A&D Dec 2015 - Jan 2016 by publish-industry India

VOL 08 | Dec’15-Jan’16 www.AandD24.in

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

Automation & Drives

INDUSTRIAL APPLICATIONS ON THE CLOUD

Managing & controlling remote equipment Also available in China, Taiwan, Singapore, Malaysia, Thailand & Hong Kong

Efficient Manufacturing

A&D - Interview Kel Kearns Site Plant Manager, Sanand Vehicle Assembly & Engine Plant, Ford Motor Company (p. 24)

FOCUS Food & beverage P. 42 P. 48 ROUND-TABLE Discovering possibilities in

simulation technology P. 26

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E D I TO R I A L

The right answer! Is my organisation best in class? How can I continue to stay competitive when raw materials costs are continually rising? Am I prepared for the challenges of system/equipment obsolescence and the knowledge gap? How can I keep both productivity and profitability high at the same time? These are the questions every manufacturer would like to have the right answer to. In many cases, manufacturers keep struggling to get a right answer to these questions, but on the other hand, many of them have found right solutions which have helped them take appropriate action for addressing these challenges. In this scenario, focus on advanced technology and flexible strategies has become no longer an option but a compulsion. With this, the understanding of the major global technology drivers and dynamics of ever-changing competitive market environment, has become very important for all manufacturers, big and small, to get an appropriate solution for overcoming the above-mentioned challenges. The current economic situation has to be viewed as an opportunity to prepare for the next upturn in business. This does not mean investing in new buildings or equipment, but investing in the most important asset, the human element as well as in appropriate technology and suitable marketing. A&D India has been successful so far in facilitating the manufacturing industry identify and anticipate the challenges, and plan appropriate strategies for technology adoption and business growth. Continuing the tradition, this issue too offers various features on cutting-edge technology and market developments in the industrial automation sector. Best wishes from all of us at A&D India for your success in 2016!

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EDITORIAL ADVISORY BOARD

Shekhar Jitkar Publisher & Chief Editor shekhar.jitkar@publish-industry.net Vijay Srinivasan Partner, Effectus Consulting LLP Anup Wadhwa Director – AIA (Automation Industry Association) P V Sivaram MD – B&R Automation Member – AIA Anant Maheshwari President Honeywell India

Presets for various surfaces

Ganapathiraman G Vice President & GM (South and South-East Asia) ARC Advisory Group Ravi Agarwal Director, Pepperl+Fuchs (Factory Automation) Raj Singh Rathee Managing Director Kuka Robotics India

Dr KLS Sharma Advisor Automation Education & Training Mandar Phadke CEO, Abhisam Software Former Head – Process Control Lanxess India Pvt Ltd Arcot Rajabahadur Automation Consultant

Jasbir Singh Vice President – Electrical & Instrument Essar Project Management Consultants

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

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

A&D India | Dec’15-Jan’16

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CONTENTS

Market

Management

Focus

Food & beverage 08

NEWS

â&#x20AC;&#x153;CONNECTING RELIABLYâ&#x20AC;?

Interview with Kel Kearns, Site Plant Manager, Sanand Vehicle Assembly & Engine Plant, Ford Motor Company

Interview with Eddie Lee, Directorâ&#x20AC;&#x201D;Global Industry Marketing, Moxa

Trends 32

Round-table 26

TECHNOLOGY

The feature analyses the advent of robotics & digital manufacturing to redefine shopfloor dynamics

The round-table features how advanced simulation technologies help in accelerating manufacturing operations and boosts the entire process of learning

The feature discusses the challenges faced by the Indian industries, while addressing the role of automation in driving the quality levels & increasing responsiveness

Cover Story 16

INDUSTRIAL APPLICATIONS

TAKING MANUFACTURING A NOTCH HIGHER

ON THE CLOUD

A post-event report on CII Industrial Automation Summit held recently at Gurgaon

A read on the best practices for managing & controlling industrial equipment remotely by putting industrial applications on the cloud

Event Preview 78

REVIVING PRODUCTIVITY WITH AUTOMATION

REDEFINING INDUSTRIAL IoTâ&#x20AC;Ś

A post-event report on the recently held 12th edition of NIDays at Bengaluru 76

AUTOMATION OF PROCESS CONTROL

The article briefs on the three automation approaches, which can be deployed to achieve an intelligent combination of different automation concepts 48

DISCOVERING POSSIBILITIES IN SIMULATION

â&#x20AC;&#x153;REDEFINING SHOPFLOOR DYNAMICSâ&#x20AC;?

Event Report 74

â&#x20AC;&#x153;DRIVING LOCALISATIONâ&#x20AC;Śâ&#x20AC;?

â&#x20AC;&#x153;EXPLORING ELECTRICITY ECOSYSTEMâ&#x20AC;?

A pre-event report on the 12th edition of ELECRAMA 2016 that will be held at Bengaluru

CONTENTS

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Technology

Viewpoint 36

INCORPORATING NEXT-GEN TECHNOLOGIES

Safety & Security 62

SAFETY SOLUTION

Industrial Computers & Peripheries

Digital Manufacturing

A read on how Pilzâ&#x20AC;&#x2122;s open, flexible and decentralised safety system has helped Oystar to enhance its packaging solutions

ON THE FACTORY FLOOR

The feature talks on the top five challenges typically encountered on the factory floor and offers some criteria to consider when selecting industrial PCs and associated components reliability of wireless network

Machine Vision 58

OPEN, ADAPTABLE & MODULAR

The article discusses the current advanced technologies implemented across manufacturing applications, while highlighting their application benefits

ADDRESSING THE TOP FIVE CHALLENGES

KEYS TO SUCCESSFUL

Cover image courtesy: HMS

New Products 71

Secure remote maintenance component; Online data portal; Power plug connector; Retraction system

The article briefs on how digital enterprise strengthens the manufacturerâ&#x20AC;&#x2122;s vision for the factory of the future

Remote PLC; Corrosion-proof titanium transmitters; Diagnostic system; Inductive switches

Manufacturing IT

Confocal chromatic controller; Motor protection relay; Safety devices; Pneumatic rotary units

DRIVING DIGITAL TRANSFORMATION

5 STEPS TO AN EFFECTIVE ERP-MES INTEGRATION

The article highlights the integration of these systems for manufacturers to digitise processes and gain faster access to vital data

MULTICORE OPTIMISATION

The article highlights the four keys to successful multicore optimisation for machine vision applications

Columns 05 06 80 80

Editorial Contents Highlights - Next issue Company index

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MARKET | NEWS

B&R’s productive partnership with Comau

EtherCAT Technology Group oraganises seminars

As the collaboration between Comau Robotics and B&R continues to mature and expand, the companies can already boast ten thousand units installed and operating all around the globe. “This is the concrete result of an intense collaboration that has allowed both companies to become key players in the market, with the aim to continuously improve in technologies and grow in new market sectors,” said Tobias Daniel, Head—Robotics (Europe and America), COMAU. This achievement underscores the quality of COMAU products, which rely on powerful, 10,000 COMAU robots have been accurate and reliable control equipped with B&R control technology electronics from automation specialist B&R. As per Walter Burgstaller, Director—Sales, B&R Europe, “We are pleased to say that this cooperation is yielding tangible results on a growing market. More and more companies are looking to robotics as a means to optimise production and respond to the ever-increasing flexibility and complexity of their plants.”

The EtherCAT Technology Group (ETG) will be organising the Industrial Ethernet seminars from January 11-15, 2016 at Mumbai, Bengaluru and Chennai. These seminars are free of charge that specifically address endusers, system integrators, OEM, machine builders as well as product developers, and everybody else who wants to learn about the latest trends in industrial automation all over the world, and in India, in particular. During the events, participants can learn about the benefits & challenges of Industrial Ethernet and get the possibility to talk to EtherCAT experts face-to-face. Additionally, a sponsor’s table-top exhibition will give an impression of the variety of EtherCAT in practical use. The event is scheduled to take place on January 11, 2016 at Mumbai; on January 13, 2016 at Bengaluru and on January 15, 2016 at Chennai. As one of the largest Industrial Ethernet and Fieldbus organisations, the EtherCAT Technology Group supports, promotes as well as advances EtherCAT technology across the globe. It is the fastest Industrial Ethernet solution that provides industry leading performance, flexibility and cost advantages.

HUMMEL AG acquires JAEGER Connecteurs

CST becomes InnoVista Sensors™

HUMMEL AG has recently acquired France-based JAEGER Connecteurs. In the past few months, HUMMEL AG has invested a lot in the manufacturing plants and infrastructure in France. Their goal for this acquisition is to get JAEGER in shape for the future. By integrating JAEGER's product range, the company has clearly HUMMEL AG has increased its portfolio of increased its portfolio of circular connectors through the acquisition circular connectors. As a result, it also satisfies their customers’ desire for one-stop shopping, that is, for a provider of solutions, which has the correct product to fit all needs and offers appropriate service. JAEGER is aimed at industrial clients with particular requests. In the collection, there are connector series, which are purposedesigned for maritime use, mining or for power plant construction. The connectors fulfil special requirements for tightness, power transmission, robustness and durability. JAEGER also has complete series of moulded circular connectors in M8 and M12 sizes available. With these additions, the company now covers the whole spectrum of circular connectors from M8 to M40, and for industrial clients from around the world it is the complete provider of solutions for connector systems.

Following the sale of some of the activities of its portfolio (brands: BEI Kimco, BEI Sensors, Kavlico, Crydom and Newall), Custom Sensors & Technologies (CST) is now re-organising. As of, December 1, 2015, the company InnoVista Sensors™ is created with the Crouzet Aerospace, Crouzet Automation, Crouzet Control, Crouzet Motors, Crouzet Switches as well as Systron Donner Inertial commercial brands. With its dynamic and wellestablished commercial brands, this change of identity relies on a dual ambition—it increases the company’s presence in the sensors and other components markets at the heart of automated systems and critical application. Secondly, it strengthens the company’s innovation policy as a major axis for development. Through the company’s recognised expertise, reliability and adaptability, it is strengthening its investment towards excellence and innovation. This evolution confirms the company’s renewed commitment to bring the performanceenhancing solutions that will meet current and future market demands. Through its brands, it offers a wide range of reliable, efficient and customisable components for the aerospace & defence, transportation and other segments.

A&D India | Dec’15-Jan’16

MARKET | NEWS

Dr KLS Sharma awarded at ISA’s Annual Gala Dr KLS Sharma was recently felicitated with the ISA’s Members Choice Award for student mentor of the year at the 53rd annual ISA Honors and Awards Gala, held at Louisville, Kentucky, USA. The award recognises a member, whose activities in the previous year have promoted and encouraged student involvement in automation programs. Dr Sharma has worked in the automation industry for over 33 years (25 years in ABB India), followed by academic institutions, promoting automation education & Dr Sharma serves as an advisor on automation training. He has dedicated himself education and training to teach/train people in industry and academic institutions in current philosophy, technology, terminology, and practices in automation. He has several articles to his credit in automation education and training in automation magazines. His book “Overview of Industrial Process Automation”, published in 2011, has helped those who are beginning careers in automation as well the existing as reference guide. Dr Sharma serves as an advisor on automation education & training and holds a doctorate degree from IIT, Delhi.

NI collaborates with Astronics National Instruments recently collaborated with Astronics Test Systems, a wholly owned subsidiary of Astronics Corporation to deliver PXI-based products designed for the aerospace and defense community. The combination of Astronics’ strength in test system integration and NI’s leadership in PXI-based automated test systems is expected to produce a best-in-class portfolio for automated test equipment (ATE) applications. Speaking on the occasion, Jim Mulato, President, Astronics Test Systems Inc, said, “We are focused on providing the latest technology to our customers. This move from VXI to PXI will retain the investments made in test program sets (TPSs), while providing a seamless upgrade path for our popular legacy instruments. The ability to collaborate with NI will be a tremendous boost to the long-term sustainability of DoD test systems as we narrow the gap between commercial & military products.” The first product to be delivered as a result of the collaboration is the Astronics Frequency Time Interval Counter (FTIC) for PXI Express, modeled after the Astronics VXIbus 200 MHz Universal Counter. Designed for full TPS compatibility, the instrument can replace existing VXI-based FTICs and deliver the same capability in a newer PXI-based subsystem.

