A&d Apr May 2016 by Jogindar Dumde

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A U TO M AT I O N & D R I V E S

Automation & Drives

AUTOMATION AS A STRATEGY

Efficient Manufacturing

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Drawing a full roadmap

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E D I TO R I A L

Celebration of achievements! Milestones in any journey provide landmarks for judging progress that has been made as well as offer an opportunity to reflect upon what is to come. For us, at A&D India, anniversary issue is meant to be a celebration of both the accomplishments of the past and the potential for the future. This issue marks the 8th Anniversary of A&D India. The magazine has enjoyed many significant achievements during its journey, as we continued to stay focussed and adapted through the many challenges of a demanding industry and competitive environment. We have many mountains to conquer, many miles to travel before we can say A&D India is an ultimate choice for those who want to stay abreast with the latest developments in the automation & robotics world. A&D India has already begun to solidify a reputation as a professional forum for not only the Indian industry, but also the global one. Your success will tell us if we are on the right track to provide the information you need to reach your objectives today and in the future. Let us know what your needs are and we will put all our efforts in providing you the best and the right contents, issue after issue. We owe a debt of gratitude to the many people who supported us in our journey to success – our advertisers and contributors, advisory board members, partners, and most importantly our readers. We are thankful to all of them. Best wishes!

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EDITORIAL ADVISORY BOARD

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

Vijay Srinivasan Managing Director, Global Alliances, CSC

Anant Maheshwari President Honeywell India

Dr KLS Sharma Advisor Automation Education & Training

Anup Wadhwa Director – AIA (Automation Industry Association)

Ravi Agarwal Director, Pepperl+Fuchs (Factory Automation)

Mandar Phadke CEO, Abhisam Software Director, Risknowlogy Solutions

P V Sivaram MD – B&R Automation Member – AIA

Raj Singh Rathee Managing Director Kuka Robotics India

Arcot Rajabahadur Automation Consultant

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

Jasbir Singh Vice President Business Development Essar Projects (India) Limited

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

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

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Phone +91 20 267 410 09 5 www.micro-epsilon.in/color

CONTENTS

Market

Management

Focus

Cover story 08

NEWS

â&#x20AC;&#x153;DIGITAL ENTERPRISE: THE WAY TO INDUSTRY 4.0â&#x20AC;?

Interview with Karlheinz Kaul, CEOâ&#x20AC;&#x201D;Business Unit Digital Factory, Control Products, Siemens AG

Event Report 70

Chemical & Process

AUTOMATION AS A STRATEGY

The cover story features a series of interviews with industry experts, highlighting their views on the desired roadmap to drive automation & robotic technology in the existing supply chain, thereby, walking a step ahead towards achieving future-ready factories in India

7 WAYS TO IMPROVE PRODUCTIVITY AND PROCESS OPERATION

The article discusses the seven ways to leverage the advances in pressure transmitter technology so as to gain greater control over productivity and process operations

DESIGN, VALIDATE, COLLABORATE & BUILD

A post-event report on the SolidWorks World 2016 held in Dallas, Texas, USA 74

TRANSFORMING FOOD & BEVERAGE INDUSTRY

A post-event report on the recently held FoodSafe 2016 in Bengaluru

CONTENTS

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Technology

Gears & Motors 56

DESIGN TIPS FOR GEARMOTOR APPLICATIONS

Communication & Control 64

The feature highlights the five criteria that should be considered while choosing the gearmotors for an application

Safety & Integration 60

FIVE KEY ELEMENTS FOR EFFECTIVE IIoT IMPLEMENTATION

The feature examines the key elements for IIoT and explores the benefits resulting from connecting, monitoring and controlling operations

Fibre optic connector; Intelligent stop point; Detachable plastics; Timers, monitoring relays;

Cable laying system; Barcode positioning system; Capacitive sensors; Barcode readers;

Data logger; IO-link modules; Mobile terminal for HMI access; Magnetic grippers

Machine Tools

AUTHORISATION CONCEPTS IN MACHINE AUTOMATION

A read on the machinery safety and operational security in modern automation architectures

New Products

AUTOMATION IN MACHINE TOOLS

The article explains the role of automation in machine tools and the need to exploit the opportunities in the Indian machine tool sector

Columns 05 06 80 80

Editorial Contents Highlights - Next issue Company index

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MARKET | NEWS

B&R opens new office in Mumbai

Beckhoff at Hannover Messe 2016

B&R has recently opened a new office in Mumbai. The new facility is located in Thane’s industrial belt and will cater to the areas in and around Mumbai with the help of a complete team from sales, application, support and training. This expansion is a part of the company’s growth strategy for the Indian market and philosophy to be near the customers. Speaking on the occasion, P V Sivaram, MD, B&R India, said, “We always believe in delivering best of the technologies, professional consultation and expert application support to our customers, that’s why our direct office will benefit numerous machine builders and manufacturers in this region”. B&R has also announced recently its foray into process & factory automation The new facility is located at Odyssey IT Park, business in India. The Wagle Estate, Thane company now offers complete solution for smart machines and smart factories. An automation specialist and a leader in innovative technologies, B&R provides complete solutions for machines & process automation.

Beckhoff participated at the Hanover Messe 2016, in line with this year’s lead theme ‘Discover Solutions’, focusing on IoT and Industrie 4.0. Visitors could explore the expanded Industrie 4.0 forum at the company booth. Spanning 1,000 square metres, the booth demonstrated basic technologies and ready-to-use products for the smart factory. As part of the booth for the ‘it’s OWL’ technology network, there was a demonstration of the current state of ‘Scientific Automation’ and ‘eXtreme Fast Automation’, both of which are BMBFfunded leading-edge cluster research projects. All applications with Beckhoff PC control technology are essentially ready for Industrie 4.0 today. The complete process control mappings, which can be Visitors could explore the expanded generated from the control Industrie 4.0 forum at the booth technology makes it easy for the user to assess the various machines and systems. Extensive Industrie 4.0 features are available at the click of a button. All of this is made possible by a variety of new products. TwinCAT Analytics provides the foundation for predictive maintenance and machine optimisation.

ABB honours Moxa with supplier award

Industrial Ethernet is growing faster

Moxa has been recently felicitated with the ABB Supplier Award, best in collaboration for projects sourcing for its excellent cooperation in the DF21 Datacenter project. Moxa’s team worked closely with the various parties involved to ensure an on-time delivery to enable ABB to meet the project’s timelines. The award was presented by Jan Keller, VP—PA SCM, to Charles Chen, GM, Moxa, India. As per Chen, “One of our core values is Moxa supplied advanced serial-tocustomer focus, and we have Ethernet Modbus gateways to ABB embedded this value in our blood and soul. This project was costsensitive and urgent. I am proud that our team was able to help ABB complete the project during the holiday period with perfect execution. Our core values are integrity, mutual respect, customer focus and execution, which I found a lot similar to those of ABB, and perhaps this will strengthen our partnership by our sharing similar of values.” Moxa supplied advanced serial-to-Ethernet Modbus gateways to ABB, who was front-ending the DF 21 Datacenter project. Moxa has a distribution and service network that reaches customers in more than 70 countries. Its products have connected more than 30 million devices worldwide in a wide range of applications across different vertical markets.

As per a recent survey from HMS, Industrial Ethernet is growing faster than before, and now accounts for 38% of the market. EtherNet/ IP is in first place within industrial Ethernet globally, followed by PROFINET. However, classic fieldbuses are still dominating the fragmented world of industrial networks with 58% and PROFIBUS is still the Classic fieldbuses are still dominating most widely used industrial the fragmented world of industrial network. Some trends seen networks within industrial communication in 2016 include that fieldbus is still growing, by approximately 7% per year as users ask for simplicity, tradition and reliability. Next seen is that wireless is coming. For the first time, wireless technologies are on the chart with 4% of the worldwide industrial network market. The US market is dominated by the CIP networks where EtherNet/IP is overtaking DeviceNet in terms of market shares. “It is interesting to see that industrial Ethernet is now growing faster and that wireless technologies are gaining foothold,” said Anders Hansson, Marketing Director, HMS Industrial Networks. HMS Industrial Networks is the leading independent supplier of products for industrial communication including remote management.

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MARKET | NEWS

Honeywell partners with Indian manufacturer

Industrial robots post a new sales record in 2015

Honeywell recently announced that it has entered into a supply agreement and technology license with an Indian manufacturer to produce Honeywell Solstice® yf, an automobile refrigerant with a global warming potential of less than 1. Honeywell will license its proprietary process technologies to produce the refrigerant to Navin Fluorine International Limited (NFIL), which will manufacture Solstice® yf in India exclusively for Honeywell. Honeywell and its key suppliers are investing approximately $300 million to increase global production capacity for Solstice® yf, including Honeywell and its key suppliers are investing the construction of a new, approximately $300 million to increase world-scale manufacturing global production capacity for Solstice ®yf plant using new process technology at the company’s existing Geismar, La, refrigerants manufacturing site. Speaking on the agreement, Ken Gayer, VP & GM, Honeywell Fluorine Products, said, “This agreement reflects our commitment to delivering the supply chain reliability and security that customers can rely upon as they transition to nextgeneration products that are safe to use, available today and capable of making a significant positive environmental impact.”

As per reports from IFR, in 2015, the number of industrial robots sold worldwide surpassed the 240,000 unit mark for the first time. This corresponds to the global year-on-year growth of 8%. The greatest demand was again registered by the automotive industry. China continues to exhibit the highest demand for industrial robots—sales rose by 16%. Despite the general perception of a ‘reluctant’ investment climate, China extended its leading position as the number one sales market worldwide with unit sales reaching 66,000. Sales of industrial robots in Europe The greatest demand was again registered rose by a record of 9% to by the automotive industry nearly 50,000 units. Eastern Europe, with growth of 29%, proved to be one of the fastest growing regions globally. In the US, Canada and Mexico, a total of 34,000 units were sold in 2015 representing year-onyear growth of 11%. “Today, the automotive industry is taking a leading role when it comes to flexible and state-of-the-art automation solutions and the direct collaboration between humans and robots”, said Stefan Lampa, President & CEO, KUKA Roboter.

ISA Banagalore honours S Palaniyappan

L&T showcases smart solutions at ELECRAMA 2016

ISA Bangalore section recently honoured S Palaniyappan at the FoodSafe 2016 symposium, in the presence of a large automation fraternity. Palaniyappan (Palani) is an able administrator who has contributed to the success of ISA for well over a decade and most part of its existence. At 76 years of age, he still keeps himself busy in following up for memberships, training programs, tech-talks and symposia that the section Palaniyappan has contributed to the success organises. Palani graduated of ISA for over a decade in Mechanical Engineering from BMS College of Engineering, Bengaluru in 1963. His initial decades were devoted with NGEF Ltd, Bangalore, where he was holding a senior management position in industrial-cum-process engineering group. He was responsible for establishing time standards for industrial operations, evaluating industrial jobs to fit in the industrial wage grades, designing of incentive schemes, factory and workplace layouts, including establishing annual resource requirement. Subsequently, Palani headed the Production Management Services at Meher Capacitors and later with ARC Advisory Group.

The Electrical & Automation business of Larsen & Toubro (L&T) unveiled state-of-the-art SCADA solution on a standardised platform for the seamless integration of Medium Voltage (MV) and Low Voltage (LV) products that go into industry, infrastructure and the building segments at the recently concluded Elecrama 2016. Commenting on the display, SC Bhargava, Senior VP & Head, L&T Electrical & L&T was felicitated with the 1st runner up Automation, said,“SmartComm award for the best stall category is E&A’s new SCADA-based unified software platform for device communication, integration, data acquisition & management, monitoring & control as well as preemptive and predictive data analysis. This single platform integrates all communicable product offerings ranging from digital panel meters through circuit breakers, protection relays, AC drives, soft starters, I/O modules, building electricals and building automation devices and sensors. SmartComm is capable of providing energy management solution because of its built-in features of energy monitoring and energy billing. This will benefit user with possible energy savings and thus the cost optimisation. It has building automation and management functionality too.

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MARKET | NEWS

Lapp India receives ISO 14001: 2004 certification

NI identifies top business and technology trends

Lapp India has recently received an ISO 14001:2004 certification from TUV Rheinland, which is an internationally recognised standard for environmental management of businesses. The certification helps organisations minimise their impact on the environment, comply with applicable laws and regulations and work towards continual environmental improvement. The certification has been awarded to Lapp India for successfully implementing and incorporating international standards of Environment Management System (EMS) initiative as its corporate way of life. “This certification is a milestone achievement for Lapp India and reflects the company’s long-term commitment in achieving our environmental responsibilities. Conformance to international standards will instill confidence in our customers, of our products’ safety, reliability and quality. Attaining standards such as ISO 14001 will enable us to formalise energy management within our own operations,” said Marc Jarrault, MD, LAPP India. During the certification process, Lapp India employees were given the opportunity to understand how their work affects the environment, and to develop practices & technologies that improve environmental health. Lapp India has raised the bar for health, safety, security and environment in the wire and cable industry.

National Instruments recently released its Automated Test Outlook 2016. The annual test and measurement report delivers a comprehensive view of the key trends expected to impact automated test environments with the proliferation of connected devices, from preparing to test mmWave communication to effectively using manufacturing test data to propel business results. “We work closely with customers and suppliers to understand the top issues facing manufacturing and test departments,” said Jayaram Pillai, MD—India, National The test views the key trends Instruments. The test explores topics like expected to impact automated computing, (semiconductor organisations test environments pioneer real-time data analytics to reduce manufacturing test cost); software (obsolescence, OS churn, and compatibility challenge long life-cycle projects—an age-old problem warrants revisiting); architecture (off-theshelf test executives are effective solutions for the influx of new programming languages); I/O (RFIC companies employ IP reuse and hardware standardisation across the product design cycle to reduce cost and shorten time to market) and business strategy (test managers are adopting modular solutions to economically validate high-frequency components).

Omron unveils total tamper detection solution

Rice plant with maximum automation launched

Omron recently launched its Total Tamper Detection Solution, the first-of-its-kind—to address the national level concerns of power theft in the electricity sector. Positioned as a revolutionary offering for Smart Energy Management, the solution has been unveiled by the company at the ongoing India Smart Grid Week – 2016. Conceptualised in association with As per Raphael, Omron’s security sensor for the the utility, Tata Power smart meters is multi-functional Delhi Distribution Limited (TPDDL), the endeavour is visualised as a milestone in enabling the Smart Grid initiative of the Government of India and is also expected to play a key role in shaping the macro initiatives of national importance. As per Vinod Raphael, Country Business Head – Omron Electronic & Mechanical Components business division in India, said, “Though it is difficult to reckon the proportion of power theft in the T&D losses, it is certainly one of the major concerns for the utilities. Omron’s security sensor for the smart meters is multifunctional, imparting a unique artificial intelligence to the meter by detecting all kinds of tampering.”

Ghodawat Consumer Products (GCPL), the FMCG arm of Sanjay Ghodawat Group recently launched the new state-of-the-art rice plant at Majale, Kolhapur in Maharashtra. As part of their business consolidation and expansion plan, the new plant installed with Swiss processing technology will be able to process 180 metric tons of rice paddy per day. The new mill is equipped to efficiently produce steam, raw and boiled rice. The unit is Ghodawat Consumer Products (GCPL), Kolhapur set up in a way that the plant installed with Swiss processing technology products match the standard norms of Central Food Technological Research Institute (CFTRI). It is a highly advanced facility with maximum automation. On this occasion, Shrenik Ghodawat, Director, Sanjay Ghodawat Group, said, “The facility will further add value to our existing infrastructure. We have invested over ` 750 million in the unit. It will enable us to roll out new and improved products, which will match international quality and taste. This unit also further reinforces our commitment to provide new products, which are well researched and perfected.”

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MARKET | INTERVIEW

“Digital Enterprise: The way to Industry 4.0” …says Karlheinz Kaul, CEO—Business Unit Digital Factory, Control Products, Siemens AG, in this interaction with Maria Jerin, while discussing the company’s business models and its future-proof solutions towards Industry 4.0

Given that Siemens has recognised digitalisation as a growth driver for industries, how is it helping customers in optimising their business models in a competitive manner? Digitalisation has long grown to become a vital lever of growth in almost all industries. It makes possible to develop totally new smart solutions and spark a new level of competitive advantages. These solutions will differ depending on the industry, and even on the company, because they always have to be customised to suit the unique business situation and IT conditions that apply in each case. This is one of the reasons why open standards, common technology platforms, and the universal, global communications infrastructure of the internet will form the common building blocks in the future.

Big Data is already being used in this regard to optimise production schedules based on supply and demand, machine availability and cost constraints. It can give manufacturers information in real-time about product success and demand. Connectivity and interaction among parts, machines, and humans will make production systems as much as 30% faster and 25% more efficient and elevate customisation to new levels. Today, the buzz is that integration of the virtual and real worlds need not only be ‘Big Data’, but also ‘smart data.’ How would you define smart data? Smart data is the data from which signals and patterns have been extracted by intelligent algorithms. It is crucial to know what kind of data you have and what you want to analyse from it in order to pick a flexible data analytics solution to suite your needs. Collecting large amounts of statistics and numbers bring little benefit if there is no layer of added intelligence. Customer identification stems from smart data. It is crucial to know what kind of data you have and what you want to analyse from it in order to pick a flexible data analytics solution to suite your needs. Aside from determining data life cycles, it is also important to think about how the data should be processed.

