulation monitor RN 5897/020 can also be used to monitor unearthed

AC, DC, AC/DC system, UPS systems, networks with frequency converters

or DC drives, battery networks and mobile power generators.

Email: [email protected] | Tel: +91-80-4053 8999 Email: [email protected] | Tel: +91-99090 01585

DOLD Electric India | VadodaraSchunk Intec India | Bengaluru

PGN-plus P

RN 5897/020

7410009435/36 aandd -

56 A&D I nd i a | Fe b -Ma r20

2

» Chemical & Process

Chemical companies are adapting to the digital world at a very fast rate. The chemical industry is reshaping around several major trends. It is a rich application field of automation with a massive leverage on production economy. The following issue outlines the development in the chemical & process industry in the area of automation and digitalisation.

» Wireless Automation

With the manufacturing industry working its way towards Industry 4.0, it is embarking itself into a journey to automate production, to make machine wireless, and to make operations smarter. The installed base of wireless IoT devices in industrial automation is resulting in intelligent manufacturing. The forth coming edition discusses the recent trends, advancement benefitting the industry and the future of wireless automation in the manufacturing industry.

» Additive Manufacturing

Additive Manufacturing offers unprecedented opportunities to design complex structures optimised for performance envelopes, inaccessible under conventional manufacturing constraints. The upcoming issue focuses the current capabilities of additive processes and optimisation tools, while an emerging opportunity will be discussed to achieve a holistic design paradigm.

H IGHL IGH T S | CO MPAN Y INDEX | IMPR INT

COMPANY INDEXName . . . . . . . . . . . . . . . . . . . . . . . . . Page

ARC Advisory Group India . . . . . . . . . . . . . . 42

Aspen Technology . . . . . . . . . . . . . . . . . . . . 22

B&R Industrial Automation . . . 9, 14, 31, 34, 52

Beckhoff Automation . . . . . . . . . . . . . . . . 1, 38

BEUMER Group . . . . . . . . . . . . . . . . . . . . . 44

Capgemini Research Institute . . . . . . . . . . . . 13

Contrinex Automation . . . . . . . . . . . . . . . . . 21

Delta Electronics India . . . . . . . . . . . . . . . 3, 16

Deutsche Messe AG . . . . . . . . . . . . . . . . . . 50

DOLD Electric India . . . . . . . . . . . . . . . . . . . 54

Endress+Hauser India . . . . . . . . . . . . . . . . . 30

EtherCAT Technology Group . . . . . . . . . . . . . 13

Frost & Sullivan . . . . . . . . . . . . . . . . . . . . . 13

Gandhi Automations . . . . . . . . . . . . . . . . 5, 53

Name . . . . . . . . . . . . . . . . . . . . . . . . . Page

GreyOrange . . . . . . . . . . . . . . . . . . . . . . . . 32

HCL Technologies . . . . . . . . . . . . . . . . . . . . 20

HMS Industrial Networks . . . . . . . . . . . . . . . . 6

Honeywell . . . . . . . . . . . . . . . . . . . . . . . . . 12

Hummel Connector Systems . . . . . . Back Cover

ifm Electronic India . . . . . . . . . . . . . . . . . . . . 4

igus India . . . . . . . . . . . . . . . . . . . . . . . . 2, 54

IHS Markit India . . . . . . . . . . . . . . . . . . . . . 12

Innovista Sensors India . . . . . . . . . . . . . . . . 19

International Society of Automation . . . . . . . . 31

Karlsruhe Institute of Technology . . . . . . . . . . 12

Kubler Automation . . . . . . . . . . . . . . . . . . . 41

Lapp India . . . . . . . . . . . .52, Back Inside Cover

Mitsubishi Electric . . . . . . . . . . . . . . . . . . . . 27

Name . . . . . . . . . . . . . . . . . . . . . . . . . Page

Nord Drivesystems . . . . . . . . . . . . . . . . . . . 53

OMRON Automation India . . . . . . . . . . . . . . 32

Pilz India . . . . . . . . . . . . . . . . . . . . . . . 33, 52

Puresight Systems . . . . . . . . . . . . . . . . . . . 10

Rexel India . . . . . . . . . . . . . . . . . . . . . 17, 37

Rockwell Automation . . . . . . . . . . . . 12, 15, 47

Sampark Foundation . . . . . . . . . . . . . . . . . . 20

Sansare Engineering . . . . . . . . . . . . . . . . . . 28

Schneider Electric . . . . . . . . . . . . . . . . . 32, 53

Schunk Intec India . . . . . .54, Front Inside Cover

Tech Mahindra . . . . . . . . . . . . . . . . . . . . . . 12

UdyogYantra Technologies . . . . . . . . . . . . . . 18

Vega India Level and Pressure Measurement . . 11

Highlights – Apr-May 2020IMPRINT

Efficient Manufacturing

Automation & Drives

Publisher / Chief Editor Shekhar Jitkar [email protected]

Features Writer Juili Eklahare [email protected]

Sub-editor & Correspondent Anvita Pillai [email protected]

Content Developer (Online & Print) Namrata Singhania [email protected]

Advertising Sales & Marketing Sagar Tamhane (General Manager – North & East) Contact: +91 9820692293 [email protected]

Dhiraj Bhalerao (General Manager – West & South) Contact: +91 9820211816 [email protected]

Alok Kumar (Sr Manager – South) Bangalore Contact: +91 8861009443 [email protected]

Advertising Sales (Germany) Caroline Häfner (+49 - 89 - 500 383 - 53) [email protected]

Overseas Partner Ringier Trade Media Ltd China, Taiwan & South-East Asia Tel: +852 2369 - 8788 [email protected]

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) Shekhar Jitkar (Publisher / Chief Editor)

Subscription Cover Price: `100 Annual Subscription Price: `1000 [email protected] Tel: +91-7410006435/36

Printing Vikram Printers Pvt. Ltd., Parvati Industrial Estate, Pune-Satara Road, Pune - 411009, Maharashtra, INDIA

Copyright/Reprinting The publishing company holds all publishing and usage rights. The reprinting, duplication and online publication of the magazine contents is only allowed with written permission from the publishing company. The publishing company and editorial staff are not liable for any unsolicited manuscripts, photos and illustrations which have been submitted.

Internet https://industr.com/en/

Digital edition https://www.industr.com/en/e-paper

RNI NO. MAHENG/2010/34602

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