Lapp Innovation award winners announced

‘Make in India’ makes big at WIN INDIA 2015

Lapp India has recently announced the winners of the Lapp Innovation award at Coimbatore. Launched on the occasion of the 10 th jubilee celebrations of Lapp India and PSG College of Technology’s partnership, the award recognises outstanding industries, which uses Lapp cables and associated products and solutions for developing innovative products, which have a strong impact on sales, The award recognises outstanding productivity improvement, industries using Lapp cables and energy savings and sustainable associated products & solutions development. Out of the numerous applications, only the top 3 business cases were selected as per the above mentioned criteria and the respective companies invited to present their innovation at the PSG – Lapp Centre of Excellence in Cable technology in Coimbatore, Tamil Nadu. The jury members consisted of members from PSG College of Technology in Coimbatore and Lapp India. “It is important to foster an environment of innovation within organisations. Any innovation should first be tried out at the local regional level and every effort must be made to scale the same to the global level,” said Dr Ewald Bentz, Chief Representative of Lapp Holding.

WIN INDIA 2015 was recently organised at New Delhi, where industry leaders such as B&R Automation, Balluff, Beumer Group, Camozzi, Festo, Hyundai Forklifts, Jungheinrich, NORD Drivesystems, Pepperl+Fuchs, Phoenix Contact, Siemens, and Wago had participated. Also, China, Germany and Korea presented country pavilions, and attracted more than 9,400 visitors. The four trade fairs—Industrial Automation INDIA, MDA INDIA, CeMAT INDIA, and Surface The show attracted more than 9,400 visitors Technology INDIA covered four key industry sectors— production & process automation, power transmission and fluid technology, materials handling and logistics, and surface treatment. According to Wolfgang Pech, Senior VP, Deutsche Messe, “‘Make in India’ generated a huge amount of attention at HANNOVER MESSE in April. We carried that momentum to New Delhi in order to support India’s goals of upgrading infrastructure, manufacturing and logistics. Not only did this year’s WIN INDIA showcase the latest solutions for integrated industry, but it also featured an expansive educational program designed to bring India’s industrial workforce up to speed with the latest technologies.”

A&D India | Dec’15-Jan’16

MARKET | NEWS

HARTING advancing Industry 4.0 solutions

NORD India wins ‘Best HR Practices’ Award

HARTING Technology Group has pushed forward with the development of its Industry 4.0 solutions since Hannover Messe 2015. The company presented the results at the SPS IPC Drives trade fair recently in Germany. “We have developed concrete applications The company combines its competence from the trends in integrated as a component, application and system Industry, while consistently provider in the HAII4YOU Factory focussing on customer benefits,” explained Uwe Gräff, MD, HARTING Electric & HARTING Electronics. At this year’s Hannover Messe, HARTING clearly identified the six trends in integrated industry (customisation, miniaturisation, identification, modularisation, integration and digitalisation) and targeted product & solution development in these areas. The decidedly positive customer response has prompted the company to hold an application contest called ‘How do you use MICA?’ The three best applications will be announced at the Hannover Messe 2016. “With the implementation of ‘intelligent stop points’, we will use HAII4YOU factory as the basis for a demonstration of how the material flow within a smart factory can be controlled,” explained Dr Franke, MD, HARTING Applied Technologies & Industry 4.0 expert at HARTING.

NORD Drivesystems has been recently felicitated with the ‘Best HR Practices’ award from Genius Consultant. The company’s management is very transparent and open towards its employee to create an authentic and engaging environment at work. For employee motivation, the company organises open house on a quarterly basis, PL Muthusekkar, Managing Director, and felicitates employees with NORD, receives the award awards and recognition. In addition, the management shares business updates with everyone. For employee personal care, the company organises ‘Family Day’ and engages its employees into cultural and festival day celebrations. Such events strengthen emotional bonds as well increases motivation, commitment & satisfaction. The management also has set up complaint management system, committee against sexual harassment at work place, safety committee and has arranged a special coverage of employee’s personal & professional profile in the in-house magazines. To encourage team culture, the company has organised several departmental groups like food committee, quality, service, margin committees, etc. It also promotes togetherness inside an organisation.

Siemens acquires Polarion

OMRON completes acquisition of Adept Technology

Siemens has recently entered into an agreement to acquire Polarion, the developer of the first browserbased application lifecycle management (ALM) enterprise solution. Siemens will add the Polarion offerings to its Teamcenter® software, making ALM an integral part of the product development process. This acquisition will further enhance the company’s support for systems-driven product development, a holistic development approach that combines systems engineering with an integrated product definition, in an open environment. “By adding Polarion ALM solutions to our PLM portfolio, we are further strengthening our ability to help companies create smart, connected products. Polarion’s advanced functions integrate software specification, development, testing and simulation further into our market leading systems-driven product development environment,” said Chuck Grindstaff, CEO & President, Siemens PLM Software. Polarion Software provides 100% browser-based & unified platform. “This acquisition now offers us an opportunity to move further and faster towards the delivery of high value PLM/ALM solutions to our customers,” shared Frank Schroeder, CEO, Polarion.

OMRON Corporation recently announced that it has completed its acquisition of Adept Technology to strengthen industrial automation business. Under the terms of the transaction, OMRON’s US subsidiary is acquiring Adept through an all cash tender offer followed by a secondstep merger. The tender offer commenced on September 23, 2015 and expired at 5:00 pm New York City time on October 22, 2015. Approximately 83.32% of all issued and outstanding shares of Adept common stock were tendered into the offer and accepted for purchase by OMRON’s United States subsidiary. Commenting on the acquisition, Yutaka Miyanaga, President—OMRON Industrial Automation Business, said, “We are delighted Adept Technology, a world leader in robotics, has agreed to join OMRON. This acquisition is part of our strategy to enhance our automation technology and position us for long term growth. Robotics will elevate our offering of advanced automation.” The impact of the acquisition on the consolidated financial performance of OMRON will be the subject of timely disclosure in Japan.

A&D India | Dec’15-Jan’16

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MARKET | INTERVIEW

“Connecting reliably” Eddie Lee, Director—Global Industry Marketing, Moxa, in an interaction with Maria Jerin, details the challenges witnessed in deploying latest automation technologies. He also highlights his company’s marketing strategy and their role in the emerging IoT applications. Excerpts from the interview… Ubiquitous networks, seamless connectivity and reliable communications are essential to the success of the emerging Internet of Things. How is Moxa a part of this industrial revolution and what are the latest technologies from the company on this front? Enabling connectivity for the Industrial Internet of Things (IIoT) is essentially Moxa’s main value in the IIoT ecosystem. We enable connectivity across a broad spectrum of equipment and assets ranging from legacy equipment requiring serial/protocol gateways, to smart devices requiring Ethernet switch/router infrastructure and even wireless applications including cellular cloud gateways. All of this is accomplished primarily via industrial grade hardware designed for mission critical applications.

adoption a slow process. In addition to the conservative mindset, there is the demographic trend revealing a gap in the aging workforce. The incumbent plant managers who are nearing retirement are less inclined to become early adopters of perceived ‘new technology.’ Meanwhile, the younger generations, which are more comfortable and familiar with networking technologies, cloud computing, etc are often relatively new to their respective companies and industries. They are not yet in management positions to make the decisions for strategic investment and capital expenditures. My main suggestion is to look outside of your own industry to see how other industries address similar mission critical communications needs. For example, the concept of predictive maintenance transcends many industries. Although process automation industries may be more hesitant to adopt newer technologies for remote monitoring and big data analytics, they can investigate the intelligent transportation systems (ITS) market and discover that real time traffic monitoring and predictive analytics that are commonly being used to forecast traffic patterns, commuter delays and address emergency conditions, etc.

Your company has announced its membership in Industrial Internet Consortium™ (IIC) formed by AT&T, Cisco, GE, IBM and Intel. What is your company’s role as an industrial automation firm for this consortium? The IIC has over 200 members today and Moxa was one of the first 30 members. We contribute to the IIC as a member of the connectivity group, where our expertise can contribute to the development of industrial internet use cases and test beds to help promote IIoT implementations. We are collaborating What is your marketing strategy for the Asia-Pacific region? with other member companies to address challenges related Brief us on your future plans for the Indian market? to the impending connectivity of so many ‘things.’ We are Moxa’s marketing strategy for the Asia-Pacific region is also currently a co-chair along with IBM for the IIC’s Energy consistent with our global strategy. This involves educating Working Group (which is currently focused on oil & gas and both public and private sector organisations on the benefits power/smart grid applications.) of an Industrial IoT ecosystem as well as the obstacles and challenges to overcome. India, in particular, is very relevant According to you, what are the major challenges witnessed especially with the ‘Digital India’ initiative proposed by the in deploying latest automation technologies in the Indian Prime Minister Narendra Modi. The objective of developing industry, especially SMEs, in terms of infrastructure, a digital infrastructure to deliver services digitally is very training and manpower, etc? What would be your synergistic with our company’s core competencies. While suggestions for them? many observers are enamored with the potential end results Like the rest of the world, industrial automation in India and benefits, one of the key challenges to overcome involves faces similar challenges. The risk adverse nature of industrial how to reliably ‘connect’ all of the digital assets in the market segments has historically made new technology ecosystem. It is much easier said than done. ☐

A&D India | Dec’15-Jan’16

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

INDUSTRIAL APPLICATIONS ON THE CLOUD

Managing & controlling remote equipment

With cloud-based technologies advancing the capabilities of access control, security dealers and manufacturers are looking more to remote management as a cost-efficient and capable mechanism for expanding services and adding convenience. The use of a remote management application enables easy and secure remote access to the hosted web server, even if the device is located in a private or mobile network behind a router or firewall. The feature discusses best practices for managing and controlling industrial equipment remotely by putting industrial applications on the cloud. 16

Santosh Tatte Country Manager HMS Industrial Networks India sta@hms.se

A&D India | Decâ&#x20AC;&#x2122;15-Janâ&#x20AC;&#x2122;16

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

Engineers can be a conservative lot, particularly when they are responsible for the organisation’s core systems and assets. They are often shy of new technologies, waiting to see others use them first, and it is becoming clear that they are currently missing out on the advantages of cloud computing. As management pressure increases for engineers to deliver more for less, cloud computing may provide some of the answers. So, just what is meant by cloud computing; how will it affect users; and what are the advantages over conventional alternatives? These are some of the questions which will be answered in the following section.

Cloud computing The term cloud computing simply relates to the internet. It comes from the way it is depicted graphically, typically as a cloud diagram. More specifically, it relates to how services such as infrastructure, applications and business processes can be delivered on demand via the internet. Software as a Service: One example is the provision of software as a service (SaaS) to deliver software applications via a standard web browser. This means that software such as general office desktop applications and associated data are not resident on users’ PC, but are hosted remotely and accessed over the internet using a web browser. It uses a different business model, where users don’t buy the software and server hardware but rather lease it, paying only when used, or by the volume of data stored. The benefit is that users can remotely access all site information from any suitable browser with internet access. Not just users’ word processor but accounting package, building management systems, or ERP, in fact almost anything. As these services are provided via the internet, they are scalable (both up and down), reliable, easily accessible, and they can complement or replace the user’s own IT

A&D India | Dec’15-Jan’16

infrastructure. More importantly, new applications can be trialled, deployed and shared quickly and easily. The benefits include reduced investment, simplified maintenance and optimised plant operation. Decision making and implementation can also be faster as there is no capital expenditure needed. External servers, virtual servers, storage and other ondemand services are available to support and back-up existing functions and can often reduce the need for new or additional infrastructure investment. Cloud computing offers other opportunities such as providing an external service platform (also referred to as ‘platform as a service’) on which to build or run/host applications which may be too complex to implement internally. They can also be used to provide new external services to customers, with the benefit of not needing access to internal IT infrastructure from either side.

A growing need for monitoring machinery and industrial applications One growing demand for the use of cloud computing is for remote monitoring of plants and equipment. It is becoming increasingly important for engineers to monitor and manage machinery in order to improve up-times, reduce maintenance and operating cost. And this can be especially important when plants are geographically widely spread. A simple solution may be to add a web server to user’s plant in order to view the data via the internet, although this can leave the plant vulnerable to hackers. However, by using the SaaS model delivered over the clouds, risks and vulnerabilities are removed. The remote monitoring of a factory does not apply only to fixed installations. Potentially any vehicle or equipment with an electrical power source can be monitored, have data exchanged, and even GPS tracking enabled. Communication with remote monitoring devices is available through a range of options. These include quad band GSM/GPRS mobile

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

Typical cloud diagram

communications and Ethernet TCP/IP connectivity via LAN/WAN. Typically, the monitoring devices use serial communications such as RS-232 and RS-485 for connecting to a local plant: Modbus RTU and other popular open or proprietary network protocols may also be available.