How does your company models to Industry 4.0? What are the products in offing from Siemens that support customers, specifically as they move toward Industry 4.0? Siemens terms its way to Industry 4.0 as the “Digital Enterprise”. The path to the Digital Enterprise comprises four core elements that logically build on one another: Digital Enterprise software suite – based on Teamcenter as a collaborative platform that seamlessly integrates PLM (Product Lifecycle Management), MES/MOM (Manufacturing Execution System/Manufacturing Operations Management) and TIA (Totally Integrated Automation). We intend to extend and complete the Digital The Government of India has recently launched the Enterprise software suite in coming years. Other important ‘Digital India’ initiative. How do you think this initiative is elements are industrial communications networks, security for supporting digital transformation across the manufacturing automation and business-specific industrial services. We have industry? all of these four core elements in our portfolio. These allow Rapid technological advancement has opened up an opportunity customers to invest in future-proof solutions for a step-by-step for Indian manufacturing industry to level the playing field realisation of Industry 4.0 today. and compete with larger players. With its traditional strengths in software development, I would see India playing a very How does Big Data address the challenges in the important role in the manufacturing economy of the future. manufacturing landscape? To this extent, the government initiatives are very welcome. ☐

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C O V E R S TO R Y | M A N A G E M E N T

M A N A G E M E N T | C O V E R S TO R Y

AUTOMATION AS A STRATEGY

Drawing a full roadmap

To examine automation as a strategy for increasing productivity and reliability in manufacturing operation, one has to draw a roadmap to balance between the investment costs attributed to the implementation costs of knowledge-based engineering or engineering automation software & hardware, and the real-time benefits of automation in terms of payback. The cover story features a series of interviews with the industry experts, highlighting their views on the key trends and the desired roadmap to drive automation & robotic technology in the existing supply chain, thereby, walking a step ahead towards achieving future-ready factories in India. A 1 5& D I n d i a | A p r- M a y 2 0 1 6

Megha Roy Features Writer megha.roy@publish-industry.net

Maria Jerin Features Writer maria.jerin@publish-industry.net

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C O V E R S TO R Y | M A N A G E M E N T

“Manufacturing strategy derives automation strategy” “There has to be a good reason for manufacturers to embrace automation. It has to offer a great value add, such as improved quality, less waste, more visibility from the business side, flexible throughput and so on.” Mandar Phadke, CEO, Abhisam Software & Director, Risknowlogy Solutions

What would be the key trends vis-à-vis market requirements that will drive automation & robotic technology in the years to come? There are quite a few interesting developments happening now in manufacturing, especially in the discrete parts manufacturing. At the risk of sounding clichéd, I feel that we may be in the fourth stage of manufacturing development. In the upcoming fourth stage, we may see the end of mass manufacturing and the rise of custom manufacturing again. Small batch sizes will be designed to a large extent by the customers themselves. For example, Local Motors, a US-based company, allows their customers to design their own cars with a kind of user-friendly software, where you can choose components, colours, materials and features. The next trends are, of course, by now very well hyped that are Industrial Internet of Things (IIoT), Big Data and cyber physical systems. How do you make sure that you are prepared with the right technology and strategy to ensure the success of the automation project? The automation strategy derived from the manufacturing strategy will dictate what technology should be used. If one decides to go for newer technology, then first a small pilot project should be implemented and assessed first before making any larger investments. The people deployed on the project have to be technically competent, well-trained and committed to meeting the set targets. Lastly, there should be a ‘buy-in’ secured from the manufacturing people, as their active participation will be an important factor in the successful implementation of the automation project. What would be your recommendations on drawing a full roadmap for automation as a strategy in the long term?

It will be largely dictated by the manufacturing strategy. Do the customers want integrated small agile factories or is it one large factory? What parameters of safety, quality and hygiene are to be met? How integrated will the manufacturing be, in the entire supply chain of the company? Answering these questions will then lead to formulating the automation strategy. What are in general the challenges posed by manufacturers while leveraging automation? How do you address them? There has to be a good reason for manufacturers to embrace automation. Automation has to offer a great value add, such as improved quality, less waste, more visibility from the business side, flexible throughput and so on. When presented with such value addition, most manufacturing managements will happily embrace it. Automation is a force multiplier on many levels; it is not just to save labour cost, which may be an incidental side benefit. Lastly, the role of safety and security has to be considered while implementing new automation technology. Do you think the factories in India are future-ready? Are they equipped enough to adapt to advanced technologies in the existing supply chain? What would be the first step going forward in this direction? Indian factories range from 18th century technology to 21st century hi-tech factories. So, some factories are future-ready, while others are not. The good news is that those factories that operate with the latest technology here, are as good if not better than in any developed country. There is an opportunity for older factories to implement the latest automation technologies, at a fraction of the cost that it would have been done, say, a decade ago. So, this is a huge opportunity for these factories to upgrade themselves and reap benefits. The first step would be to decide a manufacturing strategy. ☐

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M A N A G E M E N T | C O V E R S TO R Y

“Connected enterprises are a reality today” “Today, automation encompasses the automated flow of data and automated response to abnormal situations. These data cover the gamut of production numbers, energy usage, equipment status and inventory management.” G Ganapathiraman, Country Manager, ARC Advisory Group India

What would be the key trends vis-à-vis market requirements that will drive automation & robotic technology in the years to come? The key trend would be the Industrial Internet of Things, which will transform industrial enterprises with collaboration among intelligent equipment and people. The deeper interlocking of the digital world with the world of machines holds the potential to transform the global industry, and in turn many aspects of daily life. These innovations promise to bring greater speed and efficiency to industries as diverse as aviation, power generation, oil & gas, railways, and health care delivery. How do you make sure that you are prepared with the right technology and strategy to ensure the success of the automation project? The only way to be prepared is by keeping abreast of technological developments. As technologies keep on evolving, it is essential to keep on upgrading in terms of knowledge and skillsets – both for greenfield and brownfield projects. Virtualisation has transformed the way businesses are conducted. Virtual commissioning involves the creation of a virtual model that represents an accurate and realistic 3D simulation of mechanical, electrical and control systems to validate the physical functions of a production system prior to actual physical implementation. It reduces or eliminates rework found during physical commissioning. It also reduces requirements for engineering resources, shortens time to product launch and reduces overall costs. What would be your recommendations on drawing a full roadmap for automation as a strategy in the long term? Today, automation encompasses the automated flow of data and automated response to abnormal situations. These data cover the gamut of production numbers, energy usage, equipment statuses and inventory management, to name a few. Energy management should be given top priority, as energy efficiency

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saves costs and is environment-friendly. Incorporating new technologies such as IIoT and smart manufacturing is also recommended. Goals must be derived from and aligned with business strategy and sectoral needs and convergence of information technology (IT) & operational technology (OT). What are in general the challenges posed by manufacturers while leveraging automation? How do you address them? The challenges include cost justification and solution viability. In my opinion, the prime challenge is training the people. The overall market reliance on automation expertise will continue to outpace the available talent pool. To help personnel understand the new technologies, I would suggest simulate for experience. High-fidelity simulators are becoming more common and have generally been accepted as a valuable method for training operators. Engineering personnel and technicians will also benefit from simulation technology. Also, automate experience is recommended, where workflow applications capture experience by avoiding pitfalls identified over time. Both predictive maintenance and expert systems are great examples of ‘automate experience’ concept. Do you think the factories in India are future-ready? Are they equipped enough to adapt to advanced technologies in the existing supply chain? What would be the first step going forward in this direction? The industrial world is getting increasingly connected as the volume, variety and velocity of information continue to accelerate. Information-driven companies are moving to a culture and business model where decisions are made based on analysis of plant data and business processes. They are equipped to adapt new technologies because connected enterprises are a reality today, and early adopters have realised the benefits. The first step in this direction would certainly be to realise that the Industrial Internet of Things (IIoT) is connecting, collaborating, and transforming how businesses are conducted globally. ☐

C O V E R S TO R Y | M A N A G E M E N T

“Automation is the road to smart factories” “Manufacturers should involve automation vendors, consultants very early in the discussions, while fixing the key result areas and measurement tools for various departments like operations, maintenance, quality and management” PV Sivaram, Managing Director, B&R India

What would be the key trends vis-à-vis market requirements that will drive automation & robotic technology in the years to come? The key trends include flexible manufacturing and mass customisation, where manufacturers who can react to changing consumer trends, while maintaining cost-effective production can hope to compete on a global scale. Next is regulatory compliances, where more and more companies are finding themselves obligated. Market demands like operation flexibility, increased throughput and waste reduction are the driving forces behind the growing use of robots in many industries. As such, with integrated robotics, harmonised operations and optimised cost can be achieved. Next is predictive maintenance, the ability to predict machine and system failures before they happen, reduce costs and increase availability and remote connectivity. Machine break-downs are typically costly events requiring travel expenses of a service technician and loss of production hours. With IT technologies, it will be easier for technicians to access machines from anywhere in the world, enhancing remote connectivity. How do you make sure that you are prepared with the right technology and strategy to ensure the success of the automation project? B&R has recently announced its foray into process & factory automation business in India. We now offer complete solution for smart machines and smart factories. An intuitive sense of market dynamics and emerging trends has established us to lead the way with most innovative technology in the market. What would be your recommendations on drawing a full roadmap for automation as a strategy in the long term? We have to evaluate all the constituents of the smart factory project to arrive at a roadmap for automation as a strategy. Manufacturers should involve automation vendors, consultants

very early in the discussions, while fixing the key result areas and measurement tools for various departments. Convergence of IT and shop floor is leading us towards future smart factories or Industry 4.0. What are in general the challenges posed by manufacturers while leveraging automation? How do you address them? Manufacturing plant typically is a host to different equipment supplied by its vendors with their choice of automation technologies. This creates automation islands as few equipment use latest technologies, whereas others use legacy or conventional one. Yet again, proprietary technologies are very commonly used in plant automation system. This puts user at risk. On one hand, he faces major problems during maintenance to get the parts easily. On the other hand, he finds difficulty to connect one equipment with other or to the IT systems. It is sensible to have a process control system, which is scalable and advanced enough to take care of plant capacity expansions and integration of open technologies from various vendors. One example could be APROL process control system from B&R, which provides such scalability making it attractive even for a small plant. Do you think the factories in India are future-ready? Are they equipped enough to adapt to advanced technologies in the existing supply chain? What would be the first step going forward in this direction? Embracing technology is the way forward promising Indian manufacturers as serious contenders in global market as well as ever growing domestic market. Fortunately for us, ‘Make in India’ is coming timely with Industry 4.0. Equipping for this transformation is a serious challenge for the manufacturers, but time is ripe to take few initial steps towards building future-ready factories. Cost being a deterrent, companies should focus on taking step-by-step approach. ☐

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C O V E R S TO R Y | M A N A G E M E N T

“Factory automation is growing considerably in India” “To examine automation as a strategy for enhancing productivity and reliability in manufacturing operations, one has to achieve a balance between the investment costs and the real-time benefits of automation in terms of payback” Hans Bangert, Managing Director, Bosch Rexroth India

What would be the key trends vis-à-vis market requirements that will drive automation & robotic technology in the years to come? Market fluctuations have shifted the trends in market. Customers are increasingly looking for one single source that can cater to all their automation needs. Although cost plays an important role; quality, machine safety and energy efficiency coupled with productivity also play a significant role, when a customer considers a particular solution. Earlier, customers mainly considered cost of investment and simple automation. But the scenario is different today. Due to strong demands from the machine users, OEMs understand the need for scalability, flexibility, quality, productivity and energy efficiency with automation. These demands request new solutions, which is clearly driving the market towards new investments. How do you make sure that you are prepared with the right technology and strategy to ensure the success of the automation project? Factory automation is growing considerably in India. We have market segment focused, and we have specifically developed our systems to work according to the specific sector demands. We provide integrated one-stop solution for automation applications and services (hydraulics, pneumatics, linear motion & assembly technology and electric drives & controls). The expansion of our product portfolio in last few years has opened new avenues, especially in mid-size automation. What would be your recommendations on drawing a full roadmap for automation as a strategy in the long term? Machinery manufacturers and users require more engineering efficiency for quick-to-market and future-proof automation solutions in order to protect their investments. At the same time, they are looking for possibilities to customise their machines economically. They are looking up to new automation ideas for machine processes and functionalities to meet the needs

of individual customers. This is how they can set themselves apart from the competition. The need of the hour is to achieve more flexibility to implement the concept of customisation. To examine automation as a strategy for enhancing productivity and reliability in manufacturing operations, one has to achieve a balance between the investment costs (attributed to the implementation costs of knowledge-based engineering or engineering automation software & hardware) and the real-time benefits of automation in terms of payback. What are in general the challenges posed by manufacturers while leveraging automation? How do you address them? Technology adoption has become imperative in today’s scenario, be it to drive down costs or improve quality and use of data and automation is the key element in the process of adopting technology. India’s journey, to achieve more than 15% growth in the manufacturing sector on a sustained basis, requires a skillful adoption of automation technologies to raise productivity, consistency and effectively manage the complexities of varying business cycles. Do you think the factories in India are future-ready? Are they equipped enough to adapt to advanced technologies in the existing supply chain? What would be the first step going forward in this direction? The future belongs to connected industry, where virtual world of IT, the physical world of machines and internet will converge. It centres on the increasing integration of all areas of industry, which is made possible by Information Technology. Connected industry creates new opportunities for manufactureres and OEMs through merging the key elements that can result in rapid transformation of the industry. India has well-recognised the importance of manufacturing for future requirements and the implementation of such concepts will bring forth great potential for growth in the coming decade. ☐

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C O V E R S TO R Y | M A N A G E M E N T

“Selection of right technology is the key” “Selection of the right technology and its timely implementation is the key. Minimum time to transfer from old to new technology and wherever possible in the running plant will give confidence.” Vivek Gupta, General Manager, DCM Shriram

What would be the key trends vis-à-vis market requirements that will drive automation & robotic technology in the years to come? Using machine-learning technology, manufacturers can identify and diagnose glitches in plants in real time, ability to better monitor & control technical faults that improve efficiency and, hence, enhance productivity. The concept of Totally Integrated Automation allows efficient inter-operability of all automation components in the production process. Robotic technology is gaining wide popularity, but cannot replace manpower. It can be used where conditions are hazardous and exposure to human being is not advisable. Further, it can give good repeatability and, thus, same quality material. How do you make sure that you are prepared with the right technology and strategy to ensure the success of the automation project? Selection of the right technology and its timely implementation is the key. Minimum time to transfer from old to new technology & wherever possible in the running plant will give confidence. At DCM Shriram-Kota, we moved to DCS from Pneumatic Control System in Urea plant with no shutdown. What would be your recommendations on drawing a full roadmap for automation as a strategy in the long term? Innovations, improving product & material performance and improving productivity are the prime pointers. Higher production is not enough. It should be with lesser energy, better efficiency, smart manufacturing and most importantly, safety for higher productivity. Basic Process Control System (BPCS) & Safety Instrumented System (SIS) on the same platform helps a lot in this direction. Project management from Concept to Commissioning (C-to-C) and beyond is the key. For an automation project to deliver its full value, it must be conceptualised, engineered, installed, commissioned and maintained well. MIMO (Multiple Inputs Multiple Outputs)

technology used in Advanced Process Control (APC) provides least human intervention and, thus, process operates near to set point. This also saves energy, which is the key ingredient of the profits. Energy-intensive processes like oil & gas, fertiliser & steel plants should order APC at the time of ordering main automation package. What are in general the challenges posed by manufacturers while leveraging automation? How do you address them? Large companies are investing in automation projects (revamp/ upgrade/forced due to obsolete technologies) to stay competitive in the market, but small & medium companies cannot. Probably, market conditions are stopping them to do so. So, government policies have to be more transparent so as to encourage them to come forward and invest in automation projects. Also, RoI needs to be clearer in respect of automation. Do you think the factories in India are future-ready? Are they equipped enough to adapt to advanced technologies in the existing supply chain? What would be the first step going forward in this direction? Indian factories are not fully ready. ‘Make in India’, ‘Digital India’, ‘Smart Cities’ are some initiatives that will help in this direction. Choice of appropriate technology for the manufacturing philosophy aptly supported by strong innovation culture will be the key characteristics of future-ready factories. It is high time more and more companies looked at the following key paradigms in manufacturing and prepare themselves to compete in the future. One of the biggest obstacles for the adoption of Industry 4.0 across India’s process industry is related to data security, skill sets, infrastructure and overall reluctance to change. The need for an advanced production optimisation tool such as a Manufacturing Execution System (MES) is increasingly being felt by manufacturers. Also, IIoT will give an IP address for every machine, which will pave path for future. ☐

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C O V E R S TO R Y | M A N A G E M E N T

“Right automation improves flexibility” “The major challenge a manufacturer pose is the selection of right technology partner for the supply of production line, who is not only the supplier, but a long-term partner. These suppliers should take up turnkey projects and provide services on continuous basis.” Jasbir Singh, Vice President—Business Development, Essar Projects (India)