How it works? There are three main elements to any cloud-based remote monitoring solution. The first is the physical layer that comprises of a Communication Gateway that links to field equipment, acquires the data, and communicates it to the remote server. The second is the remote server that collects and stores the data, and the third is secure access to the data through a customised online dashboard. The connection between field devices and Communication Gateway is generally through serial communications or by using a popular open protocol such as Modbus RTU. Additional functionalities such as global positioning systems (GPS) are available to meet the demands for location-based services (LBS) like tracking and Geofencing (providing notification when a tracked device enters or leaves a predetermined geographical location). Acquired data is sent to the remote server by the Communication Gateway device at selected logging intervals ranging from real-time to 300 seconds as demanded by the application. To communicate with the server, Gateway generally uses either quad-band GSM/GPRS wireless technologies or Ethernet TCP/IP connections: both may be used concurrently on the same installation. GPRS (General Packet Radio Service) is a newer function integrated into GSM that allows for the simultaneous transmission of high speed data across a mobile telephone network. The costs for

data only transmissions using GPRS are significantly lower than for voice calls. Where the Communication Gateway uses Ethernet-based connectivity it is normally via wide/local area networks (WAN/LAN) with direct connection to the server via the internet. The use of special firewall-friendly communications between the remote Gateway and the data centre makes it possible to retain the existing broadband security infrastructure at the user’s site. This procedure is accepted by most IT departments and gives confidence that the installation is controlled from a security perspective. Communication Gateway devices are normally pre-configured and require no programming or IT expertise, so neither virtual private network (VPN) nor static IP addresses are needed. Data is communicated to and stored on a remote server. In case of HMS’s Netbiter Argos solution, the server is located at one of three data centres and the data backed up at the other two. Information held there can be displayed graphically in the form of customised dashboards (see below), or downloaded into the customer’s business management system for analysis and reporting. Graphical dashboards makes for easy overview: Information on the server is viewed using a standard web browser. To simplify configuration of the graphical display, standard tools are incorporated into the server. These include downloadable device templates for establishing communications between the remote plant and the communicating device and auto web pages (dashboards). Some systems contain libraries of ready-made web page dashboards for applications such as mobile towers, boilers, compressors, machines, power generators, water / waste management, base stations, building and HVAC management, pumps, wind energy, solar energy and many more.

A&D India | Dec’15-Jan’16

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

By analysing the operation of each installation remotely, user will be able to get a better grip on equipment health and more efficiently schedule service visits in the field

It is possible to quickly and easily create a graphical layout of the remote installation. The dashboard includes functions for loading pictures into the layout, analogue and digital graphical components (such as gauges, meters, indicators, bar graph, lamps, switches, etc), which makes it possible to detail a remote system with a visual layout that is easy to understand. Where appropriate, GPS data makes it possible to view the location of each device in the field on an overview map (using Google maps), the system also lets you build multiple installations.

Stand-alone applications such as power generators For monitoring and controlling simple stand-alone equipment not required to communicate with the central server, a range of Communication Gateways with integrated web server functionality are often used. These can be wired or wireless types, and support for an external GPS receiver means that it is also possible to identify the location of the equipment. This can be particularly useful for fleets of rental machines such as standby generators. In addition to handling communications, these devices will also provide built-in features for data logging, alarm handling (via email of SMS messaging), report generation, historical data and configurable web pages for monitoring and control from remote locations via the internet without special tools or software.

Using the data Access to the server information means that users can Log Historical data and produce graphical trends or diagnostics, manage alarms, or automatically backup or restore remote configurations. Although not originally conceived as a SCADA package, the functionality exists to easily configure one. The servers data can also be accessed by the users own ERP system for further analysis and reporting. Security of data and access: Establishing a secure and reliable communication path over the internet requires solving a number of technical challenges such as, firewalls and Public IP addresses. Rather than using complex and expensive solutions to install and manage this such as VPN, special M2M SIM cards, etc, the Netbiter remote management solution has been developed to provide a simpler firewall-friendly solution. This enables the user to focus on the plant issues without the needs for specialist IT skills, or calling on others to address the extensive internet, firewall, GPRS/APN configurations. Moving data off-site raises concerns over both its security and availability. By using special firewall-friendly communication between the remote Communication Gateway and the data centre, it is possible to keep existing broadband security infrastructure at the userâ&#x20AC;&#x2122;s site. This procedure is accepted by almost all IT departments and gives confidence that the installation is secure from a security perspective.

A&D India | Decâ&#x20AC;&#x2122;15-Janâ&#x20AC;&#x2122;16

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

Remote alarm dashboard with integrated GPS functionality

Data storage is rigorously protected as the remote server / data centre is automatically backed up, so the risk of losing data, or downtime due to access problems with the server are minimised. Data centres run on professional enterprise-class architecture that is designed to support both small and large-scale deployments. They provide 24/7 monitoring of the server health, redundant servers at different geographical locations, redundant storage and protection against fire, theft and similar eventualities. To ensure the security of wireless communications over GPRS, dedicated SIM cards can be selected. These mean that it is not possible to ping or try to access the remote site except through the data centre and also avoids unnecessary and costly GPRS traffic. If, however, the system does not need this added security normal data enabled SIM cards can be used. Access to the online system is centrally controlled and requires password authentication. Multi-level password layers are used to provide permissions to access different functions, and the server authenticates users and ensures their correct access levels. Password activity is logged by the server, and all communication are secured using Secure Socket Layer (SSL) encryption. This is the same method banks use for secure online transactions.

Typical adopters Typical adopters have been machine monitoring and analysis, building automation and monitoring, tank farms

monitoring, pump and pumping stations monitoring, and monitoring renewable energy sites. Mobile communications via GSM and GPRS mean that monitoring even the smallest sites is viable

Costs and conclusion Custom-made remote management systems are often costly to develop (although they deliver the exact functionality required). A ready-made remote management solution is substantially cheaper. For example, in the Netbiter remote management solution from HMS, users purchase only the communication gateways, which attach to their field equipment. The cloud services (in the Netbiter example, usage of www.netbiter.net) are free of charge. If information is sent over the mobile phone network, there is also a data traffic cost involved. Quick ROI: The return on investment is quick. The cost for a gateway usually equals the costs for few service visits. By cutting down on travelling, it is also possible to reduce a company’s carbon footprint and only do service visits when really needed. Cloud-based services may not be the answer to all manufacturing issues, but its secure performance and potential to reduce investment costs is likely to have a huge impact. Most people are comfortable with online banking for checking their assets and transferring money from one place to another, so maybe remote management of our business assets is not such a big a leap into the unknown. ☐

A&D India | Dec’15-Jan’16

MANAGEMENT | INTERVIEW

“Driving localisation…” Kel Kearns, Site Plant Manager, Sanand Vehicle Assembly & Engine Plant, Ford Motor Company, led the design, construction and launch of the vehicle assembly and engine plant at Sanand in Gujarat since Feb 2011. In this interview with Shekhar Jitkar, he briefs on the new facility at Sanand and shares Ford’s plans for localisation in India. Excerpts…

Ford has recently inaugurated its second factory in India at Sanand, Gujarat. Brief us on this factory in terms of its current capacity, environment-friendly operations, etc? Since breaking ground in September 2011, Ford has invested over US$1 billion in the two facilities in Sanand. Today, Sanand Vehicle Assembly and Engine Plant is spread over 460 acres and includes stamping, body, paint and assembly operations for vehicle manufacturing, as well as machining and assembly operations for engine manufacturing. The vehicle manufacturing plant in Sanand has an initial installed annual capacity of 2,40,000 units, while the engine plant has been launched with an initial installed annual capacity of 2,70,000 engines. Ford’s Sanand plant has been launched with single shift operations with approximately 2500 employees. The plant also generates employment of more than 7500 across tier I suppliers and the rest of the value chain. Talk about the environment-friendly operations and the state-of-the-art integrated manufacturing plant in Sanand redefines manufacturing excellence with its state-of-the-art modern equipment and advanced technology to deliver quality

products. For example, the press shop not only ensures that we produce the highest quality parts, but also maintains an exceptionally clean environment for employees with positive ventilation being deployed. The paint facility at Sanand uses Ford’s innovative three-wet paint process that allows three coats of paint to be applied and baked simultaneously. The energy efficient process significantly reduces wastage, energy consumption and helps in lowering paint shop carbondioxide emissions by up to 25%. Can you give us more details on the automation systems and robotics deployed in both the plants in Sanand? Our vision with the plant operations continues to be geared towards achieving a culture of ZERO Injuries, ZERO Defects, and 100% flow that supports standardisation of our processes as a base for ensuring great quality. The level of automation varies across different sections of the plant. For example, the body shop in Ford’s Sanand plant has close to 95% automation, which first and foremost ensures the most efficient line speed along with high levels of quality.

A&D India | Dec’15-Jan’16

INTERVIEW | MANAGEMENT

“Our vision with the plant operations continues to be geared towards achieving a culture of ZERO Injuries, ZERO Defects, and 100% flow that supports standardisation of our processes as a base for ensuring great quality” Kel Kearns

How much investments have been already made and how much more are in the pipeline? We have already committed US $2 billion in India which includes US $1 billion that has been spent on our facility in Sanand, Gujarat.

There are several changes happening all around the world in the field of manufacturing. With every new plant, we at Ford, improve on our earlier record, while learning and implementing something new. To see the transition over the years, let me start with Ford’s greatest contribution to the manufacturing world – the first moving assembly line. Almost How many suppliers have confirmed their participation 100 years ago, this process, first started by Ford, revolutionised in Ford’s vendor park? How is Ford helping its suppliers production and dropped the assembly time for a single vehicle to set up shop, grow, and develop in close proximity to the from 12 hours to about 90 minutes. And the journey continues. new facilities? Building on this tradition, Ford continues to accelerate its A robust supply chain is essential for building high quality efforts to standardise production, make factories more flexible vehicles satisfying our customer requirements and for and introduce advanced technologies to efficiently build the increasing localisation to make our products more affordable. best vehicles possible at the best value for our customers, no The state of Gujarat has reserved 200 acres of land for an matter where they live. automotive supplier park and as many as 19 of our suppliers have already set up their factories or are in the process Can you elaborate on the Ford Production System? of doing so to support our operations. Close proximity How does it ensure Zero Defect & 100% Throughput in facilitates Just-in-Time sequenced delivery of parts to the manufacturing? plant reducing inventory and providing maximum build It was not long ago, people thought Zero Defect manufacturing options/variations for customers. was not achievable and today it has become a reality and is the expectation now. What helps Ford achieve this is the What are your localisation strategies? How will they Global Ford Production System (GFPS), which provides help protect the company from the ups and downs in the a foundation of standardisation, a framework of systems demand in the domestic market? for safety, quality, delivery, cost, people, maintenance and We understand the need to continuously increase local environment as well as key unifying processes. It delivers content in manufacturing. It is a business imperative. As we zero defects and 100% throughput in manufacturing. work towards creating a strong brand in India by introducing GFPS is the foundation for all manufacturing operations, high value products, we are also looking to build effective which provides stability to our inputs, standardises our scale and substantially increase local content. We have processes, and provides for continuous improvement. Key a team dedicated to drive profitability by increasing the elements of the system include effective work groups, zero local content on our nameplates. The goal for the team is waste / zero defects, aligning global capacity with global to drive localisation of tier one suppliers as well as overall market demand, optimising production throughput, and localisation. using total cost to drive performance. By following the disciplined processes and deliverables, we have been You have a great experience in automotive manufacturing in successful in preventing defects and reducing “things gone different regions of the world. Can you give a brief overview wrong” at Ford. Everybody at Ford is committed to further of how manufacturing operations have undergone changes developing our work teams to continue on the path to deliver over the years vis-à-vis rapid changes in technology? quality products to customers. ☐

A&D India | Dec’15-Jan’16

R O U N D - TA B L E | M A N A G E M E N T

Discovering possibilities in simulation technology Today, simulation technology has become an effective tool for reducing costs, improving quality and shortening the time-to-market for manufactured goods in the industry. The round-table features how advanced simulation technologies help in accelerating manufacturing operations, while boosting the entire process of learning. According to experts, simulation technology helps reducing costs, improving quality, and shortening the timeto-market for manufactured goods. Potential simulation impact areas are closely intertwined with strategic manufacturing. Yet, a number of factors currently inhibit the deployment of simulation technology in the industry today. However, the development of new simulation interface standards could help increase the deployment of simulation technology. Interface standards could improve the accessibility of this technology by helping to reduce the expenses associated with acquisition and deployment, minimise model development time & costs, and provide new types of simulation

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

functionality that are not available today. Suggesting benefits to industry, resulting from the widespread & pervasive implementation of manufacturing simulation technology are Rajneesh Shinde, Senior Director – Marketing, Altair India; Rafiq Somani, Country Manager—India, Ansys; Vineet Seth, Director – South Asia & Middle East, Delcam and Gautam Dutta, Director—Marketing, Siemens PLM India.

Re‐engineering manufacturing processes Today, simulation modeling tools are used to effectively re‐engineer manufacturing processes and discover possibilities

A&D India | Dec’15-Jan’16

M A N A G E M E N T | R O U N D - TA B L E

“Digital simulation is the way for validating engineering decisions across the product lifecycle” Gautam Dutta Director—Marketing Siemens PLM India

to increase the throughput of the system. According to Shinde, boundaries of simulation tools for analysing & optimising manufacturing processes are getting developed at a faster rate and many leading OEMs, suppliers & toolrooms have been using simulation tools for manufacturing processes for an equally long time. “The challenges here include machine tool parameters, material consistency & post processing techniques used in the production process,” he opines. As per Seth, simulation modeling tools are indispensable. “Existing manufacturing processes can be virtually defined in a digital manufacturing environment by specifying constraints, kinematic models, layouts, process models, what-ifs and options amongst other parameters, thereby, allowing the planning department to make changes to the system dynamically or by evaluating virtual manufacturing data”, he says. He also believes that this allows systematic virtual iterations to the process without disrupting physical manufacturing. Since this is a parallel process, the system throughput will eventually reach the optimal point through discrete changes to the virtual process. It goes without saying that shifting business factors such as demand for smarter environment-friendly products, more sustainable production and increasingly competitive global markets require companies to constantly adapt & improve their business strategies. In this context, Dutta highlights, “Launching faster, getting more from their capital investments and delivering quality products are always at the core of growth & prosperity, even in demanding economic times. Therefore, it is no surprise that leading manufacturers around the world are turning to digital manufacturing to help them deal with these challenges.”

Strategic manufacturing target areas Strategic manufacturing is a buzzword today, and manufacturing simulation is treated as a key component of strategic manufacturing. Speaking on various strategic manufacturing target areas that simulation can support, Shinde suggests that it can be used for stamping, extrusion, casting, plastic injection, forging, composite design & manufacturing, factory floor simulation—design virtual

A&D India | Dec’15-Jan’16

“Including simulation early in the design cycle doesn’t need to build physical prototypes to test products on different parameters” Rafiq Somani Country Manager—India Ansys

factory & digital mock-ups—immersive virtual reality technologies and 3D printing. According to Somani, today’s products are more complex and deliver more sophisticated functionality. “To meet tomorrow’s time-to-market goals, more strategic deployments of simulation focus on compressing, eliminating and parallelising. While there are many factors that drive the success of a product, a key factor is the time-to-market,” he suggests. Moving on, Seth believes that few areas of strategic manufacturing where simulation is important are CAM (NC), material flow, plant/factory layout & planning, FMS cells & lines and robots. When it comes to digital manufacturing, Dutta believes that it encompasses several areas like factory layout planning, assembly simulation and validation, robotics simulation and programming, logistics & material flow simulation as well as human simulation & ergonomics.

Important tool in workforce development In workforce development, simulation is becoming an important tool, more so in the high-risk environments. When asked how does it accelerate the speed of learning, Shinde suggests that it produces robust products in lesser time & cost by reducing trial & errors. He explains, “From a stamping perspective, numerous case studies are available highlighting how customers reduced number of stages for dies or providing insight to help reduce part count and, hence, impacting manufacturing process/cost substantially or transfer die simulation to capture manufacture sequence process and intermediate interference issues as panels move between

R O U N D - TA B L E | M A N A G E M E N T

“Simulation training becomes important for helping trainees gets a clear understanding of the actual physical process in a virtual environment”

different stations. It also helps identify and give insight into how manufacturing process behaves and this is a great learning tool, which mimics on-the-job training at lower cost and faster pace.” Often, owing to various constraints like not being able to stop production, expensive equipment, hazardous or highrisk environments, it may not be possible to provide extensive training to an ever-growing workforce. Emphasising simulation in such cases, Seth avers that training becomes important for helping trainees get a clear understanding of the actual physical process in a virtual environment. “Since virtual environment is a point-to-point replica of physical environment, new users will get the feel of working in a real environment without putting themselves (or others) in risk, especially in the case of high-risk environments.” When asked about inhibiters, he suggests that cost, cross-framework applications, multi-level integrations and complexity models are a few of them. With product lifecycles shrinking, product designs and manufacturing processes changing rapidly, Dutta averred, “Workforce involved in manufacturing needs to adapt to these changes rapidly. There is no room for failure. To be able to be first-time-right and deliver products on time, within cost and as per requirement, digital simulation is the way for validating engineering decisions. Therefore, simulation training is very important for manufacturers.”

Vineet Seth Director – South Asia & Middle East Delcam

“Boundaries of simulation tools for analysing & optimising manufacturing processes are getting developed at a faster rate” Rajneesh Shinde Senior Director – Marketing Altair India

Training/availability of skilled manpower is a big inhibiter,” he adds. Citing an example, Dutta explained, “One of our clients in India faced issues that they had not foreseen every time they set-up a new plant. This led to a lot of re-work as well as time & cost overruns, which they could ill-afford. They then started using digital manufacturing tools to build a complete 3D plant model and virtually validate the plant design to identify structural and utility interferences with plant facilities like conveyors at an earlier stage. This ensured that problems were resolved before they made the final construction drawings.”

Manufacturing optimisation

According to Shinde, it is not only manufacturing teams who use manufacturing simulation; vendor development teams at OEMs are also using it for effective part cost estimations today. He says that usage of 1-step feasibility Human factor: an essential key simulation by product designers to evaluate impact of design Since training & competency management are important based on a manufacturing perspective – viz cast, stamp, forge for an organisation, human factor is an essential key for or injection mould components provide valuable insights to immersive training system that uses high-fidelity 3D process help reduced iterative changes & issues in downstream simulation & a virtual walkthrough of the plant. According to manufacturing process. Seth, it is imperative that training & competency management, It also leads to manufacturing optimisation and process & especially in virtual manufacturing simulation is defined & productivity improvements, workforce as well as machine validated by a team of people who have hands-on experience productivity. “On the workforce side, repetitive use of of the physical systems; particularly in the areas of cross- simulation methods will enable users to get habituated or interaction of man, machine, material and methods. “This expertise in handling specific sub-processes. All of these will allows for an all-round programme that will help the system have a positive impact on the overall productivity, including designers as well as the users in developing analytical skills. that of machines, methods and man,” says Seth.

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R O U N D - TA B L E | M A N A G E M E N T

With human simulation and ergonomics tools, one can improve the safety, efficiency & comfort of the workplace environment using human modeling in a virtual environment. Emplacing this, Dutta says, “Human-driven operations can be analysed with lifelike models that can be scaled to match different population characteristics. One can test design and operational aspects of a wide variety of human factors, including injury risk, timing, user comfort, reachability, lineof-sight, energy expenditure, fatigue limits and other important parameters. This helps to ensure compliance with ergonomic standards during planning and to avoid the discovery of human performance and feasibility issues during production.” He further states that assembly simulation and validation tools use virtual assembly to simulate and validate assembly sequences, including all required human and machine interaction. “With assembly planning tools to digitally validate production systems, one can reduce tool installation time and minimise system try-out costs. This ability to digitally optimise assembly processes and validate assembly feasibility can also significantly increase productivity,” he adds.

Is simulation technology underutilised? Whether simulation is still largely underutilised today is a dilemma. Answering this, Shinde says, “Not quite for large OEMs and suppliers, but yes for SMEs. “That’s because of the combination of availability & retention of trained manpower and perceived cost of ownership issues,” he explains. Seth too agrees and suggests that demand for quick changes to production lines, manufacturing systems, etc will make it a necessity in the near future for manufacturers to adopt this technology. Today’s OEMs are becoming more of system integrators, and innovation has also shifted to suppliers and SME’s. As per Somani, SMEs are visionaries and are investing in simulation technology. “They are extremely conscious of this pressure and partner role and about the ROI as it is a huge investment for them. In such cases, our company makes them

aware of how this technology can help them grow. The key benefit for businesses in including simulation early in the design cycle is that they don’t have to build physical prototypes to test their products on different parameters. The virtual prototypes are sufficient and can be repetitively tested to meet any condition. This helps in making improvements to the final design of the product.”

Replacing physical prototyping The application of virtual prototyping in the product development process is not fantasy. It is used today, and with further developments, the number and breadth of applications will increase. Shinde believes that simulation in certain cases already has replaced physical prototyping and testing in some industries or substantial reduced dependence on physical prototyping and will continue to help improve this. As per Somani, the old practice of developing a design, building a physical prototype, testing, redesigning, and, then building a new prototype is no longer sustainable. “This is especially true as product architectures become more complex by using mechanical, electrical and embedded software subsystems. Manufacturers need to know not only how individual subsystems will perform, but how the complete product will perform in the real world — long before physical verification,” he says. According to Dutta, there are a few factors that sometimes hold manufacturers back from implementing digital manufacturing. “First, there is a mistaken belief that these solutions are meant for larger manufacturers. To be globally competitive, digital manufacturing is equally relevant for SMEs. Then, there is lack of trained manpower. We are working to address this technical skill gap, in partnership with vocational training institutes and universities across the country. Next, there is a perception among manufacturers that these tools are useful only when setting up a new facility. However, digital manufacturing can help in unearthing potential areas for improvement even in existing plants and, therefore, achieve productivity improvements even in day-to-day operations,” he concludes. ☐

A&D India | Dec’15-Jan’16

MARKET | TRENDS

I m ag e C o u r t e s y : Siemens PLM

Redefining shopfloor dynamics The only way for manufacturers in Asia to manage growing product complexity, maintain quality assurance & competitive costs is to take advantage of the boom in global & technological advancements. The feature analyses how the advent of robotics & digital manufacturing is redefining shopfloor dynamics in the Asian countries.

John Louie Marketing Manager – Asia Pacific Siemens Industry Software

In the 1990’s, the world economy started experiencing a Asian manufacturing industry and were proven right. global increase in trading, altering the nature of traditional The growth of Asia’s market share from a global value chains. There was a massive migration of manufacturing manufacturing standpoint is shifting the balance of economic industries from advanced countries to developing economies, power in its favour. The continued increase in this market transforming some Asian countries into industrial giants. share has a significant implication on the rest of the world; it The chain of events that followed resulted in the concentration has already generated ripples, and radically altered the and redistribution of industrial activities in China and India parameters governing development pace and composition. – the two most populous and fastest-growing economies in But what does this mean for the average manufacturer at the Asia – and stirred industrial changes in Singapore, Malaysia, heart of this industrial revolution? How are the shopfloors in Thailand, Indonesia, Philippines and Vietnam to gather Asia responding to this tremendous appetite for growth and momentum. Many analysts had predicted a boom for the the challenges that it brings today?