What would be the key trends vis-à-vis market requirements that will drive automation & robotic technology in future? The incorporation of automation & robotic technologies is mainly a customised way of industrial automation solutions to meet the factory requirements, specific to every production line. Over the period, we have seen that automobile industry adopted the robotic operation not only for the movement of the product from one place to other, but also for the fabrication and assembly of components at every stage. The similar robotic automation is noticed making its space in the textile industry to a larger extent. This is a consumer-driven market, where changes are observed fast, creating short-term demand of high volume and also sometime lasting for unpredictable shorter period. The adaptation of these changes is possible with automated machine supported by robotic operation. How do you make sure that you are prepared with the right technology and strategy to ensure the success of the automation project? All new factories require right automation in the first place, which improves flexibility and ease in operation. These projects demand for skilled professionals that have the capability to design and engineer, select right sensors, use robotics and machine vision to build, integrate in equipment of complete process line. The integrator of the automation technology should have understanding of the main process, needs to be flexible, adaptable and experienced enough to implement it. Now, the sensor technology has changed very fast with Nano footprint output level. What would be your recommendations on drawing a full roadmap for automation as a strategy in the long term? Automation providers should have the right knowledge and skillset to bring the best available product/solution in the market. The customers, using their own knowledge gathered over the period can further add value in that, to quickly

implement in their production line. The solution providers keep on doing the similar work for decades and carry out process improvement in consultation with operators in all areas of machine automation. The important point here is using digital technology, which can be easily programmed for frequent demand changes. What are in general the challenges posed by manufacturers while leveraging automation? How do you address them? The major challenges the manufacturer poses are the selection of right technology partner or service provider for the supply of production line. These suppliers should take up turnkey projects and provide services on continuous basis, select the right components for process improvement, and provide regular consultation to the user. By doing so, they will also learn the failures if any, suggest improvement and the ones to be incorporated in the next generation release. The clients shall allow them for application evaluations to provide add-on features and clear doubt of the possibilities that are available. Do you think the factories in India are future-ready? Are they equipped enough to adapt to advanced technologies in the existing supply chain? What would be the first step going forward in this direction? Today, the choices for industrial automation equipment demands the consumer to be completely up-to-date for taking the full advantage of all new cutting edge technologies arriving in the marketplace or development taking place elsewhere. In India, we have limited solutions available with the consumer to understand the arrival of new technologies and improve their learning curve. Also, the major problem lies with many factory owners in India. They save cost of training, don’t allow people to spare time for regular discussion about the small developments. Quality circle is a good concept, where small groups are made across the business to discuss on improvements in their operational area. ☐

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“Plan for modular automation solution” “We observe automation implementation in Indian industries range from very basic level to very high level due to market dynamics. With the government becoming more focused on improving manufacturing sector and skilling people, we see the automation level to increase at a faster pace.” Rashmikant Joshi, Managing Director, Festo India Pvt Ltd

What would be the key trends vis-à-vis market requirements that will drive automation & robotic technology in the years to come? Automation requirement will be fueled by demand of hygiene in food industry, higher volume production of consistent quality products, safety & operator-friendliness in production, reduction in downtime and higher utilisation of equipment for cost efficiency. Focus on ‘Make in India’ and increase in demand through improving lifestyle should further enhance automation requirement. In India, there is a large number of small & medium-size manufacturing units, which require simple cost-effective automation solutions to improve productivity & quality consistency. Training employees on automation will create awareness and capability to implement improvement projects through automation. How do you make sure that you are prepared with the right technology and strategy to ensure the success of the automation project? We introduce a large number of new products & technologies as experienced by all users every year. We develop new technologies to ensure that automation solution offered by us are optimum. Success of any automation project finally depends on the knowledge level of people involved in designing and implementing it. We train and re-train our experts through regular training sessions in India, and overseas every year. We also offer product and application training to the users through didactic training courses and Application Days. What would be your recommendations on drawing a full roadmap for automation as a strategy in the long term? To draw a roadmap for automation, the automation user needs to know what the market demands are in mid and long term, and what the overall business roadmap is. The same can help work out investment calculations for cost-effective automated equipment. While preparing the roadmap, one needs to plan

for modular automation solution that can be easily modified or upgraded in line with change in market demand and change in technologies. What are in general the challenges posed by manufacturers while leveraging automation? How do you address them? Insufficient awareness and scarcity of well-trained manpower are the biggest challenges faced by the manufacturing industries. The product life cycles are getting shorter, which requires regular training of employees on new technologies. On the other hand, education institutes, though well placed to cater to the needs of non-manufacturing industries, are yet to equip themselves sufficiently to cover needs of manufacturing industries. We are playing an important role, supporting industries and institutes for education in industrial automation. To create awareness about industrial automation, we have two exhibition vehicles with dynamic application examples on board. The vehicles are on move through-out the year across the country, visiting industries and educational institutes. Our wide spread sales network and industry contacts provide us information about the current and future technology requirement of the market. The information is used by Festo Didactic to develop training modules and related course and hardware. We have six training centre of our own, mainly to train the users of automation. Do you think the factories in India are future-ready? Are they equipped enough to adapt to advanced technologies in the existing supply chain? What would be the first step going forward in this direction? There are many future-ready industries in India. We observe automation implementation in Indian industries range from very basic level to very high level due to market dynamics. With the government becoming more focused on improving manufacturing sector and skilling people, we see the automation level to increase at a faster pace. ☐

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C O V E R S TO R Y | M A N A G E M E N T

“Key to success is knowing when to automate” “Increase in automation combined with other advantages such as young & skilled labour, supply chains and customer proximity are driving companies to bring production to the India” Sunil Raibagi, Managing Director, Gudel India

What would be the key trends vis-à-vis market requirements that will drive automation & robotic technology in the years to come? Today, Indian companies want to augment existing production methods with new technology. They want their robotic automation to communicate with other parts of the manufacturing, such as their manufacturing execution system. This means automating the internal material delivery, movement and intra-logistics, material flow control and even ERP. Fool-proofing process, flexible but agile production, multi-variant production to use maximum capacity are today’s requirements. Saving of space, energy, cost to admin, quality & safety has to go down day-by-day with intelligent and smart systems. Mostly, these techniques will then be able to produce locally at same cost and less labour cost. How do you make sure that you are prepared with the right technology and strategy to ensure the success of the automation project? First, you should understand the existing process to be automated. Then, simplify the process and automate. You normally deploy a system for reliability – consistent working, quality/accuracy, throughput – productivity, flexibility, safety, space, availability & manurability. Evaluate each point, which is giving you advantage. Consider a supplier’s location and its preferred brand. Manufacturers should also consider the installation process when purchasing a robot, as this will impact on design and cost. Insist on factory acceptance tests. Be sure the supplier has adequate personnel to support the robot on an ongoing basis. Also, make provision to buy run-off assistance. What would be your recommendations on drawing a full roadmap for automation as a strategy in the long term? Specifications must look for all limitations including building size, floor, raw material discipline, etc. Many times, it is

not possible to focus on one odd job and 90% of work is done through lower capacity model. One should look at all possibilities and then optimise the solution. The layout and innovative process mapping also can dramatically change the investment pattern. Involve your system integrator as well as machine and robot manufacturer along with production manager to draft specifications. It is always good to team up while deriving speculations. It is also important to have your strategy clear. What are in general the challenges posed by manufacturers while leveraging automation? How do you address them? Key to success is knowing when to automate. This is often overlooked and sometimes under-valued. Even the best of automation approaches could fail to give RoI, if the timing of automation is wrong. It is pointless to do automation at fag-end of the product lifecycle. Do you think the factories in India are future-ready? Are they equipped enough to adapt to advanced technologies in the existing supply chain? What would be the first step going forward in this direction? India is ready and deploying automation successfully since 2000. We have good education, installed base and exposure. Increase in automation combined with other advantages such as young & skilled labour, supply chains and customer proximity are driving companies to bring production to India. If the government invests in right infrastructure, stable power and good transport system, we will be growing provided we adopt and learn productivity. Driving improved productivity and cost competitiveness through increased automation is not a short term trend, nor is it limited to the Indian market. This looks like a secular trend on a global scale and is a new wave. Due to IT knowledge and software skills, India will combine advantage of machine, process & business process automation and will be a leading global player in the coming years. ☐

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“Opening up the possibility of being future-ready” “Good automation systems with smart remote devices and data analytics built on it can generate a productive environment to help ensure proactive decisions during or before a mishap” Vikas Chadha, Managing Director, Honeywell Automation India Ltd Leader, HPS India

What would be the key trends vis-à-vis market requirements that will drive automation technologies in the years to come? Industrial automation has the potential to transform several sectors in the county. Increasingly, India is recognising that in a competitive, globalised environment, investing in intelligent automation and control systems to optimise manufacturing, plant optimisation, and control and process monitoring systems is the way ahead. How do you make sure that you are prepared with the right technology and strategy to ensure the success of the automation project? Today, automation is a business strategy. Good automation systems with smart remote devices and data analytics built on it can generate a productive environment to help ensure proactive decisions during or before a mishap. For the process industry, it is extremely interesting to see how IIoT has been evolving for several years now and Honeywell solutions allow customers to retain their intellectual assets as they take advantage of new functionality. Honeywell offers cyber security vulnerability assessments that examine the three-core facets of an organisation’s cyber security – people, process and technology. What would be your recommendations on drawing a full roadmap for automation as a strategy in the long term? Today, a large number of plants in India have a basic level of automation, but lack advanced automation solutions that can really help them realise the true potential of automation. The core verticals where maximum potential lie are the chemicals, petrochemicals, oil & gas, power and pharmaceutical industries. In these verticals, technologies like cyber security, critical infrastructure protection and integrated fire and gas solutions will see growth due to increasing safety and security threats. I would also recommend customers to invest in advanced

automation technologies for existing plant upgrades. What are in general the challenges posed by manufacturers while leveraging automation? How do you address them? Managing safety and security, maintaining plant efficiency and increasing productivity are some challenges. To achieve higher levels of plant safety, a comprehensive and integrated approach to safety is necessary. Plants and refineries use Honeywell’s safety instrumented system (SIS) platform, Safety Manager, to safeguard their assets and share critical safety information with process control systems. Do you think the factories in India are future-ready? Are they equipped enough to adapt to advanced technologies in the existing supply chain? What would be the first step going forward in this direction? Businesses in India are increasingly opening up to the possibility of being future-ready. Industrial Internet of Things (IIoT) has been evolving towards the processing industry for several years and Honeywell solutions allow customers to retain their intellectual assets as they take advantage of new functionality. IIoT by Honeywell technologies involve bringing people, processes and assets together. In this regard, we recently launched Honeywell PulseTM that remotely connects plant managers, supervisors and engineering staff using a mobile application. Another example is the Experion™ Collaboration Station – a first-of-its-kind in the process automation world to integrate with control systems and show information from any available source. It enables plant, business and support personnel to use interactive displays, embedded video and other telecommunication capabilities to communicate, collaborate and make quick decisions. Another example would be Honeywell’s Industrial Cyber Security Risk Manager that is designed in a way that operators are aware of their cyber risks and have the ability to direct cyber resources to areas that require immediate attention.☐

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M A N A G E M E N T | C O V E R S TO R Y

“New technologies will push automation” “For the success of the automation project, it requires core knowledge in the process of manufacturing, understanding of the new upcoming technologies as well as trained manpower to implement these on the shop floor with the help of automation” Bipin Jirge, Managing Director, ifm electronic India

What would be the key trends vis-à-vis market requirements that will drive automation & robotic technology in the years to come? I sincerely feel that consistent quality, long-term cost benefits and safety will be the key factors for continued drive for automation in the coming years. Also, newer concepts such as Industry 4.0 / IoT, etc, which will redefine the market requirements will be the key factors for pushing automation in the industry. How do you make sure that you are prepared with the right technology and strategy to ensure the success of the automation project? For the success of the automation project, it requires core knowledge in the process of manufacturing, understanding of the new upcoming technologies as well as trained manpower to implement these on the shop floor with the help of automation. The selection of the rightly engineered technologies for the appropriate process in manufacture is one of the basis to prepare the company for the success in automation – that too at a cost, which can give us the required RoI at least in medium-term. What would be your recommendations on drawing a full roadmap for automation as a strategy in the long term? For a roadmap for automation as a strategy in the long-term, the company should start adapting the new technology/ modules in a step-by-step way; the technology being adapted should be flexible and modular. Parallely, we should employ,

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train and retain the manpower required for this up-scaling of the technology being implemented in the company. As the technology itself changes faster, modularity and flexibility to adapt changes in process as well as in automation is of vital importance. What are in general the challenges posed by manufacturers while leveraging automation? How do you address them? While leveraging automation, initial costs are one of the major challenges. This can be looked in to by automating in a step-by-step way, so that we can experience the returns in a step-by-step way too. Another major challenge in this regard is to train the manpower to handle this higher level of automation. This might take a long time, but is a necessary investment to achieve the best out of automation investments. Do you think the factories in India are future-ready? Are they equipped enough to adapt to advanced technologies in the existing supply chain? What would be the first step going forward in this direction? I sincerely feel that factories in India, at least, in few industry verticals such as automotive and steel are future-ready in many aspects, and can adapt new technologies with some additional investments in supply chain. However, this also depends on many factors like size of production volume, variety of manufacturing, etc. Going forward in this direction, the first steps could be to start automation for the processes that can give us quick RoI in shorter time and for the processes where safety is a major issue. ☐

C O V E R S TO R Y | M A N A G E M E N T

“Automation has to be done in a modular way” “An organisation must define a product-centric approach where the market dynamics and core competence of the manufacturer meets a common objective for the growing market volumes/demands” L R Katrat, Managing Director, Katlax Enterprises

What would be the key trends vis-à-vis market requirements that will drive automation & robotic technology in future? With a high-volume manufacturing sector like automotive, there is a definite need of robotics and automation in manufacturing of high-volume components, which are cost-sensitive and quality dependent. The rising growth of workshop machinery like CNC, VMC, multi-access SPM and use of advanced software in modeling and manufacturing has already penetrated and demonstrated use of robotics and automation. Tools, fixtures, jigs, material handling and manufacturing accessories are extensively using some form of robotics and automation, and the usage is on rise with small manufacturers of tiny components or large equipment. How do you make sure that you are prepared with the right technology and strategy to ensure the success of the automation project? The pressure being faced from the market is evolving in the innovative features, competitive pricing, timely delivery and customer support. All these elements need robotics & automation in manufacturing, logistics (ware housing), distribution and huge data, not only on customers who are end users, but markets, vendor, distribution and ware housing partners. We have to track every component and subassembly of our manufacturing to ensure that no interruption in SCM (Supply Chain Management) and commitments on post sales are delivered. We have installed automatic injection moulding machines with high speed dies and tools loaded by automated stackers and by appropriate material handling equipment like conveyers and hoppers. For quality testing and packing conforming to agencies’ requirement and customers’ guidelines, bar code printing and packaging is introduced for traceability of components’ post sales and complying with SCM requirement. Appropriate ERP modules are introduced to make everything under closed loop ERP system.

What would be your recommendations on drawing a full roadmap for automation as a strategy in the long term? An organisation must define a product-centric approach where the market dynamics and core competence of the manufacturer meets a common objective for the growing market volumes/demands, a sustainable financial position. Automation has to be done in a modular way such that investment towards automation is in sync with business growth. Neither should it create distortion of volumes nor the escalating cost, not also to reach a point where the choice of adopting newer technologies is lost. This is only possible by flexible approach in automation design. What are in general the challenges posed by manufacturers while leveraging automation? How do you address them? The old technologies have to be compatible with the new technologies that need to be introduced. Also, the manufacturer wants to know that whether his investment in automation meets his production targets and makes him break even to a sustainable financial position. Resistance to change, compatibility issues within the old and new technology and apprehension towards implementing automation in its entirety are major challenges. Do you think the factories in India are future-ready? Are they equipped enough to adapt to advanced technologies in the existing supply chain? What would be the first step going forward in this direction? Today’s companies can be future-ready only if they are willing to prepare themselves not just for incremental growth, but a quantum or an exponential growth strategies and execution. The first step going forward in this direction is the change in the mindset and then embracing the advanced technologies and their adaptation in totality within each aspect of their organisation. ☐

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C O V E R S TO R Y | M A N A G E M E N T

“Robotic automation plays a key role” “Automation should always be looked as a long-term strategy for an organisation. Based on the scale of operation of the company, it is always recommended to adopt a phase wise automation in the company.” Raj Singh Rathee, Managing Director, KUKA Robotics India

What would be the key trends vis-à-vis market requirements that will drive automation & robotic technology in the years to come? Global key trends such as Industry 4.0 may not be so much in demand in the Indian market due to low robot installation base. Indian market will still be driven – for few more years – by the conventional robot technologies till the industry has a decent penetration of automated production. Flexible automation in manufacturing is one of the key requirements as product/line shelf-life is reducing and turn-around time for a new product/line is expected to be always shorter than before. Hence, robotic automation can play a crucial role in providing the flexible automation for manufacturing. How do you make sure that you are prepared with the right technology and strategy to ensure the success of the automation project? Understanding the customer requirement is the key to be successful in the market. Once you understand the customer requirement, then you can offer them the right product, technology or the solution. Once implemented, the success of the automation project lies in extensive training of the customer manpower handling the project. Initial handholding is required in most of the cases. A good after-sales support further ensures the success of the automation project. What would be your recommendations on drawing a full roadmap for automation as a strategy in the long term? Automation should always be looked as a long-term strategy for an organisation. Based on the scale of operation of the company, it is always recommended to adopt a phase-wise automation in the company. The company needs to adapt/ change a lot of internal processes in order to successfully switch to the automation from the manual processes. It brings up a lot of learning and improvement areas in an organisation. Thus, we always recommend that organisations should prepare

a plan for the kind of automation they want to realise in their processes as a long-term strategy and try to implement the same in small steps, rather than going in one shot for full automation unless it is a complete product line. What are in general the challenges posed by manufacturers while leveraging automation? How do you address them? The main challenge lies investing in the research & development of new products and in training the manpower for handling the automation. High quality reliable products can only be manufactured by using high quality automation. There is no alternative technology to make it possible otherwise. We address these issues by providing a thoroughly studied customised solution, constantly educating the customers and explaining them the advantages of using automation in longterm perspective. Do you think the factories in India are future-ready? Are they equipped enough to adapt to advanced technologies in the existing supply chain? What would be the first step going forward in this direction? The automotive industry in India uses robots to a good extent. Though outside the automotive industry, the penetration of robotics is still very low. If we talk about growth for robotics in India, however, it will not be exponential, but rather gradual. The growth will come from industrial sectors beyond the automotive branch. For example, machine tool, foundry & forging, metal fabrication, food & beverages and consumer goods. So, based on the above information we can say that apart from the automotive industry, it is still a long way to go for the Indian factories to make them future-ready and adapt the advanced technologies. The first step in this direction could be that the manufacturers should educate themselves directly as well as learn from the experience of the companies producing advanced technology products. ☐