A&D India | Dec’15-Jan’16

TRENDS | MARKET

Shopfloor tasks commonly performed by industrial robots include welding, painting, polishing, deburring, assembling components, transporting items and machining

The age of automation

The new generation of robots is increasingly able to understand their surroundings better through sight and In the past, manufacturing in Asia signified a large sound systems and can distinguish between different production volume, low-level technology and cheap labour – components, even work alongside human beings. To sustain a fact that is no longer true. The increase in domestic demand, successful robotic applications, shopfloors need well-trained evolving consumption patterns, the advent of emerging and highly skilled engineers to operate robotic simulation technologies and fast changing infrastructure development processes, offline programming and robot maintenance. The levels in different countries have transformed the playing successful implementation of robots can help in visualising field. Today’s consumers are more interested in personalised and predicting operational results with a heightened degree products of higher quality with better safety features at a of certainty. Not to mention increased job satisfaction for competitive price. The marketplace has no room for flaws in employees due to smart, efficient and accurate results. quality, especially at a time when massive recalls are rattling In addition to robotic installations on the shopfloor, even the biggest brands. factories are implementing several other automation models The only way for manufacturers in Asia to manage by employing programmable logic controllers (PLC). PLCs growing product complexity, maintain quality assurance and help in controlling robots, machinery, equipment, switches competitive costs is to take advantage of the boom in global and alarms – they manage data communications among these and technological advancements. Recent statistics suggest elements to minimise human intervention, hence, reducing that this fact is not lost on manufacturers in Asia. In 2013, human errors. The virtual commissioning model, in which 98,807 industrial robots were shipped to Asia, 17% higher factories replicate the behaviour of a physical manufacturing than in 2012 - the highest level ever recorded. With the environment with a software system, has numerous benefits industry’s increased awareness of the business benefits of for manufacturers including savings in labour, energy costs automation, installation of industrial robotics is expected to and improved product quality, accuracy and precision. increase across Asia from 689,349 units in 2013, to 1,107,600 units at the end of 2017. At the cusp of a societal shift Today, shopfloor tasks commonly performed by industrial In recent years, China has had to increase its purchases of robots include welding, painting, polishing, deburring, assembling components, transporting items and machining. robots because of the growing use across the developing

A&D India | Dec’15-Jan’16

MARKET | TRENDS

Robots have to be linked to a flexible conveyor and automation system to improve product quality, lower costs, and increase efficiency

nations owing to the fact that lower labour costs constitute much less of a competitive advantage than they did in the past. Industry research shows that the gap in manufacturing costs between China and the US has been narrowing from an average of 18% cheaper in 2003 to only 7% today. The reasons for this include rising labour costs in China, cheaper US energy costs and increased automation of factories. As the trend towards automation continues to increase, so, will the volume of robotic installations. Industry 4.0 - the vision for the future of manufacturing that is becoming an increasingly stronger theme in global manufacturing to link the real-life factory with virtual reality. Robots are currently assigned multiple and dynamic tasks by human operators, however the robots of tomorrow will be able to solve problems together. Robots will have the ability to interact with each other, share information about pending operations, and assign tasks together. Nevertheless, robots have to be linked to a flexible conveyor and automation system to improve product quality, lower costs, and increase efficiency. The key for a successful industrial production under Industry 4.0 environment is strong product customisation under flexible production conditions. This will ensure reduced error margins, thanks to the availability of real-time data throughout the production cycle. To realise this vision, digital manufacturing plays an important role, and it is expected to re-shape the shopfloor due to the following factors: t Global competition will require modernisation of production facilities t It is energy-efficient and uses new materials, e.g. carboncomposites, which require retooling t Human-machine collaboration will open up new applications and attract new customers

Growing consumer markets will require expansion of production capacities t Decline in product life-cycle and increase in the variety of products will require flexible automation t Technical improvements of industrial robots will increase the use of robots in the general industry and in small and medium-sized companies, e.g. user-friendly robots, uncomplicated, and low priced robots for simple applications t Improved quality will require sophisticated high tech robot systems t Robots will improve the quality of work by taking over dangerous, tedious and unpleasant jobs that are not possible or safe for humans to perform Growing technological advancements and rapidly decreasing costs are leading to a vast increase in the number of jobs, which robots can perform in an efficient manner. This will lead to a major increase in productivity, and also to the replacement of human workers in many sectors of the economy. The growing use of robots will reduce the competitive advantage, which cheap labour historically provided by many developing countries. Robots will make vital contributions in helping aging societies like Singapore and China obtain better control of their healthcare costs. The combined impact of all these technological advancements and industry trends puts a sharp focus on the potential of robotics and automation to transform the future of workplace efficiency, improve profit margins for companies and enhance the quality of life of the end users. How Asian manufacturers employ this evolving technology to realise its full potential, will determine the future of shopfloors and consumers alike. â&#x2DC;?

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VIEWPOINT | TECHNOLOGY

Incorporating next-gen technologies The article discusses the current advanced technologies implemented across manufacturing applications, while highlighting the application benefits of such technologies that increase manufacturing capacity and reduce time-to-market. The market is flooded with new trends that are reshaping the business landscape. Smart manufacturing and Industrial Internet of Things (IIoT) are the buzzwords in the industry today. These technologies herald the future of industry and automation in a connected & collaborative world.

Adopting smart strategy… Before the shale oil & gas boom in the US, and in Europe after the financial crisis of 2008, the industry GDP was declining. The European Union started issuing manufacturing competitiveness reports to guide policy makers to stimulate

Valentijn de Leeuw Vice President ARC Advisory Group Europe vdeleeuw@arcweb.com

the economy. The studies found that manufacturing contributes over-proportionally to exports, a way of bringing liquidity to the region, and increases the resilience to crises and capacity to recover after them. Benchmarking with countries such as Germany, with a higher than average industry GDP demonstrated that the average level of industry GDP could be increased. Finally, the fact that innovation in manufacturing is proven to stimulate manufacturing growth made the EU innovation program Horizon 2020 focus on manufacturing. Both the programmes for the discrete & process industries are set up as private-public partnerships to increase ownership

A&D India | Dec’15-Jan’16

VIEWPOINT | TECHNOLOGY

by industry, and multiply the public investment. Europe’s strategy inspired the member countries to set up their own programmes in line with national needs, the most wellknown being Germany’s Industry 4.0; however, the UK’s Catapult programme and France’s Industrie du Futur are also likely to create economic impacts. For the so-called innovation-driven economies as the World Economic Forum calls them, initiatives that impact product value are the most effective to boost growth. However, cost-related improvements in the domain of process and productivity innovation are also useful. Some initiatives, mostly government initiated, such as Horizon 2020 or Industrie 4.0, but also SMLC are concerned with environmental footprint, and the European initiatives also have social sustainability goals, such as well-being at work, jobs, quality of life etc. In conclusion, these initiatives are a smart strategy for growth, environmental conservation and well-being.

IoT, but also the technologies that have long existed, and that have not been applied to all domains or all industries to which it could be applied to. For example, advanced or model-based process control, often applied in refining and petrochemicals, could be applied to a larger degree in smaller chemical processes. Industrial data analytics have a great potential for the industry, especially in combination with cloud.

Application benefits

Current manufacturing processes & technologies can be augmented with smart manufacturing or Industrial IoT, and create incremental value quickly. In Europe, one of the integrated companies consistently implements Industry 4.0 across domains and operations. The company was able to increase the throughput of a plant producing intermediate products (transforming steel slabs into rolled steel), by applying pull manufacturing and coordinating manufacturing Smart Manufacturing or Industrial IoT? and logistics with real-time information. While pull As there are many definitions in use, sometimes there is manufacturing is not new, it is a great opportunity for many confusion about the meaning or definition of smart industry sectors to apply it. Fortunately, Industry 4.0 creates manufacturing and Industrial IoT. For clarity, we make a momentum to do this. distinction between these two. Smart manufacturing is more In seven demonstration projects running for more than encompassing and includes all methodologies, processes five years at several major chemical, polymer, and life sciences and technologies that substantially improve the outcome companies, the EU-sponsored F3 Factory project of manufacturing, be it in the form of product value, quantity demonstrated its ability to reduce both capex & opex or quality, or in the form of productivity or reduced significantly, shorten time-to-market, and improve environmental footprint. There are two main sources sustainability. The objective was to create smaller, modular of improvement—advanced manufacturing that involves units with proportionally high production capacity. These improvements in fundamentals, such as physics, or miniatured chemicals, pharmaceutical or polymer plants chemistry, such as photonics, or chemical nanostructures – in a container will make supply chains much more agile. engineering science, such as modular production technology But to plan and optimise them is a complex procedure. and intensification, Additive Manufacturing or advanced Manufacturing capacity can then be very fast and flexibly forming. scaled up and down, and production units can be shipped to The second group is related to IT, communication or sites close to raw material production or consumers. Early automation related technologies, among which we find examples today are on-site production of liquefied air and internet enabled applications, often referred to as Industrial dangerous gases as feedstock for downstream production.

A&D India | Dec’15-Jan’16

VIEWPOINT | TECHNOLOGY

Remote Management of industrial equipment

Access Field Devices REMOTELY! Industrial data analytics have a great potential for the industry, especially in combination with cloud

A large food & beverage company gained a highly on problem solving by providing easily interpretable analyses standardised modularised production in its packaging lines. within context and unload them from repetitive tasks. Then The company employed the ISA 88-based PackML standard the operator can work at his best, and assess, delegate, to dramatically reduce engineering and integration effort interpret, judge and decide with consciousness and skill. As when purchasing new machines. The above-mentioned each decision involves emotional processing in the brain, for industries are looking to learn from this example on how to example when it concerns ethics, we will continue to need setup modularised automation to realise plug & produce or operators as part of our systems. The other humans in the system, supervisors, experts, modular production or skid-mounted units. With An Netbiter Remote Access you can isremotely example of applying advanced manufacturing the managers or executives also need to play their role, and new Singapore plant of a large pharmaceutical company, contribute in creating an environment in which people can FRQÂżJXUH RU GHEXJ \RXU 3/& '&6 RU PDFKLQH IURP DQ\ which decreased the time to produce the active ingredient flourish. Together these build social sustainability, resulting ORFDWLRQ $ 1HWELWHU JDWHZD\ FRQQHFWV WR \RXU UHPRWHO\ ORFDWHG HTXLSPHQW DQG RSHQV in superior performance. from 12 months to six hours. Also, another manufacturing company uses a private D VHFXUH FRQQHFWLRQ WR \RXU 3& <RX GR WKH FRQÂżJXUDWLRQ MXVW DV LI \RX ZHUH RQ VLWH cloud solution to implement so called operational intelligence. Roadmap for changing manufacturing landscape The companyâ&#x20AC;&#x2122;s operations personnel can globally view realtĹ?Ć&#x161;Ĺ&#x161; ZÄ&#x17E;ĹľĹ˝Ć&#x161;Ä&#x17E; Ä?Ä?Ä&#x17E;Ć?Ć? Ç&#x2021;Ĺ˝Ćľ Ä?Ä&#x201A;Ĺś Ä?Ĺ˝ĹśÄŽĹ?ĆľĆ&#x152;Ä&#x17E; Ä&#x201A;ĹśÇ&#x2021; ĹŹĹ?ĹśÄ&#x161; Ĺ˝Ä¨ W> ÍŹ Ć&#x152;Ĺ?Ç&#x20AC;Ä&#x17E; ÍŹ ^ Ĺ˝Ć&#x152; Ä&#x201A;ĹśÇ&#x2021; Ĺ˝Ć&#x161;Ĺ&#x161;Ä&#x17E;Ć&#x152; ÄŽÄ&#x17E;ĹŻÄ&#x161; Ä&#x161;Ä&#x17E;Ç&#x20AC;Ĺ?Ä?Ä&#x17E; Since the smart manufacturing landscape changes quickly, time smelter production data with real-time analytics Ć&#x161;Ĺ&#x161;Ä&#x201A;Ć&#x161; Ć?ĆľĆ&#x2030;Ć&#x2030;Ĺ˝Ć&#x152;Ć&#x161;Ć? ^Ä&#x17E;Ć&#x152;Ĺ?Ä&#x201A;ĹŻ Ĺ˝Ć&#x152; Ć&#x161;Ĺ&#x161;Ä&#x17E;Ć&#x152;ĹśÄ&#x17E;Ć&#x161; Ä?Ĺ˝ĹľĹľĆľĹśĹ?Ä?Ä&#x201A;Ć&#x;Ĺ˝ĹśÍ&#x2DC; dÄ&#x17E;Ć?Ć&#x161;Ä&#x17E;Ä&#x161; Ä&#x201A;ĹśÄ&#x161; Ç&#x20AC;Ä&#x17E;Ć&#x152;Ĺ?ÄŽÄ&#x17E;Ä&#x161; Ç Ĺ?Ć&#x161;Ĺ&#x161; Ä&#x161;Ä&#x17E;Ç&#x20AC;Ĺ?Ä?Ä&#x17E;Ć? Ä¨Ć&#x152;Ĺ˝Ĺľ indicating smelter â&#x20AC;&#x2DC;healthâ&#x20AC;&#x2122; and providing recommendations some roadmaps must be updated regularly like smart ZĹ˝Ä?ĹŹÇ Ä&#x17E;ĹŻĹŻÍ&#x2022; ^Ĺ?Ä&#x17E;ĹľÄ&#x17E;ĹśĆ?Í&#x2022; DĹ?Ć&#x161;Ć?ĆľÄ?Ĺ?Ć?Ĺ&#x161;Ĺ?Í&#x2022; Ä&#x201A;ĹśÄ&#x161; ^Ä?Ĺ&#x161;ĹśÄ&#x17E;Ĺ?Ä&#x161;Ä&#x17E;Ć&#x152;Í&#x2DC; manufacturing is not a goal in itself. Innovation goals must for operation via the internet. To shorten time-to-market, a large manufacturing be derived from and aligned with business strategy and company used digital factory concepts such as 3D laser sectoral needs. Also, radical efficiency improvements should scanning integrated with 3D engineering to simulate be targeted, including benefits from sustainability. Improving product & material performance where possible production within the premises to test & validate the and improving process, energy and material efficiency and production environment. use advanced & smart manufacturing innovations should be implemented. Lastly, companies should get involved with Engineering humans into the system +06 ,QGXVWULDO 1HWZRUNV ,QGLD 3ULYDWH /WG national or regional initiatives and projects like the Smart Industrial IoT, supply chain&optimisation and analytics Manufacturing Leadership Consortium in the US, Horizon Corporate Plaza, Unit 1A 1B, Senapati Bapat Road, can help the operators best, when they allow them to focus 2020 in the EU, or NASSCOM in India. â&#x2DC;?