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C O V E R S TO R Y | M A N A G E M E N T

“Meeting the demands of tomorrow” “The technology is getting upgraded continuously & it has become important to seamlessly integrate the new products with the existing products. In some cases, it is to recondition existing equipment with the latest FA products.” Sunil Mehta, General Manager – Technical Support, Factory Automation & Industrial Division, Mitsubishi Electric India

What would be the key trends vis-à-vis market requirements that will drive automation & robotic technology in the years to come? In my view, key trends in the market are cost and quality. In today’s scenario, mass production and quality maintenance of products has become most important. With increasing demand for cost-effective and quality products, there is an exponential increase in the demand for top-end automation and robotics technology in the overall industry to maximise production output and maintain quality. To cater to the needs of the versatile industry, we introduced our robot series MELFA in the Indian manufacturing industry. How do you make sure that you are prepared with the right technology and strategy to ensure the success of the automation project? We work with the users to define the needs of tomorrow and, thereby, engage in developing technology, which can redefine the deliverables of automation. Our latest generation PLC with shortest scan time of 9 nano second and CC Link IE Field with data handling capability at 100 Gbps are testimony to the initiative of developing product today to meet the demands of tomorrow. Success in an automation project for us is being able to deliver beyond the expectation of the customer. Our R&D centres across major locations in the world including India, continuously strive for innovative engineering enabling us to deliver products to redefine the needs of the customer. What would be your recommendations on drawing a full roadmap for automation as a strategy in the long term? It is important for the manufacturer to understand trends in the industry and predict the future demands. The technology is getting upgraded continuously and it has become important

to seamlessly integrate the new products with the existing products. In some cases, it is also important to recondition existing equipment with the latest FA products (even though the existing automation products are working fine, they may not support necessary networking, data handling requirements). What are in general the challenges posed by manufacturers while leveraging automation? How do you address them? The general challenge posed by manufacturers is the lack of trained human resources to explore the latest automation products. Mitsubishi Electric India addresses this by providing necessary trainings to manufacturing engineers on regular basis. We are expanding our channel / system integrators network and we support our channel engineers to understand the products to maximum extent. Even though there are many factory automation products available from different brand, it is important to focus on one or two brands so as to have trained resources available to work upon. Do you think the factories in India are future-ready? Are they equipped enough to adapt to advanced technologies in the existing supply chain? What would be the first step going forward in this direction? Automobile industry has been one of the key drivers to adopt advanced technologies in the production environment. A lot of work still needs to be done in other industries like F&B, pharmaceutical and textile. However, with growing influence of foreign manufacturers / regulations particularly from Europe & USA, these industries stand to gain significantly. Integration of factory automation products (controllers, VFDs, AC Servo systems), vision systems, RFID, sensors with IT technology will play a key role in manufacturing industry. The e-factory concept propagated by Mitsubishi Electric, is our endeavour to contribute to get the factories more open and accessible. ☐

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C O V E R S TO R Y | M A N A G E M E N T

“Way forward involves platform-based approach” “Robotics, automation and control augmented with the power of networking will play a key role in reducing the manual errors and increasing the throughput of the manufacturing lines. This means that machines would become smarter through local processing.” Satish Mohanram, Sr Marketing Manager – India, Russia, Arabia and Africa, National Instruments

What would be the key trends vis-à-vis market requirements that will drive automation & robotic technology in the years to come? Cyber-physical systems, Industrial Internet of Things (IIoT) and Industrie 4.0 are some of the names given to the technological advancement that bring together the three worlds of computation, communication and control. With these enabling technologies, companies can build completely automated manufacturing lines powered by robotics, advanced control to achieve what is termed as the factory of the future. Robotics, automation and control augmented with the power of networking will play a key role in reducing the manual errors and increasing the throughput of these manufacturing lines. This means that machines would become smarter through local processing and communication for collective intelligence. How do you make sure that you are prepared with the right technology and strategy to ensure the success of the automation project? The only way to meet the needs of today and tomorrow is not by predicting the future, but by deploying a network of systems flexible enough to evolve and adapt. The way forward involves a platform-based approach; a single flexible hardware architecture deployed across many applications removes a substantial amount of the hardware complexity and makes each new problem primarily a software challenge. The same principle must be applied to software tools to form a powerful hardware-software platform that creates a unified solution. An effective platform-based approach does not focus on hardware or software, but instead on the innovation within the application itself. What would be your recommendations on drawing a full roadmap for automation as a strategy in the long term? In long term, the platforms that system designers choose need to be based on an IT-friendly OS, so that they can be

securely provisioned and configured to properly authenticate and authorise users to maintain system integrity and maximise system availability. These platforms can achieve this through an open OS that helps security experts from around the world unite and develop the latest in embedded security. These platforms also need to be based on standard Ethernet technologies and incorporate evolving standards to enable a more open and deterministic network, while maximising interoperability between industrial systems providers. What are in general the challenges posed by manufacturers while leveraging automation? How do you address them? Designing the next generation automation systems is complicated by the use of disparate tools and techniques. Central to solving this cyber-physical design challenge is designing beyond implementation and instead at the system level. Engineers need tools for the holistic design of the system and its interactions with the real world. A proven design methodology is a platform-based design, which was pioneered at the University of California, Berkeley. It is used widely across the automotive and aerospace industries to plan and build platforms that scale to large complex systems with long life spans. Do you think the factories in India are future-ready? Are they equipped enough to adapt to advanced technologies in the existing supply chain? What would be the first step going forward in this direction? India has been very open to technology; the sheer adoption of the smartphones is a great testament to that. The manufacturing companies that are expanding into India need manpower skilled in using tools that can enable implementation of the next-generation manufacturing systems. Identifying the right platform that can scale to meet tomorrows needs and investing in improving the skills in using the platform is the key first step in become future-ready. ☐

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C O V E R S TO R Y | M A N A G E M E N T

“From process automation to business automation” “The industry should encourage innovation and provide a base platform to all R&D teams to try their ideas in pilot projects, through various mechanisms like partnerships with shared RoI” Arundhati Bhattacharya, General Manager (PE-C&I) & CTF, (Darlipalli & Muzzafarpur TF) NTPC Ltd

What would be the key trends vis-à-vis market requirements that will drive automation & robotic technology in the years to come? One will see more connectivity between all stakeholders in the supply chain to reduce production and delivery time; a sort of ‘just-in-time’ concept so as to minimise inventory both at the supplier and customer’s end. IoT is expected to play a major role in this area. I can also see automation technologies embracing IT technologies in the coming years. The line is already getting thin and will eventually vanish in future. Big Data analytics will be leveraged to increase productivity, cut costs and maintain good quality consistently. We will graduate from process automation to business automation. How do you make sure that you are prepared with the right technology and strategy to ensure the success of the automation project? In NTPC, we have annual technology-adoption targets. Normally, to protect investments in technology, proven track record is insisted. But this should not deter the implementation when the business case of technology adoption is sound. In such situations, where proven track record is not available, a pilot project or a trial is generally undertaken to reap the benefits in time. What would be your recommendations on drawing a full roadmap for automation as a strategy in the long term? First, let’s analyse the success stories of economies where industrial automation has made a difference in manufacturing. One of the key factors behind such success is a strong industry-academia connect. This has to be improved in our country & should evolve as part of a long-term strategy for automation. Another key ingredient of a roadmap for automation is the appetite for innovation. The industry should encourage innovation and provide a

base platform to all R&D teams to try their ideas in pilot projects, through various mechanisms like partnerships with shared RoI, no commitment trials, etc. One of the key factors for making manufacturing in India competitive is manufacturing of related automation products in India. This necessitates the development of Indian semi-conductor industry in a big way. What are in general the challenges faced by end-users while leveraging automation? What are your expectations from automation suppliers to address these challenges? The concerns to all end users of automation systems is obsolescence. This necessitates re-investment in automation systems very early in the plant life cycle. A major contributor in this is high degree of reliance of automation system developers on commercial off-the-shelf (COTS) IT products. Automation suppliers must devise their own ways and means of coming out of this avoidable problem like virtualisation. One area where automation suppliers should work and which can be of great help to end users is standardisation in interfaces and protocols. Do you think the factories in India are future-ready? Are they equipped enough to adapt to advanced technologies in the existing supply chain? What would be the first step going forward in this direction? ‘Make in India’ has provided a great impetus to the country’s industrial outlook as can be seen by the increasing FDI inflows in manufacturing. To make India a global manufacturing hub and be competitive globally on a sustained basis, advanced technologies have to be adopted in the supply chain. The more of these automation products are sourced from our country; more competitive will be the manufacturing. This will also boost the ancillary industries and open up a range of allied services. The first step towards this would be to draw out a roadmap for automation. ☐

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C O V E R S TO R Y | M A N A G E M E N T

“Focus on RoI takes centre-stage” “Technology-led trends are giving rise to smart human-machine interface, which could only be enabled by the use of automation technologies including robotics which plays an intrinsic part.” Sameer Gandhi, Managing Director, Omron Automation India

What would be the key trends vis-à-vis market requirements that will drive automation & robotic technology in the years to come? The market requirements are becoming complex day-by-day driven by the needs of advanced automation, especially in sectors like automotive, F&B and pharmaceuticals. So, the key trends, which have a huge potential to shape up the dynamics of the sector are majorly going to be technology-based, which have capabilities to support these kinds of requirements. For example, usage of vision systems in quality inspection and utilisation of Big Data in manufacturing processes. I believe that proper application of Big Data in manufacturing can lead to significant improvement in productivity as well as reduction in down-time and ensuring quality for the customer. Omron’s latest technological innovation allows PLCs and vision systems to interact directly with the enterprise resource planning (ERP) layer, ensuring realistic Big Data processing to improve productivity and aid predictive maintenance, and much more. Another very important emerging trend is Industry 4.0. A recent report by HIS technology forecasts that industrial automation is expected to make up the majority of the Internet of Things (IoT) by 2025, with Internet Protocol (IP)-addressable devices as the key enabler. So, all in all, these technology-led trends are giving rise to smart human-machine interface, which could only be enabled by the use of automation technologies including robotics. Robotics is an intrinsic part of the industrial automation portfolio and considering its potential and efficacy in rendering operational excellence, it is expected to play a bigger role in the next 5-10 years. How do you make sure that you are prepared with the right technology and strategy to ensure the success of the automation project?

As an automation partner, we invest time and skills right from the process of conceptualisation and it goes till the stage of maintenance. Omron has also invested in automation centres where a customer can actually experiment with the solution before it is actually implemented. Our sales and application teams ensure that the implementation leads to deliverance of the optimal RoI. Since automation is an investment, the manufacturer and the automation solutions provider have to work diligently so that it does live up to the desired results. What are in general the challenges posed by manufacturers while leveraging automation? How do you address them? One of the basic challenges is the level of acceptance amongst end users to invest in something that is adding to the cost. Hence, the focus on RoI takes centre-stage. However, acceptability is going higher off-late, which is good for the industry. Lack of skilled manpower is another challenge. An automation system needs the right set of skills from the point of conception to deployment to maintenance. Do you think the factories in India are future-ready? Are they equipped enough to adapt to advanced technologies in the existing supply chain? The ‘future-ready’ concept is yet to percolate effectively in all the manufacturing sectors. Some sectors like automotive, FMCG, F&B, pharmaceuticals are progressing very well. However, the acceptability for the automation solutions is still not up to the desired level in other sectors - especially the SMEs. Currently, the picture is changing slowly but steadily, fuelled by many macro and micro level factors, such as growing population, disposable incomes, ever-increasing need of complying to global standards, the constant need for improving operational excellence, desire for zero-defects and zero-effects, productivity & quality improvement, etc. ☐

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C O V E R S TO R Y | M A N A G E M E N T

“Flexible automation technology is vital” “We have to make sure that the technology being used is in line with global standards, simple to work with and yet innovative. For bigger automation projects, considerable past experience on similar applications provides an edge.” Sanjay Kulkarni, Managing Director, Pilz India

What would be the key trends vis-à-vis market requirements that will drive automation & robotic technology in the years to come? An increased consumer demand in various industrial sectors is sure to increase the demand for productivity. While increasing the productivity, costs have to be controlled without compromising on the quality of final products. In this scenario, adapting automation and robotic technology which is fast, accurate, safe and economical is desired. Along with these factors, to meet the product innovations, automation technology that is flexible, sustainable and simple will play a key role. With the ‘Make in India’ initiative by the government and further foreign investments, we are expecting prevailing automation and robotic technology to get a facelit and be more efficient, scalable as well as flexible. How do you make sure that you are prepared with the right technology and strategy to ensure the success of the automation project? The first and the foremost thing to ensure success of the automation project is to completely understand the customer’s requirement and offer our best and competitive solution

addressing it. We have to make sure that the technology being used is in line with global standards, simple to work with and yet innovative. For bigger automation projects, considerable past experience on similar applications provides an edge. Some other important factors for this are accomplishing project in committed time-frame, having skilled workforce as well as having network of reliable vendors. What are in general the challenges posed by manufacturers while leveraging automation? How do you address them? While leveraging automation, incorporating new automation solutions with the existing ones is challenging as the compatibility can be an issue. Further, ensuring seamless communication across the devices adds to extra cost. Moreover, reluctance towards acceptance of new automation solutions and breaking the mould of traditional manufacturing also exists among some manufacturers. To tackle this issue, creating awareness about the new trends of the automation and impact in increasing the productivity is necessary. Automation providers need to convince customers about capability of handling automation projects and providing solutions best suiting their requirements in best price. ☐

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Automation system PSS 4000 – for standard and safety

Implement even complex automation projects for standard and safety-related tasks with ease! With its various control systems, editors and network components, the automation system PSS 4000 is flexible and easy to handle. The simplicity of the graphics Program Editor PASmulti is particularly impressive, enabling programs to be universally transparent and structured, including a high level of reusability. PSS 4000 – Simplify your AutomationTM

Scan the QR code to find out more about the automation system PSS 4000. Further information: www.pilz.com/pss4000 Pilz India Pvt. Ltd Office No 102 and 202, Delite Square, Near Aranyeshwar Temple, Sahakar Nagar NO 1, Pune – 411009 Telephone:

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C O V E R S TO R Y | M A N A G E M E N T

“Factories in India are getting future-ready” “With vision in mind and correct planning, one can achieve success in automation projects. By helping the staff to enhance their technical skills and the ability to adapt to new advance technologies can take the company one step forward towards this.” Sagar Jeevan Bhosale, Managing Director, Schmersal India

What would be the key trends vis-à-vis market requirements that will drive automation & robotic technology in the years to come? Automation ensures consistency, improves processes as well as enhances productivity with increased accuracy. On implementing automation, people can focus on more challenging tasks that can lead to revenue rather than repetitive, time-consuming tasks. Also, automation yields safer working conditions and better output rate. Slowly, small and medium-scale manufacturers are understanding this fact and have started investing in new technologies to increase the level of automation. How do you make sure that you are prepared with the right technology and strategy to ensure the success of the automation project? With vision in mind and correct planning, one can achieve success in automation projects. To be prepared with the right technology and strategy, the staff can be helped to enhance their technical skills and the ability to adapt to new advance technologies. This can take the company one step forward towards achieving sucess. What would be your recommendations on drawing a full roadmap for automation as a strategy in the long term? As a long-term strategy, we should evaluate our own requirements and look out at the current problems that prompt us the search for an automated solution. For implementing the automation solution, a dedicated team with a team leader should be handed over the responsibility. The leader should review the need, manage the objective and ensure the adaptability to change within the organisation.