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Remote Management of industrial equipment

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FOOD & BEVERAGE | FOCUS

Automation of process control The best solution for large and complex plants is usually not a single, one-dimensional automation concept covering the entire production process. In fact, an intelligent combination of different automation concepts will provide the best results. To achieve this goal, three equally important automation approaches in parallel can be deployed. A read on the approachesâ&#x20AC;Ś Within the food & beverage industry, the key to finding the best automation solution is a thorough analysis of each individual part of the plant or installation. By carrying out an in-depth analysis of the application, it can be determined if a centralised control system using non-intelligent nodes will deliver the required performance, or if the sheer size of the system means that the control has to be decentralised using a fieldbus system working with field controls,

intelligent valves and actuators. Pneumatically actuated process and control valves play a key role in manufacturing within the food & beverage industry. They are the core elements for controlling fluid movement within practically every production plant. However, the economic and hygienic aspects of these process fittings in a centrally controlled automation process are not without their difficulties.

A&D India | Decâ&#x20AC;&#x2122;15-Janâ&#x20AC;&#x2122;16

FOCUS | FOOD & BEVERAGE

Reasons for improved automation

Three-way approach to automation

Legislation: In the food & beverage industry, stringent standards with regards to cleanliness and product quality are put in place. These standards are intended to protect the consumer and they are enforced rigorously in most countries by specification and regulation. In order to comply with many of the statutory regulations, there will be a requirement to provide process data and analysis as evidence of compliance. In addition to statutory requirements, there are also guidelines on process validation, which require a basic level of data capture that can be achieved even with older legacy equipment. More modern process control systems can capture in-line data, which can be exported to a database for analysis. Competition: Companies operating in the competitive global market are, however, forced to make their production processes not only safe and hygienic, but also as efficient as possible. This has led to an increased demand for improved automation solutions at process level. However, the conventional approach of centralised automation of process valves cannot adequately meet the ever-more stringent requirements of the industry. Intelligent process valves with integrated automation functions offer a viable and efficient alternative. Efficiency: Levels of efficiency are determined by the scale of the production facility, however, improving the levels of automation with a process of any scale can deliver improvements to maintenance costs, production cost, reliability and, most importantly, quality. Improved control and monitoring also reduces wastage of expensive compounds, provides improved production reliability, while also delivering the continuous data required to meet regulatory standards. By making significant reductions in costs, a properly engineered production system can deliver high quality products in an efficient process.

Centralised: The centralised control concept is the most traditional approach to process automation and although somewhat displaced in many larger plants, centralised cabinet solutions with automation systems for electrical and pneumatic signals have certainly not lost their importance. Pneumatically operated valves are currently used at numerous points within production plants in the food & beverage industry. These valves are normally automated through conventional centralised control cabinet systems, including a valve terminal, an I/O system and interfaces for communication via field bus. Each individual pneumatically operated fitting inside the production plant must thereby be connected to the control cabinet through a control air line as well as a discrete feedback line. Centralised pneumatic control solutions can be effective, especially when intelligent modular valve manifolds are used, providing a compact solution that can encompass a variety of I/O and connection to plant-wide fieldbus, plus, supervisory control and management systems using plug-in communication and control modules from multiple suppliers. In practice on the shop floor, the control air lines can be quite long, which increases air consumption and has a negative effect on the switching times of the fittings. The situation is exacerbated even more by the high power requirement, e.g. for evacuation of air from chambers and hoses, which is undesirable in terms of energy efficiency.The fact that the pilot valve operating level can be a considerable distances from the fitting makes it even more. Decentralised: In many cases, especially in larger facilities, working towards a decentralised system of process control can provide a number of benefits compared to the more traditional approach. This concept uses intelligent, pneumatically operated process valves at the field level, which

A&D India | Decâ&#x20AC;&#x2122;15-Janâ&#x20AC;&#x2122;16

FOOD & BEVERAGE | FOCUS

As part of the planned improvements, the CIP system was to be integrated into the fully automated control system

can be equipped with all the required automation components such as a pilot valve with manual actuation, electrical feedback units and optical status indication, fieldbus interfaces and even positioners and process controllers. By integrating an AS interface as a fieldbus interface, the entire range of advantages of this approach can be fully utilised. All that is required for the power supply, feedback and communication is a two-wire cable connecting the PLC with up to 62 valves. Each process valve is connected directly to the main compressed air supply line in the field, allowing these connections to be kept as short as possible. This reduces the number and length of hose and wire connections as well as the number of required control cabinets to a minimum. The valve systems themselves are designed specifically for use within a hygienic environment. As a result, they feature the high IP rating required by the actual application and are made exclusively of detergentproof materials. The IP rating is therefore not affected by prolonged use in environments with high air humidity or by frequent cleaning with aggressive chemicals. In addition to better hygiene, there are other advantages to reduced electrical wiring and fewer control air lines. Even prior to commissioning, users benefitfrom the decentralised concept as it simplifies project planning and allows for more flexible solutions, thanks to easier integration of the process and automation levels. This also applies to any subsequent installation, commissioning and maintenance. Furthermore, the inclusion of a clearly visible status indicator, integrated into the fitting, allows the operator to monitor processes and the operating status of valves not only at a central control point, but also directly at the location of the fitting.

Local: To bridge the gap between centralised and decentralised automation concepts, flexible pneumatic valve units and compact automation systems can be used. These units are wall-mounted directly inside small, hygienically designed cabinets that can be installed close to the process in question. These small, pre-configured and standardised units eliminate the long runs to valves and field devices, and can be easily kept clean. Bürkert’s new AirLINE Quick is pioneering this concept. The AirLINE Quick adapter is a complement to Bürkert’s valve terminals and automation systems, which are designed for use in many different areas of hygienic processes and readily fulfil the high standards demanded by hygienic applications. This compliance is ensured by the integrated process safety features of the type 8640 valve terminals and type 8644 automation system: features that are especially important in hygienic processes. For example, check valves integrated in the exhaust air galleries ensure that during system emergency stop situations all actuators are shut down simultaneously and safely. These units also prevent back pressure accumulation in a valve block, which could result in unwanted switching of a valve. In addition, Burkert’s HotSwap function allows replacement of valves, even during operation, without loss of air pressure on the entire valve block. With AirLINE Quick, all pneumatic connections, the Fieldbus interface and the I/O modules can be mounted directly in the control cabinet. This facility allows for an altogether smaller design of control cabinet, where additional components such as pipes, cables or control cabinet connections are eliminated, due to direct mounting, further reducing the time needed for installation and commissioning.

A&D India | Dec’15-Jan’16

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FOOD & BEVERAGE | FOCUS

Intelligent control heads on various sizes of process valve in a production environment

Improving automation As the leading fruit syrup manufacturer in France, Teisseire required Bürkert to deploy one of the company’s latest innovations to achieve decentralised control and aid process performance as well as integration. The project scope was to introduce a new fluid control system, which would accommodate third party control valves and also provide fieldbus communications to improve the management of the production line. Another goal was to reduce the overall maintenance stores inventory, so using just one control head type (8681) would make a significant reduction in spares. The existing valve control system was approximately 15 years old and consisted of an assortment of different control heads, some manual, some automated, but the wide variety of components did not interact well together and overall performance was inefficient. One of the problems stemmed from the existing air supply, which included oil mist from the compressor and was not suitable for control of hygienic valves that had prevented any upgrade to a more modern control system in the past. With a decentralised automation concept, the control head takes over all pneumatic actuation, feedback and diagnostic functions up to and including fieldbus communication. The housing is easy to clean and features proven electrical IP protection and chemically resistant materials for use in hygienic processing in food & beverage industries. By using the 8681 control head with its universal adapter, it can be combined with all normal commercial butterfly valves, ball valves, single and double seated valves. In addition to the main production controls, the plant also has

a clean-in-place (CIP) system, which was originally a manually controlled process. As part of the planned improvements, the CIP system was to be integrated into the fully automated control system, which would greatly reduce the overall time required by maintenance engineers to perform this operation.

Conclusion With the development of practical solutions that integrate automation functions into the pneumatic actuators of process valves, the advantages of decentralized automation have become a real alternative to control cabinet systems for many users. Companies in the food & beverage sector are now in a position to reconcile the commercial necessity of a high degree of automation of their production with the requirements of hygiene and safety. Thanks to their modular structure, systems based on intelligent process valves can be adapted to suit many situations and applications, whereby such optimised solutions are always based on high-quality, tried and tested components with a long service life. By employing its three-tier automation approach, Bürkert is able to provide independent consulting and flexible hygienic processing control solutions from a single source. With a high degree of standardisation and state-ofthe-art design, these solutions can make the engineering and commissioning of automation systems much easier and less costly. In addition, end-users benefit from plant standardisation, with easier plant monitoring and diagnosis, as well as reduced costs for maintenance and ownership of their facilities. ☐ Courtesy: Bürkert Fluid Control Systems

A&D India | Dec’15-Jan’16

FOOD & BEVERAGE | FOCUS

Reviving productivity with automation Expectations of today’s consumer are rising, be it in product quality, packaging or freshness. This places higher demands on how consumer products are sourced, manufactured and distributed. The article discusses the challenges faced by the Indian industry, while assessing the role of automation in driving the quality levels and increase responsiveness. Today, there is a crisis brewing in Indian manufacturing. A recent study of the consumer industry projects a growth of 6.7% per annum over and above the inflation rate, meaning demand growth will be robust. Almost two-thirds of retail in India is accounted for by food & groceries. So, the food & beverage industry can expect high sectoral growth. This overall growth in volume is accompanied by an increase in the sophistication of the consumer.

Alagu Balaraman Partner & Managing Director CGN Global India

Meeting customers’ demands This rising expectation of the consumer and growth in demand is not being matched by a similar rise in availability and skill levels of labour. This is leading to serious problems of talent in factories. This is on top of the challenges that started when the NREGA was introduced. The program had a strong & laudable social objective, but it reduced the

A&D India | Dec’15-Jan’16

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

FOCUS | FOOD & BEVERAGE

attractiveness of manufacturing jobs, making it difficult to attract workers into the shopfloor. Today, the aspiration of the youth is towards service sector jobs, leading to increased difficulty in staffing the manufacturing sector. Looking ahead, it is likely that this shortage will increase as the ‘Make in India’ initiative gathers steam and newer industries start using available talent. India has a large population, but inducting new people into the workforce is not easy. This real life example describes the problem. A new unit of a biscuit plant was set up at Rudrapur to take advantage of fiscal benefits extended by the state. Most of the workers hired came straight off farm work. Having never worked in the food manufacturing industry, or in any industry, they did not understand the need for hygiene (“Why should I wash my hands at the start of the shift?”) to arriving on time for a shift (“It was raining and we decided to come later”). Given the poor state of the Government-run ITIs, this is not likely to change very soon.

A&D India | Dec’15-Jan’16

The combination of rising demand and sophistication, coupled with a shortage of skills is leading to a crisis on the shopfloor, which could very well lead to shortages and drive up inflation.