What are in general the challenges posed by manufacturers while leveraging automation? How do you address them? One challenge posed by manufacturers, while leveraging automation is capital cost. The next challenge could be mindset. The Indian manufacturers are of the view that investing in automation will in turn result in an increase in product cost. With the competition increasing day-by-day, the product cost needs to be moderate and so the Indian manufacturers are quite reluctant to go an extra mile, while leveraging automation. Another challenge could be a lack of awareness. Lack of awareness or knowledge on automation technology obstructs the vision of the manufacturers to foresee the returns on investment. To address these challenges, one can seek an expert’s advice, make up one’s mind to accept, adapt and incorporate the changing technology trends. Do you think the factories in India are future-ready? Are they equipped enough to adapt to advanced technologies in the existing supply chain? What would be the first step going forward in this direction? Yes, I think in this global era of competition, factories in India are getting future-ready with their technological innovation and capable human resources. Based on the fact that the company, which does not deliver price competitive quality products in shorter period of time is out of the race, Indian factories are feeling the need of advanced production optimisation tools that reduces non-value added activities and, thus, enhancing productivity. So, we can say they are on track to adapt to advanced technologies in the existing supply chain. The first step going forward in this direction is coping with the accelerating pace of technological trend. This will be marching one-step forward going in this direction.☐

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C O V E R S TO R Y | M A N A G E M E N T

“Digitalise, rather than digitise” “Manufacturing will be transformed from single automated cells to fully integrated, automated facilities that communicate with one another. This will be an evolutionary process for Indian companies to be globally competitive.” Ashish Bhat, Executive VP—Digital Factory, Siemens India

What would be the key trends vis-à-vis market requirements that will drive automation & robotic technology in the years to come? Digitalisation of the manufacturing process has become a vital lever of growth in almost all industries. For example, connectivity and interaction among parts, machines, and humans are expected to make production systems as much as 30% faster and 25% more efficient, and elevate customisation to new levels. Manufacturing will be transformed from single automated cells to fully integrated, automated facilities that communicate with one another. This will be an evolutionary process for Indian manufacturing companies to be globally competitive. How do you make sure that you are prepared with the right technology and strategy to ensure the success of the automation project? We believe that manufacturers must weave a digital thread from ideation (conceiving the product), to realisation (producing the product) and utilisation (operating or servicing the product). It is not enough to digitise—mimicking processes digitally for incremental improvement. You have to digitalise—make the digital thread a proactive agent in driving your business. With a fully optimised ‘Digital Enterprise,’ manufacturers are better equipped to initiate or respond to disruptive innovation. What would be your recommendations on drawing a full roadmap for automation as a strategy in the long term? The seamless integration of data along the entire production value chains will gain more and more importance, becoming a key criterion for the survival of developing/manufacturing companies. Siemens Digital Factory (DF) division offers a comprehensive portfolio of seamlessly integrated hardware, software and technology-based services in order to support manufacturing companies worldwide in enhancing the flexibility and efficiency of their manufacturing processes and

reducing the time to market of their products. What are in general the challenges posed by manufacturers while leveraging automation? How do you address them? The growing inter-connectivity of machines, products, parts and humans will require new standards that define the interaction of the elements in the digital factory of the future. Industrial automation vendors and most machine tool manufacturers have built significant software development capabilities, but Industry 4.0 will require more. The vendors will have to compete with IT players that are moving into the growing market for shopfloor and production-related applications and data-driven services. The key measures can be uniformity in standardisation, managing intricate systems, proper training for employees and environment & people safety. Do you think the factories in India are future-ready? Are they equipped enough to adapt to advanced technologies in the existing supply chain? What would be the first step going forward in this direction? The expanding role of software and electronics in what have been traditionally mechanical products is driving new levels of product innovation and intelligence. Profound changes are expected in products and the way they are designed and manufactured, which will cause the global manufacturing sector to look very different in the future from how it looks and operates today. Next generation technologies – Big Data, Cloud, IoT, 3D printing, robotics, which are transforming today’s products have an even greater opportunity to be leveraged across all phases of product development, production and delivery. This, therefore, is the key to successfully bringing new innovations to market. With established prowess in software, India should be able to take the leap. But, we should not wait for global benchmarks and follow. We will succeed only if we set these benchmarks in India. ☐

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M A N A G E M E N T | C O V E R S TO R Y

“Technology demands intelligence & connectivity” “We expect more industry networking among the supply chain. This may help the Indian factories to become ‘future-ready’. This means there will be more exchange of ideas at all the levels with suppliers, integrators, R&D and production teams.” Atul Dave, Managing Director, SICK India

What would be the key trends vis-à-vis market requirements that will drive automation & robotic technology in the years to come? Technology may demand more intelligence and connectivity to achieve higher autonomous flexibility. This will be in line with Industry 4.0. The industry experts also predict that more ‘human safety’ demands will be needed by the robotic industry in the very near future, while more & more robots will be in demand for many applications in the manufacturing sector. How do you make sure that you are prepared with the right technology and strategy to ensure the success of the automation project? We have a strong commitment to the customers to provide with the products and solutions obtained from latest technologies. As a part of this commitment, we invest 10% of our revenue in research & development. This helps us to remain at the leadership position. Besides, we work closely with our customers to understand their ‘pain areas’, where we can develop solutions together. This is why we identify ourselves as a partners and not vendors for our customers. What would be your recommendations on drawing a full roadmap for automation as a strategy in the long term? A roadmap for automation as a strategy in the long-term, we have to remain close to our customers with continuous improvements in our products, solutions and services.

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What are in general the challenges posed by manufacturers while leveraging automation? How do you address them? Customers are correct in expecting from us high reliability and performance. To achieve this, we invest heavily in adding the competency in our employees. The challenges are mainly in this area. We offer over 35,000 products for various industries & applications. Every year, this number expands due to investments in R&D. To cope up with this challenge, we also develop our channel partners who specialise in their domain and remain closer to our customers. Do you think the factories in India are future-ready? Are they equipped enough to adapt to advanced technologies in the existing supply chain? What would be the first step going forward in this direction? Yes, India is a manufacturing hub for many companies from Europe and the US. This way, some of them are already using the advanced technologies in their manufacturing set-up. Many automotive OEMs, Tier 1 & 2, FMCG companies have already started to plan in the direction of Industry 4.0. Going forward in this direction, we expect more industry networking among the supply chain. This may help the Indian factories to become ‘future-ready’. This means there will be more exchange of ideas at all the levels with suppliers, integrators, R&D and production teams. ☐

CHEMICAL & PROCESS INDUSTRY | FOCUS

7 WAYS TO IMPROVE PRODUCTIVITY AND PROCESS OPERATIONS Todayâ&#x20AC;&#x2122;s highly reliable pressure transmitters offer greater confidence in pressure measurement and more informed process decisions. The feature discusses seven ways to leverage the advances in pressure transmitter technology to gain greater control over productivity and process operations. To achieve operational goals, processing facilities must consistently produce at optimal throughput levels. Successfully meeting the challenges of minimising equipment maintenance, maximising uptime, accounting for process variability and achieving faster start-ups can make the difference between achieving production and revenue goals and missing deadlines and losing business. Pressure is a foundational measurement at the heart of any process control and monitoring strategy, providing critical insight into the health and productivity of an operation. Pressure technology continues to advance from traditional analog-only measurement devices to smart transmitters that provide more reliable and accurate measurements, enhanced

Michael Olivier Senior Product Manager Emerson Process Management Michael.Olivier@Emerson.com

diagnostics coverage, and new capabilities that reduce maintenance, outages, and process variability.

Utilising diagnostics coverage Pressure transmitters are used to take simple pressure readings that inform operators about the state of a process at any time. With this information, engineers can make any adjustments needed to keep the process running within required specifications. Most pressure transmitters include a basic set of diagnostics that notify the operator when the device is broken or needs to be serviced. While this information is useful, it only enables a

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FOCUS | CHEMICAL & PROCESS INDUSTRY

Figure 1. Use advanced diagnostics data to make proactive decisions

Figure 2. Eliminating mechanical components greatly reduces maintenance costs and time

reactive maintenance strategy that can result in unplanned downtime and lost productivity. Todayâ&#x20AC;&#x2122;s more advanced transmitters can provide additional diagnostic insights not only into the state of the transmitter, but also into the electrical loop and process itself, issuing proactive alerts so operators can respond immediately and avoid downtime. New advancements in diagnostics capabilities include: t Process monitoring â&#x20AC;&#x201C; Pressure transmitters can listen to the background noise of a process and detect deviations from normal operation that could signify plugged impulse lines or more serious issues with the process itself such as distillation column flooding, flame instability, or pump cavitation and cause shutdowns. t Loop monitoring â&#x20AC;&#x201C; Diagnostics can monitor the integrity of the electrical loop that connects a field device to the control room to notify operators of any irregularities; conditions such as water in housings and junction boxes, wire corrosion, unstable power supplies or environmental or human errors can create additional current paths or increase electrical loads and lead to on-scale failures.

and require less ongoing maintenance. These solutions permit close-coupling, a best-practice installation procedure that results in more accurate measurements. In traditional differential pressure (DP) flow applications, for example, integrated flowmeter assemblies eliminate a significant amount of impulse piping. These flowmeters can replace up to ten components including multiple transmitters, many mechanical parts and pipe penetrations, all of which contribute to leaking, plugging, freezing and inaccurate process measurements. The complete assemblies are easier and faster to install, leak-checked and drop-in ready. In tank level applications, an electronic remote sensor system, which is a DP level technology, replaces impulse piping with two gage or absolute pressure transmitters installed on the top and bottom of the vessel and connected electronically. One of the devices calculates differential pressure and transmits it back to the control system using a standard 4-20 mA HART signal. The remote sensors eliminate impulse piping and associated environmental effects to minimise variability, reduce maintenance, improve measurement accuracy and operational productivity.

Simplifying process connections

Eliminating heat tracing

The way in which a pressure transmitter is physically connected to the process can greatly impact the overall accuracy and reliability of the measurement. Simple installations often use impulse piping that is prone to leaking, plugging, freezing, and other maintenance challenges. More complex applications, including those on tanks and meter runs, can require multiple components, pipe penetrations and connections that can increase the amount of impulse piping required by tenfold. Newer pressure transmitters are available in compact assemblies that utilise fewer components, are simpler to install

Obtaining accurate and reliable process level measurements with applications involving extremely hot processes, cold ambient temperatures, or both can be difficult. In hot processes, heat tracing is commonly installed to keep the hightemperature, high-viscosity fluids used with impulse lines or capillary at elevated temperatures. In cold environments, heat tracing ensures fill fluid response time does not slow down, and that impulse lines and capillary do not freeze. Heat tracing can add considerable cost and complexity to any process and requires a great deal of maintenance to keep it operational. Because of these challenges, applications using

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CHEMICAL & PROCESS INDUSTRY | FOCUS

Figure 3. Improve reliability by replacing mechanical components with digital communications

Figure 4. Specialised remote seals and fill fluids increase measurement accuracy

heat tracing often suffer from frequent and unplanned process shutdowns, sub-optimal performance leading to lower throughput, degraded product quality, and cost overruns. A new DP level solution is available and utilises specialised remote seals with an expanded temperature operating range to address these operational challenges. The remote seals can operate in hotter or colder temperatures than traditional transmitters can handle. In this solution, an intermediate diaphragm seal in the transmitter separates two different fill fluids with different optimal operating temperatures. For example, on a high temperature application, the high temperature fill fluid is only used immediately next to the hot process, and a general-use fluid fills the remainder of the connected capillary. The solution is not dependent on heat tracing and produces more reliable, accurate and faster process measurements when conditions get extreme.

Adding measurement points “You can’t manage what you don’t measure” is a common phrase in the business world that is equally true in the industrial process world. However, in any given operation, the degree to which a process is automated and can be measured will vary: in some areas, measurements may not be made at all; in other areas, measurements may be made manually and only updated on a weekly basis; in other cases, variables may be assumed to be constant even if the process is dynamic and variables are known to constantly change. There are a number of factors why an operation may knowingly or unknowingly run at a sub-optimal level of automation, including: t Space constraints – Adding transmitters or sensors requires available I/O in the controller t Budget concerns – Running cable, trays, conduit and other required infrastructure adds cost

Geography – Remote locations are too difficult to access or wire t Design – Moving or rotating equipment creates challenges for wired instrumentation Wireless technology breaks down these traditional barriers, allowing installation of additional measurement points quickly and economically, and providing the precise and stable measurements needed to reduce variability and maximise throughput. Paul Kinne, a Head Operator with Chevron who was able to implement wireless technology in his operation in just three hours, gained reliable steam injection measurement at eight stations and eliminated excess steam usage. Installing and implementing wireless devices takes 75% less time than wired devices and the capital costs associated with wireless technology are 42% less. In addition, the insights gained from added pressure monitoring points help extend the life of assets, creating an even greater return on investment.

Compensating flow measurements Differential pressure is a common method of measuring the flows of gas, steam, and compressible liquids. However, differential pressure measurements alone do not take into account dynamically changing process conditions which can decrease the accuracy and repeatability of flow measurements and lead to process upsets. This can be especially problematic in critical applications such as material balance, custody transfer and energy steam flow. A multivariable transmitter allows compensation for changing process conditions by measuring absolute or gage pressure and temperature in addition to differential pressure. The transmitter measures flow 22 times per second and dynamically compensates for over 25 different parameters, giving greater control over the process and significantly

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MLG-2: DETECTS ANY OBJECT. EVEN THE INVISIBLE.

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CHEMICAL & PROCESS INDUSTRY | FOCUS

Figure 5. Wireless technology installation costs are 40-60% lower than wired installation costs

Figure 6. Multivariable transmitters calculate fully compensated mass or energy flow

improving flow measurement accuracy to ensure your product transfers get recorded & billed properly.

Operate closer to set point No process operates in a perfectly steady state. Fluctuations in operating conditions, variations in feedstock, and daily and seasonal environmental changes can all lead to a control strategy that has wider than desired tolerances around the desired set point of the loop. This can result in reduced efficiency and decreased productivity of operating units. Using high-accuracy instrumentation, dynamic process changes can be accurately measured and responded to, to consistently operate closer to the desired set point. Three key transmitter capabilities that help determine the accuracy and repeatability of pressure measurements include: t Reference accuracy describes the best-case accuracy of a device under perfect laboratory conditions where pressure and temperature are constant. Pressure transmitters today are available with up to 0.025% reference accuracy. Specialised pressure transmitters are also available for flow applications that are designed to maintain accuracy over a wider flow turndown. t Total probable error describes the installed accuracy of the pressure transmitter based on the reference accuracy, and any error from changes in static pressure and ambient temperature. t Stability describes the amount a transmitterâ&#x20AC;&#x2122;s measurement output may drift over a set period of time. For example, a pressure transmitter with a stability specification of 0.15% and 15 years will experience less than 0.15% shift in output over a 15-year interval, resulting in fewer calibrations and better measurement repeatability over time. Using high accuracy pressure transmitters, you will get less process variation in your measurement, operate closer to set point, and reduce waste and rework.

Standardising on a common instrument platform The range of pressure measurement technologies that facility operators have to choose from to operate at an optimal production level can be overwhelming, especially for the instrumentation and engineering personnel responsible for keeping the various instruments up and running. Each instrument may need to be uniquely specified, installed, calibrated, operated, maintained and serviced. In general, the more distinct devices an operation deploys, the more it needs to invest in training, tools and inventory. Maintaining multiple instrument platforms is not only expensive, but it also creates the kind of complexity that can lead to human error and process disturbances and shutdowns. When a facility harmonises its design, procurement, installation, commissioning, as well as training and maintenance procedures by standardising on one technology platform, it gains efficiency and lowers its costs. Advanced platforms are scalable and allow economisation on devices: one series of instrumentation can offer equipment with wide range down or turn down specifications, devices that measure pressure as well as level and flow, advanced diagnostics, wireless communication and transmitters that fit the needs of multiple applications.

Conclusion Advanced pressure measurement technology gives more control over the operation by providing additional insights at measurement points and extending visibility even further into the process and connectivity. Todayâ&#x20AC;&#x2122;s highly reliable pressure transmitters offer greater confidence in pressure measurement and more informed process decisions; minimise process variability, extend the life of assets, increase uptime with better installation practices and utilise new technology to help the operation meet its productivity and revenue goals. â&#x2DC;?

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G E A R S & M OTO R S | T E C H N O L O G Y

I m ag e C o u r tes y : Bodine Electric Company

Design tips for gearmotor applications To select the best gearmotor for an application, one must go into more detail than just selecting the best suitable output speed and torque. The article highlights five criteria that should be considered while choosing the gearmotors for an application. A gearmotorâ&#x20AC;&#x2122;s purpose is to act as a power transmission component. As such, the two most important factors at the gearbox output shaft are its speed (in rpm) and how much work it can do, as determined by the amount of torque it produces. But certain applications need a detailed analysis to maximise the overall efficiency of a gearmotor system.

Gearmotor mounting orientation Gearmotors are typically designed to be mounted with the

gearbox level with the motor, and with the drive shaft in horizontal orientation. Other mounting positions are possible, depending on the type of gearmotor and how its gearbox is lubricated. If you require non-standard mounting (e.g. vertical), the first step in choosing a gearmotor should be to call the manufacturerâ&#x20AC;&#x2122;s technical support team. Most fractional horsepower (FHP) gearmotors feature unvented gearheads that are lubricated for life, but some gearmotor types are oil lubricated and others are grease lubricated. If oil lubricated gearmotor is mounted in a position

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T E C H N O L O G Y | G E A R S & M OTO R S

other than horizontal, the chance of leakage increases in both static and dynamic conditions as the shaft seals wear. Grease lubricated products are less prone to leakage, but gear life can be compromised.

upward, then a grease-lubricated, right-angle gearmotor would be a better solution. If you require a non-standard mounting position, you may need to consider a custom gearmotor with modified lubrication or fill level.

Design tip 1: Oil vs grease

Gearhead efficiency

Oil provides more consistent lubrication to the gear teeth under load conditions. Grease provides greater flexibility in mounting and minimises the risk of leakage. Despite advantages, oil is not always used in smaller FHP gearmotors because of these sealing considerations. If a non-standard mounting orientation is required, one possible alternative is semi-fluid grease. Avoid mounting an oilfilled gearbox directly above the motor. There is a shaft seal between the gearbox and the motor, but seals don’t last forever. Eventually, the lubricant will find a path into the motor. This could interfere with commutation in a permanent magnet DC motor, the centrifugal starting switch in an AC split-phase motor, or the electronic commutator assembly in a brushless DC motor. If the drive shaft must point

The worm gears found in most right angle gearboxes are less efficient and generate more heat than the spur or helical gear assemblies used in parallel shaft gearboxes. Therefore, right angle gearmotors often require a larger motor to match the output torque of a parallel shaft gearmotor with the same gear ratio. The efficiency of the worm gears is even worse at low speeds, providing less torque for starting and acceleration.

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Self-locking right angle gearheads ‘Self-locking’ right angle gearboxes can’t be driven backwards by applying constant torque to the output shaft. These gearboxes can provide holding torque even when the power to the gearmotor is turned off. This is desirable in

G E A R S & M OTO R S | T E C H N O L O G Y

applications where a load is expected to remain stationery even after the power to the gearmotor is turned off. However, this is not recommended as a ‘fail-safe’ application solution because holding torque diminishes as the gears become worn or if shaft vibration occurs.

Design tip 2: When to use brakes In applications where a load has to be held securely during a power-off condition, an external holding brake should be added to the motor or gearmotor. The brake is typically installed on the high-speed or accessory shaft (armature or rotor shaft) and not on the drive shaft (output shaft).