The productivity imperative In the FMCG beverage space, a client was mentioning that earlier bought individual machines would themselves assemble and integrate them for production. Today, they look to buy out entire lines, where equipment is synchronised for speeds & capacities. As a result, throughput and responsiveness to the market is much higher today than in the past. This drive towards automation is also being pushed by regulation. The Food Safety & Standards Authority of India (FSSAI) was set up to provide regulations to help improve safety and wholesomeness of food produced in the country. While there have been issues around the responsiveness of the body and it’s approach to handling approvals, there is widespread acceptance that food quality standards are an important topic. Ensuring consistency and quality is a challenge. Being able to establish process capability to give assurance of consistency and quality will require going beyond the craft based approach to food manufacture. A movement towards scientific methods will significantly help increase productivity. But this will not be enough. The Indian industry will need to make significant investments in automation to offset capacity shortfalls caused by labour and to help ratchet up quality levels to meet the demands of today’s customers.

I m a ge Co u r te s y : Baumer

FOOD & BEVERAGE | FOCUS

Challenges of automation Today, the biggest challenge with automation is the upfront investment cost. Traditional cost accounting models and budgeting systems are very accustomed to a low-cost labour pool. They are also used to a high cost of funds. So, instinctively almost, there is a tendency to look to lowering high fixed capital investment cost by supplanting it with low variable labour cost. This error has been replicated in many planning processes. However, higher total cost does not need to translate to higher unit cost. The goal of designing and budgeting for such an initiative should focus on controlling unit costs. Also, the truth is that labour costs have not followed a linear path and, today, the cost of labour has reached a level where it makes financial sense to reduce headcount by investing. The financial numbers on labour cost control have been skewed by an increasing percentage of contract labour. Data from the Annual Survey of Industries shows that the percentage of contract labour was 15.6% in 1998-99 and that it has almost doubled to 28.6% by 2005-06. This is increasing level of contract labour has kept costs down. The increase in contract labour has had strong negative effects as well. Terrible events arising from labour unrest in the National Capital Region were well publicised. However, the structural problem that increased contract labour has caused is to drive down skill levels, just when we need higher skill levels to increase productivity. Manufacturers don’t want to train people to operate sophisticated equipment when there is no guarantee that the trained person will show up tomorrow. Or, worse still, go to some other factory and operate a machine there. Companies embarking on an

The Indian industry will need to make significant investments in automation to offset capacity shortfalls caused by labour

automation drive on their shopfloors are also grappling with significant changes in the profile of people on the shopfloor.

Dealing with the change Making a move from a low-cost, low-productivity curve to a higher-cost, higher-productivity curve requires dealing with change on many fronts. The financial team will need to work with new models and thumb rules from the ones that have served them in the past. They need to figure out what output & performance levels are expected to justify highproductivity equipment. For example, a high investment plant is fully capable of being the lowest unit cost producer of a product, simply by driving up productivity. On the people front, much needs to change as well. The shopfloor managers need to arrest a trend of increasing contract labour. To work with more sophisticated equipment and to operate more complex processes, they need high quality people. These people are not readily available and shopfloor managers will need to seriously invest in training people. It is important to bolster the equipment and staff with robust design inputs – in layouts and processes. In many cases, manufacturing management and material handling processes are poorly thought through. This will result in a productivity leakage weakening the shift towards a highproductivity model. Overall, the move towards increased automation in the food & beverage manufacturing sector is on a welcome note. Not only will it drive up quality levels and increase responsiveness, it can also drive down unit costs. The move will not be easy and certainly won’t be business as usual on these shopfloors. ☐

A&D India | Dec’15-Jan’16

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INDUSTRIAL COMPUTERS & PERIPHERIES | TECHNOLOGY

Addressing the top five challenges on the factory floor PC-based control systems are becoming increasingly common on the factory floor, but selecting the wrong industrial PC can lead to downtime, or even worse, lost production. The article finds the top five challenges typically encountered on the factory floor, and offers some criteria to consider when selecting industrial PCs and associated components.

Bjoern Falke Product Marketing Manager Control and Software Products Phoenix Contact

With the gaining popularity of PC-based control systems, plant engineers are turning to industrial PCs (IPCs) for control, HMI and data collection applications. Industrial PCs set themselves apart from office-grade PCs by offering touchscreen operation, industrial-grade mounting options and overall more rugged design. As in any control system, uptime is critical for an industrial application. From high-output machinery to time-sensitive data to critical processes, machine downtime is the dreaded scenario for every plant.

Choosing the right mass storage Selecting the right mass storage for an industrial environment is crucial for the long-term reliability of an industrial PC. Factors to consider are not only size, but also shock and vibration as well as read and write speed and number

of write cycles. Mass storage choices usually are the traditional rotating hard drive (HDD), the newer non-rotating solid-state drives (SSD) or small CompactFlash® (CF) cards. Each of these mass storage options has advantages and disadvantages. Traditional rotating hard drives offer large storage space upwards of a couple hundred gigabytes (GB), fast data access and a relatively low price per GB of storage space. Disadvantages are their relative susceptibility to shock and vibration. While rotating HDDs are perfectly suited for applications that write a large amount of data, they can be the incorrect choice for applications on moving or vibrating equipment. Non-rotating solid-state drives (SSD) are gaining popularity due to the drop in prices in the last few years. Originally developed for military and space exploration projects where price was no object, this memory chip-based, rugged mass storage drives are now affordable enough for industrial

A&D India | Dec’15-Jan’16

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INDUSTRIAL COMPUTERS & PERIPHERIES | TECHNOLOGY

Easy accessible mass storage drives increase service ability

applications. Due to their design, SSDs are virtually immune to shock and vibration, which allows them to tolerate higher temperature swings than HDDs and are completely silent in operation. While the general features of an SSD may make them appear as the perfect fit for industrial use, they do not come without certain design limitations. One problem is that certain SSDs are not suited for write-intensive applications, such as constantly writing data to a SQL data base. Another mass storage choice is the small CompactFlash (CF) card. These cards are typically offered as a smaller storage size option below the SSDs. CFs come in removable and fixed disk flavours, so selecting the right CF is important. While CF cards are now available with SLC technology, they are limited by the read and write speed of the IDE bus. Thus, they are slower than a SSD on a SATA bus. Due to the CF’s smaller size, they are well suited for embedded operating system use, such as Microsoft® Windows® Embedded Standard or Windows® CE.

Embedded versus Desktop Operating System Embedded operating systems, at least on paper, have several advantages over their full-featured, bigger brothers. Embedded operating systems typically cost less, fit on a smaller (thus lower cost) mass storage device and do not require a formal shutdown procedure. This all sounds good, but once you dig a little deeper, the picture changes. There are not only limitations as to features, but also legal implications.

One such issue is that embedded operating systems should not be used as general purpose operating systems like those commonly found in desktop PCs. Embedded OS’s use is limited and bound by the often-overlooked Microsoft Embedded licensing agreement. Besides other limitations and restrictions, the agreement states that the system shall only be deployed for purpose-built functions. While Windows® Embedded Standard or Windows® Embedded CE 6.0 Core have a lower price point and smaller footprint than Windows® XP or Windows® 7, they also have lower functionality. To get their footprint smaller, the operating systems omit features such as drivers or certain applications. This alone may make them unsuitable for more complex industrial applications. In addition, embedded operating systems require that the customer has specific knowledge plus the tools necessary (e.g. Microsoft embedded toolkit) to build the software image and deploy it.

Underestimating the security risk The world is becoming more and more interconnected. So are your plant and the machines in it. While the connectivity can be great for fast and easy data exchange or remote machine monitoring, it can also open up the door for unauthorised outside network access, hackers, viruses or just unnecessary traffic that hinders performance. This not only poses a risk for your machines, but also for your entire plant network. While Stuxnet has gained international headlines, it is just one of

A&D India | Dec’15-Jan’16

INDUSTRIAL COMPUTERS & PERIPHERIES | TECHNOLOGY

Direct machine mount industrial PCs with IP65 protection

several attacks on industrial equipment in recent months. You can mitigate cyber security threats with a few simple steps: t Using a dedicated hardware firewall prevents unauthorised and unwanted traffic without siphoning off IPC resources like software firewalls do. The hardware firewall can also log traffic and access attempts, giving you an audit trail of who is trying to access what. t Disabling USB access removes a very common attack vector and will help keep your IPC malware free. This is easily done right in the BIOS. Adding password protection to the settings ensures they aren’t switched back on. t Use the enhanced write filter feature with embedded operating systems to make the system partition read-only. t Using a router to separate your plant network from the IT network can give you insulation and isolation. With today’s private networking, there’s no need to share a subnet with the rest of the office world. Putting your plant on a separate IT network gives you more protection and makes it easier to control access; all the while still reaping the benefits of being able to share information with plant management, logistics, etc. Security isn’t something that just happens, so be proactive. Using multiple layers of security, as outlined above, provides defense-in-depth that will keep your IPCs, in particular, and plant network, in general, safe and productive.

Energy-efficient design Energy costs are on the rise. While the purchase price of an industrial PC is often a huge selection criteria, the associated operating/energy costs are often overlooked or, worse yet, ignored. Over the lifetime of a single PC, you can save a significant amount in energy costs by simply purchasing a more energy-efficient model. While that model may cost a little more initially, it will save you money in the long run. Design features such as low-power consumption CPUs or SSDs

as well as more energy-efficient external power supplies all have a positive impact on your energy bill. Multiply these savings by 10, 50 or 100 systems, and your plant can save thousands of dollars in energy costs over the intended life span of the equipment.

Easy serviceability Fast access to connectors, mass storage and the Real-Time Clock (RTC)/BIOS buffer battery can be the crucial difference in whether a machine is down for just a matter of minutes or a matter of hours. Easily removable mass storage drives utilising pull out trays can be exchanged within minutes without removing or even disassembling the PC. This also applies to the Real-Time Clock/BIOS battery or secondary CompactFlash or SD cards. In addition, external 24 V power supplies, as well as easy integration of uninterruptible power supplies (UPSs), increase serviceability and system uptime. Long-term availability of spare parts and CPUs from the long-term road map series gives additional peace of mind. This ensures the freshly purchased IPC will not be obsolete six months later. Pair this with a repair-friendly, modular design, and any required repair can be performed quickly, limiting downtime to a minimum.

Conclusion Education is key. This is also true when it comes to the topic of industrial PCs. IPCs offer a lot of benefits when compared to traditional PLCs, so they are here to stay. Selecting the right mass storage, a suitable operating system or the proper cyber security system can be challenging but does not have to be. With a little research and a close partnership with the right vendor, you can prevent misapplication of an industrial PC. This will ensure your IPC system can grow with your business and keep your plant running. ☐

A&D India | Dec’15-Jan’16

MACHINE VISION | TECHNOLOGY

Keys to successful multicore optimisation Optimising a machine vision application for multicore PCs can be a complex process with unpredictable results. To achieve best overall system, it is necessary that developers pay close attention. Field-testing under actual conditions is the only way to fully measure system throughput. Machine vision speed increased automatically with increasing microprocessor speeds. However, with multicore PC architectures, it is different, as it requires software design changes to take advantage of parallel processing architecture. A multicore strategy for machine vision can be implemented at multiple levels. Independent high-level tasks — especially those with hardware dependencies, such as acquisition and I/O — can be written to run asynchronously on separate cores, leaving processor free to do those tasks that are not blocked. Individual vision tools can also be parallelised so that they divide their processing task among several cores.

Didier Lacroix Vice President — International Sales & Marketing Cognex Corporation didier.lacroix@cognex.com

Multicore PC architecture Earlier, to handle bigger and complex application, vision applications depended on advances in PC hardware. However, this requires higher heat dissipation, where cooling has become a limiting factor. Manufacturers like Intel and AMD use multiple processors instead of a single processor. These processors are packaged on a single chip. Each processor is called a ‘core’, and new chips are called multicore processors. Two, four and eight-core processors are now common, while much higher density models are also being designed.

A&D India | Dec’15-Jan’16

TECHNOLOGY | MACHINE VISION

Figure 1: Example of partitioning an image across multiple threads

Optimised software is the key It is not possible to move an existing machine vision application from a single-core PC to a multicore PC and expect performance improvement. Some applications may not run any faster on a multicore machine due to operating system overhead and other inefficiencies. Programmes must be rewritten to speed up their applications, as many algorithms do not lend themselves to parallel processing. Here are four keys to successful multicore optimisation for machine vision applications. These are application optimisation; vision tool optimisation; tuning for overall system performance, and software portability.