Noise and load Gearboxes are designed to be quiet, but some are quieter than others. In some cases metallic gears produce more noise than non-metallic gears, and helical gears tend to be quieter than spur gears. The noise from a gearbox is affected by the number of gear stages, the load, and armature/rotor input speed. Some smaller parallel shaft and planetary gearboxes use a Nylon-type first stage gear as a way to reduce noise and vibration. Worm gears are generally quieter than spur/helical gear reducers because they operate on a sliding action. Because the worm and gear teeth are under crushing rather than cantilever loads and more teeth are usually in contact, worm gears have higher resistance to shock loads than spur or helical gearing.

Gearmotor life Gearmotor life is affected by many factors. The obvious ones are operating speed, load, duty cycle, and ambient temperature. The higher any of these operating conditions are, the sooner the gearhead components will wear out. But there are also design details inside a gearbox that determine the gearmotor’s life. For example, the sliding action of worm gears is more difficult to lubricate and is less efficient than the rolling action of spur and helical gearing. Therefore, metallic worm and gear teeth will wear faster than metallic spur and helical gear teeth. Non-metallic gears will wear slower than metallic gears if no severe or shock loads are applied. Oil lubricated gears will last longer than grease lubricated gears because oil provides more consistent lubrication to the gear teeth under load conditions. Another design detail that can affect gearmotor life is the motor shaft and output shaft ball bearings. Possible causes of premature bearing failure can be foreign materials from dirty grease or ineffective seals, grease deterioration due to excessive temperature or external contamination, or electrical arcing due to shaft currents.

Design tip 3: Signs of bearing wear Some early warning signs for bearing problems can be an increase in temperature differential between the motor and the bearings, an increase in bearing noise, or an increase in torque (load) of the motor, resulting in an increased current draw by the motor or gearmotor. ☐ Copyright: Bodine Electric Company

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The interface to Industry 4.0

electronic ifm electronic India Private Limited Plot No. P-39/1, MIDC Gokul Sirgaon, Kolhapur - 416234 Maharashtra Ph: 0231-2672770 E-mail: info.india@ifm.com Toll Free: 1800 233 2065

S A F E T Y & I N T E G R AT I O N | T E C H N O L O G Y

Authorisation concepts in machine automation In modern automation architectures, the interaction between machinery safety (safety) and operational security (security) is increasingly becoming the key to practicable concepts. It is important to consider not only the technical and normative requirements of safety, but in particular, the need to assign information and authorisations carefully. With a safe operating mode selector switch, manipulation protection and access, authorisations can be achieved in terms of overall safety. The development towards a networked automation landscape means that companies face new security challenges. Industry 4.0 systems can be reconfigured and optimised autonomously – i.e. by the system itself during operation, which requires safety to be re-assessed during runtime. It must also be ensured that no new safety risks arise as a result of residual security vulnerabilities.

Holistic approach increasingly important There are clear differences in perspective when it comes to the issue of safety: the internationally used terms are “safety” for machinery safety and “security” for operational security; this helps with the basic differentiation. Safety requires that residual risks that emanate from a plant or machine do not

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T E C H N O L O G Y | S A F E T Y & I N T E G R AT I O N

exceed the limit values specified in the standards. This includes hazards to the machine surroundings (e.g. environmental damage) as well as hazards inside the plant (e.g. persons inside the plant). Security is concerned with protecting a plant or machine from unauthorised access from outside, as well as protecting sensitive data from corruption, loss and unauthorised access internally. This includes explicit attacks as well as unintended security incidents. When developing solutions, it is also important to consider the needs of the user from the very start, in terms of handling and user friendliness during operation, for instance. If not, manipulation of safety measures will literally be programmed in. Holistic safety concepts require the interaction of safety & security, but that’s not all. In terms of the safety aspect, it’s important to check the extent to which security issues influence functional safety. This is the case if access or authorisation systems can be defeated or copied using simple means, or are accessible to everyone when a master password is written on a note stuck to a screen, for example. Key issues here include clear, safe proof of identity for products, processes and machines as well as for authorised persons, including safe information exchange across the whole production process.

Safety must be considered from the start In the internal European market, there is an obligation for machine manufacturers only to supply safe products to its customers. All relevant hazards must be identified, based on the intended use – taking into consideration all the lifecycle phases once the machine is first made available on the market. All the various groups who come into contact with the machine, such as operating, cleaning or maintenance staff for example, are also considered. The risk is estimated and evaluated for each hazard. Risk-reducing measures are established in accordance with the state-of-the-art and in compliance with the harmonised standards. Ultimately, an intelligent safety concept must provide the greatest possible leeway and freedom as well as the highest possible level of safety. Access points to the machine or process are of vital importance. These must be protected against unauthorised opening and must guarantee beyond doubt that nobody is inside the hazard zone when the machine is started.

T E C H N O L O G Y | S A F E T Y & I N T E G R AT I O N

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No danger to people … To ensure that deliberate or accidental opening of access doors cannot cause a hazard, they are protected in classic safety style with a safety gate system. This combines safety gate

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NI PXI, LabVIEW, and TestStand

©2016 National Instruments. All rights reserved. LabVIEW, National Instruments, NI, ni.com, and NI TestStand are trademarks of National Instruments. Other product and company names listed are trademarks or trade names of their respective companies. 25273

S A F E T Y & I N T E G R AT I O N | T E C H N O L O G Y

The operating mode selector switch PITmode enables the operating mode to be switched safely and access authorisation to be controlled within one unit

monitoring with safe guard locking inside one system and also provides safety functions such as emergency stop, escape release and a mechanical restart interlock. This means that anyone who is locked in accidentally can leave the danger zone quickly and easily in the case of danger. It will not then be possible to restart the plant until it is established beyond doubt via the integrated safety and reset functions that there is nobody else in the danger zone. With a safety gate system such as the PSENsgate from Pilz, human protection is guaranteed, in terms of safety. However, the matter of process protection in terms of operational security is still open.

each operator via the RFID-based keys. These can be assigned via identification management in the machine control system. Thanks to operating mode selector switches like PITmode, authorised personnel are able to operate and control the plant in various operating modes. Operators are given the machine enables that match their individual abilities and qualifications, providing a high degree of protection against unintended actions and manipulations, as well as security of information. On delicate or sensitive machinery, all operator actions need to be logged. Here, too the system can provide support, as all operator actions are reported to the control system anyway. The authentication system can be used to assign the actions clearly to an operator. As a result, any changes during … or process the machine operation can be documented, increasing In practice, protection against unauthorised access can be traceability. Should anyone change a machine parameter achieved via a safe operating mode selector switch. It fulfils during operation, this step will be documented. If errors then two functions: it selects the operating mode and controls occur, the reasons can be identified more quickly. authorisation for machine access. Through self-monitoring, PITmode switches safely from Operating mode selector switches such as PITmode from one operating mode to the other. Five selectable operating Pilz allow you to switch between defined operating modes. modes are possible: automatic mode, setup mode, manual The operating mode is selected by inserting a transponder key intervention under limited conditions, special mode/process with the relevant authorisation and pressing the pushbutton monitoring and service mode. Thanks to the LED display, the defined for the relevant operating mode. Each key is currently selected operating mode can be clearly identified, as individually coded to enable unique user authentication, which can the key’s authorisation level. The operating mode selector prevents manipulation. As the unique key can be used on switch can be used for applications up to PL d of EN ISO several machines and can have different authorisations stored 13849-1 or SIL CL 2 of EN 62061. on it, several mechanical keys can be combined within one With the definition of safe operating modes, it is possible transponder key. This in turn reduces administrative work. to harmonise the requirements of operator safety, process security and availability. After all, issues such as manipulation protection, demarcation of areas of responsibility/jurisdictions Clearly defined responsibilities and clear proof of identity for machines and operators must Using the coded key, each operator is given access to the be safely regulated before a process can be deemed machine functions or machine operating modes allocated to ‘safe to operate’. ☐ him. Individual (access) authorisations can be assigned for Courtesy: Pilz

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PRESENTING ARC’S FOU RTEENTH I N DIA FORUM

Industry in Transition: Navigating the New Age of Innovation J U LY 7- 8 , 20 16 • B A N G A L O R E

FEATURED TOPICS: Industrial companies in India are beginning to move beyond the computer-enhanced business models of the late twentieth century. Many are embracing new models that take advantage of intelligent connected products coupled with potent software and analytics. Expect to see innovations in smarter products, new service and operating models, new production techniques, and new approaches to design and sourcing. Also anticipate changes throughout the value

IMPROVING ENERGY EFFICIENCY ADVANCE CONTROL STRATEGIES SMART GRID AND SMART CITIES COLLABORATION AT THE USER AND DEVICE LEVELS

competitors and new threats.

MANAGING LEGACY AND AGING INFRASTRUCTURES

ARC Advisory Group’s Fourteenth India Forum for process and discrete

3D TRAINING AND SIMULATION

network with new partners and new opportunities, along with new

industries is a not-to-be-missed event for all stakeholders – technology solution providers, end users, industry trackers, decision and policy makers, and the media. In an advanced automation and informationdriven world, terms such as Industrial Internet of Things (IIoT), Smart

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solutions are emerging backed by strong associated business cases. This is the new age of innovation. Join us at ARC’s Fourteenth India forum to learn more about how this industrial transformation will unfold. Discover what other companies are doing today to prepare for the new age of industrial innovation and how they expect to improve their business performance by doing so. TO REGISTER: Space Is Limited! Call India +91-80-2554-7114 or USA +1-781-471-1000, Register on-line at www.arcweb.com/events/arc-industry-forum-india/, or e-mail ramang@arcweb.com.

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C O M M U N I C AT I O N & C O N T R O L | T E C H N O L O G Y

Five key elements for effective IIoT implementation The article examines the key elements organisations should consider, when devising an effective implementation strategy for Industrial Internet of Things (IIoT), and also explore the benefits resulting from connecting, monitoring and controlling operations Many technological advances have been made over the past two decades. Of these, industrial networking and mobile computing continue to impact manufacturing and industrial environments. These are the technologies that are helping to make the vision of concepts like Connected Factory, Industry 4.0 and Industrial Internet of Things (IIoT) a reality for manufacturers and organisations around the world.

Concept definition Connected Factory: The Connected Factory is the vision of a manufacturing environment where every machine is able to

communicate with all other machines and devices across the plant floor and other remote locations. The purpose of the Connected Factory is to connect, monitor and control virtually anything, anywhere to drive operational productivity and profitability. Industry 4.0: This term originated from a Germangovernment initiative that refers to the fourth industrial revolution, based upon the dynamic optimisation of production resources within and between highly-connected factories. IIoT: IIoT will mean that organisations will be able to connect many different devices, including older equipment, and get

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T E C H N O L O G Y | C O M M U N I C AT I O N & C O N T R O L

In order to bring these devices into the Connected Factory, Industry 4.0 and/or IIoT paradigm, an organisation’s engineers must first ensure that the devices can communicate with the other equipment on the factory floor

Legacy equipment: Take inventory of the devices and equipment across the network. How old are they? Do they need to be replaced or upgraded? Is legacy equipment going to be able to communicate with newer equipment? How much time and money will this take? What cost-effective solutions can address this infrastructure? Devise an effective implementation strategy Protocols/communication: Along with the equipment, what Many of today’s organisations are eager to implement protocols are being used by networked devices? How many these concepts to realise benefits, such as reduced operational are in use? Do they need to be converted in order to get the costs and better visibility and control. While it is, however, devices to communicate with others in the same environment? unrealistic and cost-prohibitive for most organisations to What type of media cabling is being used across locations? construct green-field facilities or “rip-and-replace” legacy Fibre-optic cable? Serial (RS-232/422/485)? USB? Copper? equipment, many solutions utilise existing equipment and Location/environment: Where is the facility located? If allow components to be strategically deployed to extend equipment is in a remote location, can each device be monitoring and control capabilities without impacting day- monitored via cellular networks? Are 4G/LTE or 3G networks to-day operations. When updating a facility, it is important available to reach the site? If not, are broadband or fiberthat expectations be set early. Despite the vision of an IP based networks available? Also, within the building itself, address for every piece of equipment in a network, the reality what is the overall environment? Hot and dusty, or at a is end users will not be able to log into every panel meter, controlled temperature? Lots of vibration? Are there water pump and drive from mobile devices. Bringing a facility flammable gases? Is industrial-grade equipment that is into the 21st century involves several core fundamentals to designed with wide environmental ratings and industry help ensure a smooth transition and provide the ability to certifications being used? access, monitor and control information from anywhere. Security: According to a recent Business Insider Intelligence The first step when devising an effective implementation survey, 39% of executive respondents indicated that privacy strategy should revolve around an organisation’s operational and security are the most significant barriers to IoT environment and the devices, applications and processes that investment. Security was the most commonly cited concern make it up. Before plans are put into action, organisations among respondents. While this survey applies to all items in should consider the following five key elements: IoT, security should be an important concern for IIoT as well. them to “talk” with each other in a way that they could not before. By gathering data from both new and legacy devices, organisations can use that data to improve efficiency and gain a competitive advantage.

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C O M M U N I C AT I O N & C O N T R O L | T E C H N O L O G Y

A Connected Factory’s purpose is to connect, monitor and control virtually anything, anywhere

How can sensitive data be protected when it is collected and transferred? What security measures are in place for the systems that collect, monitor, process and store IIoT data? Are there any regulations regarding the protection of data and information? Staff: As more technology-based devices are added to the network, is the right IT staff on hand? Are other employees who are tech savvy available to help with installation and monitoring? Is software or remote monitoring needed to keep tabs on devices in other locations? Once these key elements are assessed and questions answered, organisations should take steps to enable communication between devices, ensure operational efficiencies across the infrastructure, and provide a secure platform for device communication.

Enable communication between devices Drives, sensors, PLCs, panel meters and other automation equipment are built to last years – even decades. Trouble is they often communicate via proprietary protocols that commonly use RS-232/422/485 serial cables. While these serial protocols are efficient and were often written for a specific application, many of these applications never included 24/7 monitoring across TCP/IP networks. In order to bring these devices into the Connected Factory, Industry

4.0 and/or IIoT paradigm, an organisation’s engineers must first ensure that the devices can communicate with the other equipment on the factory floor. Companies looking to connect devices from disparate manufacturers can now choose advanced HMIs, protocol converters and other automation products that natively speak different protocols. These industrial products enable devices to communicate regardless of physical medium and offer industrial fluency and multi-protocol support.

Ensure operational efficiencies across the infrastructure Operational efficiencies can be accomplished in a number of ways, one of which is using data collected from monitoring points along a manufacturing line to minimise waste and downtime. As technology continues to improve, these status points will include an increased volume of information from a wider range of sources. Managed Ethernet switches will be able to report on the flow of data throughout the facility in the same way that sensors on assembly lines can report a product’s status on a production line. This expanded collection of operational data enables organisations to make data actionable by using visual management solutions to collect, record and display critical Key Performance Indicator (KPI) and Andon messages. Displaying this critical

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I m a g e C o u r t e s y : iStockphotos

T E C H N O L O G Y | C O M M U N I C AT I O N & C O N T R O L

Using VPNs or tunneling appliances also makes factory-to-factory, supply chain-to-factory, or factory-to-distributor communication secure by creating virtual “tunnels” to transmit sensitive data through

performance data in real time helps to drive productivity and increase throughput. This concept is not limited to connecting, communicating and monitoring within an organisation. This concept can also be extended to include the supply and distribution chain to present a comprehensive view of the entire operation.

Provide a secure platform for device communication

factory, supply chain-to-factory, or factory-to-distributor communication secure by creating virtual “tunnels” to transmit sensitive data through.

Overall implementation benefits The efficiency of the Connected Factory, Industry 4.0 and/or IIoT model isn’t derived from the sheer volume of connections, but from more valuable connections, and the competitive edge gained by the sharing of information between devices and humans. Seamless communication with operators, control systems and software applications, combined with practical networking options and support for native features and protocols, deliver exponential meaning to data extracted from industrial devices. These capabilities can take automation and remote management to new levels, thereby, making this vision a reality. With the thoughtful integration of supporting components that are designed specifically for this goal, the ability to connect, monitor and control will extend equipment lifespan, improve process visibility and push control to the edge. These results not only reduce total cost of ownership and speed deployment, but also provides more robust end-to-end functionality across a wide variety of applications. ☐

Security has traditionally meant physical isolation of automation equipment and enterprise networks. If nothing is connected to automation equipment, the threat of security breaches is fairly low. Connection-free facilities are few and far between as more organisations continue to expand their enterprise networks into factory settings. As organisations embrace this new reality, security should be addressed through careful network planning and use of IP address best practices. Routers can be deployed within a network to limit network traffic to specific types of traffic or to specific users, minimizing the risk of a cyber-attack. Another tactic is the implementation of NAT (Network Address Translation). NAT is a technique that obscures devices on a network from inbound access, but doesn’t affect traffic on a network. Finally, using VPNs or tunneling appliances also makes factory-to- Courtesy: Red Lion

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M A C H I N E TO O L S | T E C H N O L O G Y

Automation in machine tools The article highlights the role of automation in machine tools and the need for machine tool manufacturers to step up their game in order to fully exploit the opportunities available in the Indian machine tool sector

Rajan Goyal Chief Managerâ&#x20AC;&#x201D;Motion Control Systems Drive Technologies Siemens Ltd

India is a leading manufacturer of machine tools, ranked growing demands and transition of technology in segments 17th in production and 12th in the consumption of machine such as automobiles, aerospace, power and medical, etc, have tools in the world (source IBEF). The country is all geared up ensured an improvement in performance and productivity. to establish a firm foothold in the global machine tool industry With the current scenario of supply and demand, investment and is likely to see substantial high-end machine tool in this sector is said to guarantee a sustainably higher ROI in manufacturing. With the current trend of â&#x20AC;&#x2DC;Make in Indiaâ&#x20AC;&#x2122; the long run. Machine tool manufacturers, hence, need to step giving the much-needed push to the manufacturing sector, the up their game in order to fully exploit these opportunities. country is on its way to become a major manufacturing giant. As a first step towards this advancement, CNCs are being The machine tools users in the industry are now moving utilised to their maximum to achieve the best quality and towards increasingly sophisticated computerised numerical finish off the product in the shortest possible time. When the control (CNC) machines imbibing the latest technology. The right manufacturing software is matched with the latest CNC

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T E C H N O L O G Y | M A C H I N E TO O L S

controllers and machine tools, it allows the user to implement a process chain that delivers maximum performance for their business. This significantly reduces the chances of errors as well as the general downtime of the machine, minimising the need of manual labour and production.

Robots lead the way Today, manufacturing companies are searching for even leaner solutions and they have found alternatives in the vast arena of robotics. An industrial robot has come into existence and its use is expanding into a wide range of applications. While the human body experiences fatigue, a robot is capable of performing repetitive tasks with the highest amount of accuracy. This not only eliminates errors, but also ensures higher productivity. Higher productivity equals higher profits. Industrial robots are credited for faster production as opposed to traditionally existing manufacturing methods, by decreasing the cycle times. The very essence of the robot is its ability to create a leaner and more efficient manufacturing cycle. Industrial robots can be used for diverse operations, including robotic handling applications like machine tending, plastic moulding, etc. In the automotive industry, these robots are mostly used on machining lines. In a machining line or cell, the robots are typically used for loading/unloading operations. Robots are electrically interfaced to the machine tool controller via typical hard-wired information exchange, or using industrial communication bus protocols, the most widely used being PROFINET & PROFIBUS.

Integrating with controllers Gantry type robots are controlled by a general motion controller, whereas the articulated arm robots require a special motion controller that can handle non-Cartesian motion. This creates another seamless opportunity for integrating the two controllers, the CNC controller and the robot controller. Grasping this exact opportunity, Siemens introduced SINUMERIK Integrate Run MyRobot—A flexible solution that allows the robot to be operated from the same user interface as that of the CNC machine. This technology package facilitates high-speed workpiece and tool handling. Diagnostics, retraction and operation can all be executed from the CNC operator panel. The robot can be easily operated from the

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SINUMERIK operate interface resulting in simple production automation and minimising the loading and unloading time. The technology does not just end with the controllers as the company realises the manufacturing sector’s need for software to guide and take the complete manufacturing process to fruition. The Product Life Cycle Management (PLM) software from Siemens works collaboratively with companies to deliver open solutions that help them turn ideas into successful products.

Combined solutions with software The combination of software and manufacturing equipment expertise provided by Siemens products support a CAD-CAMCNC process chain that maximises the value for customers using latest machine tool investments. It provides a complete package for its users in the manufacturing industry with its versatile range of CNC controllers, ability to integrate with robotics and its wide variety of software solutions. Of these, NX provides a complete set of NC programming capabilities in a single CAM system as well as an integrated set of manufacturing software applications. These applications facilitate part modeling, tool design and inspection programming. NX CAM delivers differences through key capabilities such as its advanced programming, post processing and simulation functionality. It provides advanced programming to match the powerful capabilities of SINUMERIK controllers. NX combines both automatic and user-selected options to ensure that the postprocessor provides optimised output for SINUMERIK controllers in areas such as high-speed cutting and 5-axis machining. It imparts advanced CAD tools that can be used by the NC programmer for everything from modeling new parts to creating setup drawings directly from 3D model data. Multiple-axis machining in NX enables users to produce precision complex parts with fewer operations and setups – reducing cost and delivery times. The Indian machine tools sector offers several opportunities for investment. Players who look to succeed in the sector in the long term, need to focus on key success factors, such as, developing capacity and scale, design capability, acquiring the latest technology etc and therefore automation and digitalisation will play a key role for its success in the manufacturing sector. ☐

EVENT | REPORT

Design, validate, collaborate & build Dassault Systèmes recently released SolidWorks 2016 at its 18th annual conference held in Dallas, Texas, USA, that speeds up day-to-day design work, tests and validates products before production, collaborates across multiple departments and quickly sends the products to manufacture. The four-day event witnessed several general and breakout sessions dedicated to 3D design and engineering community globally. A post-event report…

Megha Roy Features Writer megha.roy@publish-industry.net

SolidWorks has a long history of delivering innovative solutions. By listening to its community needs, the design software is able to deliver tools that make developing great products easier—be it single component, incredibly complex equipment or even entire production lines. This year, Dassault Systèmes, launched its 18th annual conference at the Kay Bailey Hutchison Convention Center in Dallas, Texas, USA, where SolidWorks 2016 was released. With a customer base of 5750 in India, and dedicated to 3D design and engineering community globally, SolidWorks World 2016 witnessed a footfall of around 6000 people, along with 40 hours of networking opportunities.

Making business model stronger Keynote presentations from the greatest of designers, innovators and visionaries were delivered at the technologydriven conference. Today, their dynamism has pushed

technological, business and sustainability boundaries far beyond what many thought possible. Day 1 began with general sessions, where Paolo Bassi, CEO, SolidWorks, addressed the first session. “This is the best year for SolidWorks because the community is growing stronger and bigger,” he exclaimed. He further said, “Communities partner with us for a better innovation that includes creativity and execution. So much so that additive knowledge of other innovators comes to our innovation. For us, the ecosystem comprises of people, application and infrastructure. SolidWorks acts as an innovative platform for making a business model stronger.” Highlighting that $1 billion user revenue was achieved by the company, Bernard Charles, President, Dassault Systèmes, announced that the company has been investing massively for SolidWorks. “We will provide the best solution for architecture, design & construction. We are changing the economic model of the current landscapes,” he shared.

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REPORT | EVENT

“This is the best year for SoildWorks because the community is growing stronger and bigger” Paolo Bassi, CEO, SoildWorks

“Innovative new tools have been introduced by us that make mass customisation easier for customers”

Suchit Jain, Vice President—Strategy & Business Development, Dassault Systèmes

In today’s age of experience, the world of design has become more social, and collaboration remains critical. SolidWorks, this year, brought together more than 5000 engineers and designers from across the globe to network, learn, share and discover the latest in SolidWorks 3D applications & engineering technologies that help millions of users make great designs happen. As per Monica Menghini, CSO, Dassault Systèmes, design is a vision. While sharing insights on the technology breakthrough adoption with the use of SolidWorks, she averred, “Today, the economical boost generates from experience. As such, consumers buy experience. The knowledge-base of experience doesn’t only cater to the product; in fact, it ranges across the entire customer journey.” Moving ahead, Bassi hosted a session inclining with future product and technology strategies designed for desktop & cloud, and collaboration with the strong user community. He also revealed SolidWorksPCB, the new printed circuit board design software from Altium. In innovating with the best-inclass SolidWorks ecosystem, Kishore Boyalakuntla, Senior Director, Product Portfolio Management & Solidworks brand UX leader, in his presentation, provided a sneak-peek into the products created around the world. He introduced xdrive, which has built-in AM features, and has an objective to expand the design paradise. “This is a new online SolidWorks design product that works in the web browser for desktop & mobile devices,” he added. The next session was presented by Yves Behar, a design entrepreneur. While explaining the current landscape on design and technology, he touched upon the futuristic vision, which covered aspects like distraction hell vs invisible interface;

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robots vs humans; virtual reality vs augmented reality; healthcare vs augmented reality; healthcare vs 24/7 personal care; first world problem vs technology for all and single mind design vs multi-disciplinary environments.

Ecosystem of design Today’s consumers are increasingly demanding more personalised products tailored to their specific needs. Based on this, Day 2 began with a presentation by Suchit Jain, Vice President—Strategy & Business Development, Dassault Systèmes. As per Jain, personalisation adds a level of complexity to the design process. “However, innovative new tools have been introduced that make mass customisation easier for customers,” he added. Also, attendees were given a preview of such a technology with presentations from David Friedfield, CEO, ClearVision Optical and Igal Kaptsan, Vice President— Product Management, SolidWorks Make, on innovative solution to personalise eyewear. Jain revealed SolidWorks apps for kids too. Day 3 witnessed Boyalakuntla explaining the two ecosystems—manufacturing and IoT. While speaking on model-based manufacturing—MBD, he said that SolidworksMBD brings design & manufacturing on the same platform. “It’s an integrated drawingless manufacturing solution for SolidWorks that helps companies define, organise and publish 3D Product Manufacturing Information (PMI), including 3D model data in industry standard file formats such as eDrawings® and 3D PDF. He also spoke on SolidWorks Inspection and showcased SureFlap, an innovative SolidWorksdesigned and xively-connected product to safeguard pets.

EVENT | REPORT

SolidWorks, this year, brought together more than 5000 engineers and designers from across the globe to network, learn, share and discover the latest in SolidWorks3D applications & engineering technologies that help millions of users make great designs happen

Moving ahead, Louis Feinstein, Senior Product Manager, SolidWorks Electrical, introduced SolidWorksPCB Connector, synchronised with mechanical & electronic design that has the best-in-class design and power to meet the parameters of design today. Since Additive Manufacturing is poised to grow in both, usage and downstream impact, manufacturers in a wide variety of industries, are actively piloting & implementing 3D printing today. Touching upon this, he further discussed the integration inside SolidWorks and 3D printers developed by Korea-based Sindoh, the first 2D printer company with massive production capabilities to expand into 3D printing business. “SolidWorks believes simplifying the complexity of connected devices. In this context, Sindoh has become a SolidWorks partner and developed an integration, so that we can not only design, but also print in our SolidWorks platform,” he added.

Catering to the Indian market According to experts, the challenges to 3D manufacturing come out of subtractive manufacturing. On this, Peter J Rucinski, Director—Product Portfolio Management, SolidWorks Desktop Products, shared that big companies, today, are heavily investing on 3D printing. Speaking on the adoption of this technology in the Indian market, he said, “Asian countries are strong on the mechanical side, but it still has to buck up on the software side. When it comes to India, schools should implement the economic and cost-effective machines from a very initial stage so that the technology can be well-adapted to them.” As per Jain, the ‘Make in India’ initiative is great for SolidWorks since it implements more manufacturing activities. “In India, business is generated more from the service industries, rather than manufacturing. We have developed a CAD training program in India. Our team there, is in the

public-private partnership, which has an involvement of the government and academia. However, the design aspect needs to be paid attention in India,” he opined. Further, explaining the growth strategy in India, he shared that in terms of Solidworks, India has a 20-25% growth. “We have become more flexible for adopting 3D tools in India. We also are growing our subscription to achieve a better rate of adoption. We will work towards the ‘Make in India’ initiative. We have already taken up the Fablab initiative in India,” he added. Sharing views on the Indian market, PM Ravikumar, Sales Director, 3DS Professional Channel, India, said, “In India, around 12% growth drives down from the business & finance sector, but the manufacturing sector is still struggling. For the ‘Make in India’ programme, we have plans of investment, more on electronic clusters. SolidWorks has been in use in the Indian market. Today, SoildWorks has around 1.5 lakh licenses involved in India, and the Indian revenue market to SolidWorks is 1.5 and 2.5%. Ather Energy, initiated by IIT Chennai students have built India’s first premium electric smart scooter with the integration of SoildWorks.”

Previewing SolidWorks 2017 While wrapping up the event, a brief on the next release was presented by the Product Introduction Team, which displayed that the next version will ease visualisation of geometries, deliver great capability in section view and will have transparent section views. Further, it will enable treehouse drawing imports, where the treehouse will automatically import associated drawings; have shaded sketch contours, where sketch contours will be shaded for clarity & easier manipulation; will have advanced hole wizard, where new functionality will create multi-step holes. The next edition of Solidworks will be hosted in 2017 at Los Angeles, USA.☐

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EVENT | REPORT

Transforming food & beverage industry FoodSafe 2016, the two-day event held recently in Bengaluru, served a platform for manufacturers, solution providers, regulatory agencies, food technologists and innovators & consultants from the food & beverage industry. A post-event report… Today, automation and digital transformation in agribusinesses is the need of the hour to make them competitive and fit for the current global scenario. Keeping this in mind, ISA Bangalore recently hosted FoodSafe 2016 – a national symposium on “Automation & Digital Transformation of Food & Beverage Industry” in Bengaluru. The symposium was inaugurated in the presence of R V Deshpande, Minister for Large & Medium-Scale Industries and Tourism, Govt of Karnataka, admist a host of industrial experts across the sectors.

Highlights The keynote speeches were delivered by D Shivakumar, Chairman & CEO, PepsiCo India Holdings and Prof Ram Rajasekharan, Dir General, CSIR-CFTRI. In his keynote

address, Shivakumar gave an end-user perspective of the main drivers of the processed foods business and future trends. He noted that F&B sector plays a key role in the GDP and workforce. He further highlighted that processed foods are the ‘edge of the plate’ components of a family’s entire food basket and that this portion is subject to dynamically changing trends as compared to the more stable ‘centre of the plate’ traditional items, like cereals. According to Prof Rajasekharan, regulations and guidelines are in place now for ensuring the hygiene and safety till final use. He expressed that the key role for automation is not only in achieving high standards in preparation, but also in developing innovative solutions. A few examples, he mentioned, were of oil in powdered form for blending better with other ingredients and creation of healthier forms of sugar from bran. He expects digital transformation to facilitate in passing more

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REPORT | EVENT

data to consumers on the food package about the most scientific and healthy way to prepare and use the product.

Scaling the industry Day 1 included a speech from G Ganapathiraman, GM & VP, India & SE Asia, ARC Advisory Group, who spoke from a global perspective on ‘Automation & enterprise trends – F&B industry’. Neville Dsouza, Industry Manager – F&B/HPC, Rockwell Automation, highlighted on the automation path for operation excellence. Also, Wolfgang Felber, Group VP, ABB, Switzerland & TR Ravishankar, VP, ABB India, jointly elaborated on ‘Tighter control to achieve food safety with process control, batch, and MES’ and Dr Ravi Kumar GVV, AVP & Head of Advanced Engineering, Infosys, shared insights on ‘Leveraging digital technologies for enhancing productivity in F&B Industry’. Next, Arjun Kumar Sahu, Manager – Quality Assurance of Hindustan Coca-Cola Beverages, delivered a valuable end-user perspective titled ‘Challenges and expectations in adopting automation and rolling out digital technologies in beverage industries’. Moving ahead, Dr Alok Kumar Srivastava, a scientist from the Food Safety & Analytical Quality Control laboratory, CSIRCFTRI, Mysore, gave a detailed overview on ‘Challenges and complexities in quality, hygiene, compliance in food & beverage industry’; Rajesh Raina, Head—Product Management, Measurement & Analytics, ABB India, focussed on ‘Applications in food & beverage industry – Measurement & Analytics’. Then, Kanchan Chakraborty, GM, Technology & Engineering ITC Limited, Foods Division, gave a practical end-user perspective on ‘Achieving excellence in automation and enterprise convergence’, while S Prasad Narasimha, DGM – Product Engineering, Lapp Group, addressed on ‘Food & beverage industry challenges and solutions’ and Arvind Mangarsi, Business Head—Products & Projects, B&R Industrial Automation, spoke on ‘Scaling industrial control technologies for food & beverage industry’. A panel discussion at the end of day 1 gave nuggets of

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experience from the panellists in response to specific questions from the moderator Rajesh Rathi. The discussion included key members from Jack n Jill LM, ITC, Omron, Endress & Hauser, Siemens, Steer, ABB, Rockwell, B&R Automation, Lapp India, Infosys, KMF.

Addressing challenges Day 2 started with a presentation by Dr Sunil Shah, Secretary, ISA Bangalore Section & Founder, Communications, Diagnostics and Control – who gave an overview of ISA Standards, delving deep into ISA 88 for batch control systems and ISA 95 for Enterprise-Control System Integration. Then, Pratish Sheth, Business Development Manager—Automation Solutions, Food & Beverage & CPG Industry, Siemens, spoke on ‘Integrating life-cycle processes for maximum efficiency’, while Dr Babu Padmanabhan, Managing Director, STEER, discussed on ‘Controlling undesirable changes during food processing with continuous manufacturing’. Rajiv Doshetty, AGM – Marketing (Analysis), Endress + Hauser India, presentated on analytical instruments in the F&B industry. Next, Deepak Gaur, Lead Design Thinker, Strategic & Design Consulting, Infosys, spoke on ‘How might we put the consumer at the centre of extended enterprise’ by being sensitive to the changing demographic preferences and KV Rehani, Automation Consultant, highlighted on ‘Solutions for adoption of automation technologies in the F&B Industry’. Also, Manjunath of iD Fresh gave an overview of the fresh food product portfolio and challenges faced by them. With expert speakers and panelists picked from among the business visionaries, policy makers, F&B manufacturers, OEM plant assemblers, automation, IT vendors and young startups bringing disruptive technologies to the market presented the latest trends. The event witnessed technologies and innovations in front of over 250+ delegates, while various exhibitors outside catered to a decent number of footfalls from over 200 visitors and delegates. ☐ Courtesy: ISA Bangalore

TECHNOLOGY | NEWS

Fibre optic connector

Intelligent stop point

Fischer Connectors has launched its new single fibre optic connector (FO1) within its Fischer FiberOptic Series. This miniature, lightweight, rugged connectivity solution is easy to use and ensures premium performance even in harsh environments. The FO1 connector is available either in pre-configured reels or integrated into custom assemblies for applications in instrumentation, sensing, defence and broadcasting – to name only a few of the various fields for which FO1 connector this new product is ideally suited. The new connector fulfills the growing market need for higher data transmission rates over long distances, while reducing space and guaranteeing performance by means of rugged miniature solutions. The FO1 connector integrates fully into the existing Fischer FiberOptic Series, well-known for its robust and faultless optical performances in any conditions, combined with easy use, cleaning and maintenance even in the field. UPC & APC polishing reduces insertion and return losses, making devices more secure, while IP68 sealing provides highly-valuable device protection. The push-pull locking system allows quick and easy connections and disconnections.

HARTING Applied Technologies has developed the ‘intelligent stop point’ for the company's own HAII4YOU smart factory. Each stop point has an Ethernet communication interface with its own switch, which allows the ‘intelligent stop point’ units to be chained to one another in any way. All inputs and outputs for the administration and function of a stop point are furthermore included. Integrated valves actuate the necessary pneumatic components. Depending on the HAII4YOU Smart Factory environment's requirements, a stop point ensures the smooth flow of the product carriers or it clamps the workpiece carrier (WPC) in a defined position for processing. In the first case, there is direct communication among the participating ‘intelligent stop point’ units. In the second case, the ISS coordinates with the coordination level. The material flow within a smart factory can be controlled without additional programming and without PLC. The machine recognises which workpiece carrier should be processed next. It is only necessary to provide all intelligent stop points with initial configuration during the installation.

Fischer Connectors India | Gurgaon Email: raman.kalra@fischerconnectors.in | Tel: +91-124-4255642

Harting India | Chennai Email: balaji.sundaramurthy@HARTING.com | Tel: +91-9600096645

Detectable plastics

Timers, monitoring relays

igus offers plastic products that are lubricant-free and at the same time, detectable for maximum safety in the food and packaging industry. This guarantees that no lubricants and no plastics enter the production chain during operation or in the event of a system failure. Magnetic, lubricant-free motion plastics aid in preventing foreign substances from entering foodstuffs. The company’s Detectable and lubricant-free plastics development of this special highperformance plastic can easily be traced with standard metal detection methods. The material is used today in selected products in the igubal series, which includes rod end bearings and clevis joints, flange bearings, spherical bearings and pillow block bearings. Both the housing and the spherical balls are made of the detectable plastic. This characteristic is sought after in other areas of bearing technology. For example, xiros M180 is a lightweight polymer ball bearing, whose material is also detectable. In addition, these highperformance polymers do not require external lubrication. The materials are compliant with the EC Directive 10/2011 for repeated contact with food.

InnoVista Sensors offers a range of products in the category of timers and monitoring relays under its Crouzet Control brand. Crouzet Control is specialised in time management, physical values and electrical values with an extensive range of automation components including timers, monitoring relays and counters. The timers are mono-function or multifunction. They offer features like delay on energisation, flip-flop, delay/timing on energisation with memory. The monitoring relays include features such as close-up protection for total Timers and monitoring availability of equipment; all anomalies are relays detected and optimise continuity of service. These products are used in applications such as heating/air conditioning, access control, heat pumps, water and air treatment, waste treatment, lifting and handling, medical equipment, pump management and many more. In addition to high-performance products, advice and support, offers tailor-made solutions for any application. As of December 1st, 2015, InnoVista Sensors™ is created with the Crouzet Aerospace, Crouzet Automation, Crouzet Control, Crouzet Motors, Crouzet Switches and Systron Donner Inertial commercial brands.

igus (India) | Bengaluru

InnoVista Sensors | Bengaluru

Email: santhosh@igus.in |Tel : +91-80-45127810

Email: india@crouzet.com | Tel: +91-80-41132204

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NEWS | TECHNOLOGY

Cable laying system

Barcode positioning system

Kabelschlepp offers EasyTrax, an extremely fast cable laying system, thanks to easy cable insertion. EasyTrax made of sturdy two-component design: hard cable carrier body and flexible film hinge. Its chain links are made of plastic with extensive unsupported length. The inside space is gentle on the cables with no interfering edges. It makes extremely low noise due to integrated noise damping. It can be used for inside/outside opening. It includes dividers and height separations for cable separation. It has single-part end connectors with and without integratable strain relief. Its features include fast and easy installation of cables and hoses, very high filling level, high side stability and divider systems for reliable cable separation. The two-component EasyTrax technology of the cable laying model ET0320 combines two seemingly incompatible features such as stability and flexibility. Cable carriers need to be extremely sturdy, with extensive unsupported length. At the same time, cables need to be inserted easily for fast cable laying. The ET0320 meets these requirements.

Leuze electronic invented the BPS barcode positioning system more than 10 years ago. The second generation of these established devices is now available in the new Leuze electronic product design. The working range of the new BPS 300i devices is unmatched at 50 to 170 mm. They are, thus, extremely tolerant of mechanical fluctuations that can arise in typical applications in intralogistics and in the automotive industry, for example, in high-bay storage devices, telpher lines, gantry cranes or pushing platforms. Even at high traverse rates of up to 10 m/s, the reproducible accuracy is +/-0.15 mm. BPS 300i BPS 300i devices feature an integrated Profinet interface; additional interfaces such as Profibus and SSI will follow. The modularity allows devices to be equipped with various connection technologies, integrated LED display and integrated heating for applications to -35Â°C. An availability control monitors and reports the performance reserve of the total system. The bars are not simply printed on top, but are instead integrated in the base material through phototypesetting.

Kabelschlepp India | Bengaluru Email: mail@kabelschlepp.in | Tel: +91-80-41158997

Leuze electronic | Bengaluru Email: info@leuze.in | Tel: +91-9731533055

Capacitive sensors

Barcode readers

Micro-Epsilon offers capacitive sensors, capaNCDT 6220 that senses air gap measurement in large electric motors. With all electric motors, a smooth operation is required in order to ensure a long operating life. Particularly with large motors, imbalance can cause significant damage in the running motor, resulting in high financial losses. The capacitive capaNCDT 6220 sensor enables 100% reliable inspection and monitors the capaNCDT 6220 concentricity during running. The capacitive sensors are resistant to the magnetic fields that occur regularly inside the electric motor. Due to the restricted installation space, flat capacitive sensors with a height of just 2.5 mm are used. The cable length is another important aspect. Due to the enormous size of the motor, cable lengths of 8 m or longer are necessary. In total, one motor normally has 8 sensor channels, but up to 16 channels can also be installed. Permanent retooling is not necessary. Measurements are generally carried out in a non-contact manner, ensuring long-term reliability and stability.

Microscan introduces the worldâ&#x20AC;&#x2122;s smallest barcode readers, MicroHAWK for installation into OEM equipment and embedded applications. MicroHAWK readers are designed for incredible power on an incredibly small scale to meet precise requirements for form, fit, and function throughout the life of OEM machines. MicroHAWK barcode readers are built around the smallest barcode imaging engine in its class, with configuration options for speed, sensor, density, decoder, MicroHAWK and lighting. This configuration agility enables optimal efficiency in both price and footprint, eliminating the need for costly overly-featured devices, or peripheral equipment for more limited devices. Precise features needed for a particular OEM barcode reading application are packaged into one of three ultra-compact form factors (MicroHAWK ID-20, ID-30, or ID-40 reader) with the ideal dimensions, connectivity, and industrial rating to meet integration requirements. Corner-exit cabling offers the tightest fit within space-constrained installation environments, while advanced optics enable devices to read codes and inspect elements at variable distances and orientations, providing the greatest freedom in device mounting.

Micro-Epsilon | Pune

Spectris Technologies | Gurgaon

Email: pragnesh.mori@micro-epsilon.de | Tel: +91-20-2674-1009

Email: vbhasin@microscan.com | Tel: +91-124-2789519

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TECHNOLOGY | NEWS

Data logger

IO-link modules

MSR Electronics offers data logger MSR385WD, which is equipped with wireless sensors and which is now also available with a GSM terminal. The data logger allows to permanently record temperature, humidity and pressure at various measuring points, in inaccessible locations and at operating temperatures from -20 °C to +125 °C, and monitor them globally via the cloud. It is equipped with a memory capacity of more than one million measured values. This multichannel data logger has an integrated ISM band receiver module through MSR385WD which it receives and stores data from up to ten MSR385SM transmitter modules. The data logger is supplied with power by means of a USB connection; with the integrated rechargeable 2400 mAh lithium-polymer battery, it can be operated autonomously for up to two days. A flash memory safeguards the data security in the event of a power failure. The colour OLED display of the data logger is at the user’s disposal for simply reading the measured values locally from the transmitter modules.

Murrelektronik offers ‘IODD on board’ which allows to ‘Plug & Play’ when integrating IO-Link devices. It allows setting up machines and systems with IO-Link devices even faster. An IODD (IO Device Description) file describes sensors and valves. It contains information about the device’s identity, parameters, process data, diagnosis data, communication properties and other details. Murrelektronik's new MVK Metal and Impact67 fieldbus modules have IODD files IO-Link devices (for participating manufacturers IO-Link devices) integrated into the GSD file. If those devices - like IO-Link sensors or valve clusters - are included in an installation, this database is available and can be quickly integrated. Prior to this, each new IO-Link master had to be individually integrated into the software taking up valuable time. If a large number of identical sensors had to be connected, the process had to be repeated for each new device on the network. This was a time consuming and errorprone process. These new modules also integrate IO-Link devices via asynchronous access.

MSR Electronics | Switzerland Email: info@msr.ch | Tel: +41-52-316-2555

Murrelektronik India | Bangalore Email: raghavendra.b.c@murrelektronik.in | Tel: +91-99-0005-7344

Mobile terminal for HMI access

Magnetic grippers

Rockwell Automation has introduced its new Allen Bradley MobileView tethered operator interface. The mobile terminal gives plant and industrial personnel the freedom to take a machine’s humanmachine interface (HMI) with them to make real-time adjustments to out-of-view applications. The MobileView tethered operator interface is ideal for maintenance tasks, machine setup or calibration Allen-Bradley MobileView activities, and other HMI applications that require the operator to see the machine. The inclusion of a hardwired e-stop button and three-position enabling switch also supports applications that require local safety functionality. The MobileView tethered operator interface complements the Allen-Bradley PanelView graphic terminals, giving manufacturers and industrial operators a range of fixed and mobile terminals for different applications. It also uses the FactoryTalk View Machine Edition (ME) HMI software from Rockwell Automation, allowing users to develop and re-use their software applications across the MobileView and PanelView platforms. Three cable-length options, ranging from 16.4 feet to 49.2 feet, offer flexibility for different machines and production lines.

SCHUNK has extended its series of digitally controllable magnetic grippers with the compact SCHUNK EGM-M monopole gripper. The smallest SCHUNK gripper so far (26 mm x 98 mm) is still precise and powerful and is suitable for handling parts weighing up to 7 kg. Since its magnetic field reaches to the outer edge, no interfering contours will become a problem. The monopole grippers can be EGM-M monopole gripper similarly used as suction cups, can be positioned anywhere on the workpiece, and can be flexibly combined with larger units. As all the SCHUNK EGM magnetic grippers of this series, the monopole grippers are working with energy-efficient electro-permanent magnets. They do not require compressed air or vacuum. Only a short current pulse for 300 ms is required for actuation and deactivation. Since no energy supply is required in activated condition, the parts keep reliably gripped even in the case of an emergency stop or a sudden loss of power. The magnetic gripper can be used in confined spaces due to its compact dimensions.

Rockwell Automation | Noida

SCHUNK Intec India | Bangalore

Email: atiwari3@ra.rockwell.com | Tel: +91-120-467-1694

Email: info@in.schunk.com | Tel: +91-80-4053-8999

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

Highlights - Jun/Jul 2016 IMPRINT

Automation & Drives

Publisher / Chief Editor ShekharManufacturing Jitkar Efficient

shekhar.jitkar@publish-industry.net Features Writer Megha Roy megha.roy@publish-industry.net Features Writer Maria Jerin maria.jerin@publish-industry.net

» Power & Energy The global power industry is undergoing unprecedented changes. Rapid increase in power consumption in the developing world will be the key driver of growth for the global power market. Market participants have to start preparing for the oncoming spike in demand. To help companies effectively navigate the market as well as successfully achieve growth objectives, the subsequent issue takes a look at the power and energy industry and gives a take on the automation trends in this sector.

» Fieldbus & Networking Although fieldbuses have been around for more than ten years, recent years have seen an increase in focus on application of this technology. One of the problems that has impeded the rapid adoption of fieldbus technology has been the lack of standardisation. Several competing alliances were created that all strived to develop an open fieldbus that would establish itself as standard. The result is that today there exist a plethora of standards for open fieldbuses. In the upcoming issue, we take a look at the recent developments in this sector.

» Test & Measurement Wireless is changing the face of test & measurement equipment at a pace never seen before. The test and measurement industry centres on the production of tools used to analyse, validate, and verify measurements of electronic and mechanical systems. The test and measurement industry creates both general use and highly specialised tools and caters primarily to high-tech industrial, automotive, communications, and medical electronics industries. The next issue gives an insight into the recent advancements and looks at how beneficial the systems can be to industries.

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COMPANY INDEX Name . . . . . . . . . . . . . . . . . . . . . . . . . Page Abhisam Software . . . . . . . . . . . . . . . . . . . 16 ARC Advisory Group . . . . . . . . . . . . . . . 17, 63 Apex Dynamics . . . . . . . . . . . . . . . . . . . . . 19 B&R Industrial Automation . . . .Cover, 6, 7, 8, 18 Beckhoff Automation. . . . . . . . . . . . . . . . . . . 8 Bodine Electric Company . . . . . . . . . . . . . . . 56 Bosch Rexroth . . . . . . . . . . . . . . . . . . . . 1, 20 Contrinex Automation . . . . . . . . . . . . . . . . . 25 Dassault Systèmes . . . . . . . . . . . . . . . . . . . 70 DCM Shriram. . . . . . . . . . . . . . . . . . . . . . . 22 Delta India Electronics . . . . . . . . . . . . . . . . . . 3 Emerson Process Management . . . . . . . . . . 50 Essar Projects India. . . . . . . . . . . . . . . . . . . 24 Festo Controls Pvt Ltd. . . . . . . . . . . . . . . . . 26 Fischer Connectors . . . . . . . . . . . . . . . . . . . 76 Gudel India . . . . . . . . . . . . . . . . . . . . . . . . 28 Harting Applied Technologies . . . . . . . . . . . . 76 HMS Industrial Networks . . . . . . . . . . . . . 8, 29 Honeywell Automation India . . . . . . . . . . 10, 30 Hummel Connector Systems . . . . . . Back Cover

Name . . . . . . . . . . . . . . . . . . . . . . . . . Page ICP Das . . . . . . . . . . . . . . . . . . . . . . . . . . 21 ifm electronic India . . . . . . . . . . . . . . . . 31, 59 IFR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ISA Bangalore . . . . . . . . . . . . . . . . . . . 10, 74 igus India. . . . . . . . . . . . . . . . . . . . . . . . 2, 76 InnoVista Sensors . . . . . . . 76, Back Inside Cover Intelligent Motion Technology . . . . . . . . . . . . 23 Inteltek Automation JV . . . . . . . . . . . . . . . . 35 Kabelschlepp. . . . . . . . . . . . . . . . . . . . . . . 77 Katlax Enterprises . . . . . . . . . . . . . . . . . 11, 32 Kuebler Automation. . . . . . . . . . . . . . . . . . . 47 KUKA Robotics India . . . . . . . . . . . . . . . . . . 34 Larsen & Toubro. . . . . . . . . . . . . . . . . . . . . 10 Lapp India . . . . . . . . . . . . . . . . . . . . . . . . . 12 Leuze electronic . . . . . . . . . . . . . . . . . . 33, 77 Microscan . . . . . . . . . . . . . . . . . . . . . . . . . 77 Micro-Epsilon. . . . . . . . . . . . . . . . . . . . . 5, 77 Mifa Systems . . . . . . . . . . . . . . . . . . . . . . . 57 Mitsubishi Electric India . . . . . . . . . . . . . . . . 36 Moxa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Name . . . . . . . . . . . . . . . . . . . . . . . . . Page MSR Electronics . . . . . . . . . . . . . . . . . . . . . 78 Murrelektronik India. . . . . . . . . . . . . . . . 43, 78 National Instruments . . . . . . . . . . . . 12, 38, 61 NTPC Ltd . . . . . . . . . . . . . . . . . . . . . . . . . 40 Omron Automation India . . . . . . . . . . . . 12, 42 Pentair Technical Solutions. . . . . . . . . . . . . . 13 Phoenix Contact . . . . . . . . . . . . . . . . . . . . . 41 Pilz India . . . . . . . . . . . . . . . . . . . . 44, 45, 60 Red Lion. . . . . . . . . . . . . . . . . . . . . . . . . . 64 Renu Electronics. . . . . . . . . . . . . . . . . . . . . 37 Rockwell Automation. . . . . . . . . . . . . . . . 4, 78 Sanjay Ghodawat Group . . . . . . . . . . . . . . . 12 Schmersal India . . . . . . . . . .Front Gate Fold, 46 Schunk Intec India . . . . . . Front Inside Cover, 78 SICK India . . . . . . . . . . . . . . . . . . . . . . 49, 53 Siemens Ltd . . . . . . . . . . . . . . . . . . 9, 48, 68 Siemens AG. . . . . . . . . . . . . . . . . . . . . . . . 14 Turck India . . . . . . . . . . . . . . . . . . . . . . . . 39 Vega India. . . . . . . . . . . . . . . . . . . . . . . . . 55 Weidmueller Electronics India . . . . . . . . . . . . 27

Board of Directors Kilian Müller (CEO - Worldwide) Hanno Hardt (Head - Marketing & Business Development) Frank Wiegand (COO - Worldwide) Shekhar Jitkar (Publisher / Chief Editor) Subscription Cover Price: `100 Annual Subscription Price: `600 AandD.india@publish-industry.net Tel: +91-20-6451 5754 Printing Kala Jyothi Process Pvt Ltd, S.No: 185, Kondapur, R R District, AP 500 133, INDIA Copyright/Reprinting The publishing company holds all publishing and usage rights. The reprinting, duplication and online publication of editorial contributions is only allowed with express 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 http://www.aandd24.in Digital edition http://issuu.com/publishi/docs

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