Processes & threads PC operating system manages programs as separate processes. Each process has an associated context and when process is blocked the operating system saves current context and swaps in another process. System processes responses to a range of demands, which is invisible to the user. A multithreaded program can be written so that different sections run simultaneously and independently. These are much lighter and share the same address space, allowing it to switch quickly making it easy for them to share data when running in parallel. Multithreaded applications do not require a multicore architecture. They are efficient on a single-core machine, but rely on operating system to manage hardware resources for them. Multithreading is suited for multicore PCs and algorithms that ran sequentially, can be partitioned into separate threads that now run in parallel on separate cores.

Commercial multithreaded software Writing multithreaded application code is not simple and requires underlying machine vision libraries to be written in a re-entrant manner that allows multiple instances of the

A&D India | Decâ&#x20AC;&#x2122;15-Janâ&#x20AC;&#x2122;16

program to execute in parallel. For this, writing custom software at application layer to take advantage of a multicore PC is usually only justified in very demanding applications. Off-the-shelf solutions may not be efficient as custom code, but can provide significant benefits at very low cost. Application optimisation: Application-level software can be optimised for multicore PCs in three ways. Firstly, by creating separate threads for tasks with hardware dependencies, such as image acquisition, accept/reject results, operator interaction and are often designed to minimise unpredictable hardware delays. Secondly, by creating separate threads for each camera in a multi-camera application, allowing each thread to run as soon as its camera is triggered. And thirdly, by creating separate threads for different machine vision tasks within a vision application. However, this works if the tasks are not dependent on each other, and the benefit will be small if one task is much shorter than the other. Some commercial machine vision products have built in these features. For example, CognexVisionProâ&#x201E;˘ software create separate threads for image acquisition and vision processing and can detect number of cores in a PC and create threads based upon it. This type of scalability is advantageous in multicore PCs for applications with multiple image acquisition and vision processing tasks, which need to be performed simultaneously. It is beneficial on single-core PCs, because image acquisition does not use much CPU time and can therefore run in parallel with image processing operations. Vision tool optimisation: In addition to application-level optimisation, it is possible to optimise machine vision tools by parallelising their algorithms so they use multiple cores simultaneously. However, not all vision tools can be easily parallelised. Parallelisation is helpful for image processing filters or other vision tools that run local operations on small regions of the image. Commonly used filters include median, Gaussian and morphology operations can be optimised by dividing image into different pieces and assigning each one to a separate

MACHINE VISION | TECHNOLOGY

Core 1 Vision thread 1

Core 2 Vision thread 2

Core 3 Vision thread 3

Core 4 OS, user interface & machine control

Vision thread 4

Figure 2: A vision application divided into

Figure 3: One vision thread per core may not be

three threads running on a four-core PC

the optimum choice. This application finishes later than the one in Figure 2, even though this one has one thread per core. Depending on the application, more or fewer threads may be better

thread (Figure 1). The final speedup depends on algorithm and number of cores. Because of overhead, there will always be some inefficiencies, so even a well-optimised vision tool may not run eight times faster on an eight-core PC. Many vision applications spend most of their processing on tools that are more complex than simple image processing filters. It is not always possible to parallelise complex vision tool algorithms such as alignment and optimising the tool might only benefit a small portion of the algorithm. The PatInspect™ tool has been redesigned so that inspection steps are divided among available cores. Even when percentage improvement is lower than for simple image processing filters, overall application may benefit more, since complex machine vision tools generally consume large portion of overall application. Tuning for overall system performance: Fastest vision application would be one that control every processor core in the PC and create one thread to run on each core. The PC must also support operating system, machine control and other background tasks. In practice, optimum number of threads for vision application may not necessarily be the same as the number of cores in the PC, and may not make sense to assign each thread to a specific core. The only way to determine optimum number of machine vision threads is to test it under realistic conditions.Cognex’s CVL™ and VisionPro™ software libraries give users a simple method to set the number of threads for multicore-aware vision tools in an application. This top-level ability lets users easily tune the system for best overall performance. Software portability: Another concern is software portability from one PC to another. PC hardware changes quickly that vision applications will be deployed on multiple PC models, either when new vision stations are deployed or needs to be replaced. Machine vision application is usually developed on a different PC than on which it is deployed and replacing PCs deployed in manufacturing lines is a constant maintenance issue. Since number of cores available may change over time,

there should be a vision application, which can account for any number of cores in the system. Redeploying existing system on a different PC may require recompilation or rewriting application software, which is high cost as development stations are modified and developers move on to other projects. CVL and VisionPro™ libraries can automatically detect number of cores on a PC and dynamically adjust number of threads that they create allowing applications written for a four-core PC to run efficiently on an eight-core PC without touching the source code or recompiling.

Summary Optimisng a machine vision application for multicore PCs can be a complex process. It is clear that developers must pay attention to achieve best overall system performance. Field-testing under actual conditions is the only way to fully measure system throughput. To maximise benefits of multicore PC technology in machine vision applications, developers should consider several key questions when evaluating machine vision software products. These should include points such as whether image processing filters have been optimised for multicore, as also other factors that can impact the performance of overall application, including: t Can the software product automatically create separate acquisition and processing threads to speed system throughput and responsiveness? t Does the software allow users to write their own multithreaded application? t Can users tune the number of threads for best overall system performance? t Does the software have the ability to automatically detect and adjust the number of threads, based on the number of cores, without having to rewrite the application? By keeping these points in mind, users can maximise their options (and minimise their work) to take full advantage of multicore PC technology. ☐

A&D India | Dec’15-Jan’16

Economical and ďŹ&#x201A;exible â&#x20AC;&#x201C; Solutions for packaging machines

Are you looking for a reliable partner for the automation of your packaging machine? We offer a comprehensive portfolio for the packaging industry, from safe sensor technology to control systems, operation and visualisation, through to drive technology.

Further information: www.pilz.com/packaging

Pilz India Pvt Ltd.

Pune 411009

020 2421399-4/-5

info@pilz.in

www.pilz.in

SAFETY & SECURITY | TECHNOLOGY

Open, adaptable and modular safety solution A read on how Pilz’s open, flexible and decentralised safety system has helped Oystar to enhance its packaging solutions.

Today’s machines have a high degree of automation, so there is a need for intelligent, modular safety concepts that seek to maintain economic viability and deliver a competitive edge. In marketing, packaging is a powerful, sophisticated instrument largely responsible for the product’s success. The forms of packaging that product and packaging designers are coming up with are ever more refined; the task of creative engineers is to develop automated and productive packaging solutions to suit.

Increased demands on safety & performance Oystar Group is based in Stutensee near Karlsruhe and is one of the world’s leading suppliers of packaging machines, including related technologies and a broad range of services. It supplies stand-alone machines through to turnkey packaging lines via ten international production sites. Products include carton erectors, tray and case erectors, all-round packaging machines, high-performance packers, multifunctional packaging lines, palleting solutions and conveyor technology. The majority of packaging systems are used in the key industries of dairy, food, pharmaceuticals and cosmetics.

Oystar A+F, specialists for final packaging solutions, is equipped throughout with an open, flexible and decentralised safety system from Pilz, which boasts extensive diagnostics functions. So, doors that have to be opened regularly or temporarily are fitted with safety gate systems designed for applications up to PL e of EN ISO 13849-1 and in many cases also have guard locking devices for process protection tasks. In the past, these tasks would have involved costly and labourintensive cabling work to install mechanical safety switches with guard locking devices, and signals would have been evaluated centrally via safety relays. Precise alignment between the switch and actuator was difficult because the mounting tolerances were low; diagnostics were not always reliable. This resulted in damaged switches and attempts to manipulate the safeguards.

Open & decentralised safety concept For a short while, Oystar A+F considered integrating the safety technology into the control systems of the various suppliers. This idea was soon shelved, however, on account of the high level of complexity of the software tools for the

A&D India | Dec’15-Jan’16

SAFETY & SECURITY | TECHNOLOGY

various systems and the complicated software validation process this involved. “Our primary aim was to define an open and decentralised safety concept that could be adapted to all control systems that could not only be designed in accordance with protection type IP67, but could also be implemented with clear separation of responsibilities between safety and standard”, said Manfred Schuster, Head—Electrical Design, Oystar A+F. The company opted for the configurable control system PNOZmulti Mini in combination with decentralised periphery, the input modules PDP67. As a central safety component, the configurable control system PNOZmulti Mini has every safety-related function in its sights. Installed in the main control cabinet, the PNOZmulti Mini base unit with 20 digital inputs and 4 digital semiconductor outputs monitors the emergency stop button, reset button and mode selector switch, as well as taking control of the servo amplifier all the way to a safe operational stop.

Ensuring higher productivity The safety gate system PSENslock from Pilz monitors the machine access points via PNOZmulti Mini. Secure safety gate monitoring is combined with a non-contact magnetic interlock with either 500 N or 1000 N. Thanks to the flexible connection options, PSENslock can be used for safety gate monitoring up to PL e, both individually and in series, and guarantees maximum manipulation protection. The safety gate system passes the signals to the decentralised PDP modules / PNOZmulti Mini. Gates, which do not require guard locking are fitted with the coded safety switch PSENcode. The connection is also made directly on-site via the decentralised PDP67 modules. “By swapping the mechanical switches for the safety gate syste, PSENslock from Pilz, our customers can increase the productivity and reliability of their machines considerably,” explained Schuster. The software tool PNOZmulti Configurator makes light work of the configuration of the whole system. The clearly structured, intuitive user interface speeds up the commissioning process. All configuration and function elements are available either as icons or in selection menus. All inputs and outputs are free to select and can be linked using logic elements via a simple drag and drop function. Pre-defined, approved function blocks and menus

make it easy for users. Safety functions require in-depth specialist knowledge, particularly during configuration and implementation, so the fact that certified safety blocks are already stored within the software tool helps tremendously in gaining approval for the machine. The Safety Calculator PAScal from Pilz enables functional safety to be verified and documented simply and with ease. The calculation software calculates and verifies the key safety parameters such as Performance Level (PL) and Safety Integrity Level (SIL) for plant and machinery safety functions. The software can use a graphic editor to model safety functions and define not only their structure, but also the usage pattern of the individual components. Given the extensive library functions, it is possible for users to import machine data in the standard library formats or to create and manage their own libraries. The result is compared with the safety parameters required for the safety functions and is displayed in graphic form.

Catering to individual requirements The close collaboration between Oystar and Pilz resulted in a system standard for safety, which can be adapted to cater to the individual needs and requirements of the various installations and machine types. Not only did Pilz supply the machines and systems, but the company was also responsible for the design, product selection, commissioning, after-sales service and support. “For us, it was an advantage that even during the commissioning phase, we were able to call on Pilz’s technical support at any time, and that support was always straight-forward”, suggested Schuster. With their distributed structure, the products in the PNOZmulti range developed by Pilz are ideally suited to systems requiring a standardised solution, from the standalone machine right through to modular networks. The large number of different communication interfaces makes the configurable control system into a safety standard that can be applied all over the world because it can be used independently of any specific operating control system. “We were looking for a new, universal safety solution that could be clearly structured. With the PNOZmulti Mini and the decentralised PDP67 modules”, said Schuster. ☐ Courtesy: Pilz

A&D India | Dec’15-Jan’16

D I G I TA L M A N U FA C T U R I N G | T E C H N O L O G Y

Driving digital transformation Through Integrated Digital Enterprise, systems are seamlessly synchronised to accomplish the available to promise cycle, most efficiently, in least time. The article briefs on how this enterprise strengthens the manufacturer’s vision for the factory of the future, while reaping benefits. While in Australia on a business tour, one of my colleagues purchased a pair of leather oxfords. During a casual enquiry at the billing counter, he was amazed to learn that the shoes were made by a company in America, designed in England and manufactured in China, while the leather was imported from Italy. This was a classic example of the demand-driven-supply-chain, which is becoming a reality quickly. The whole game of such a supply chain impacts both the top-line (such as return on equity) and the bottomline (such as return on capital employed & cash flow). The most optimal strategy to realise this demand-driven-supplychain is through an Integrated Digital Enterprise.

Integrated Digital Enterprise (IDE) An IDE is one where systems are seamlessly synchronised

Harish Mehra Global head—Plant Solutions TCS hmehra@tcs.com

to accomplish the available to promise cycle, most efficiently in least time. In realistic terms, this means achieving the ability to mass customise through optimal asset utilisation and lower time to market. The IDE is characterised through three key areas: Agility: The future of manufacturing is all about speed & flexibility for a greater availability to promise fulfillment. Intelligence: Using the vast data sets available throughout the product lifecycle to build intelligent models. This can help simulate & validate the process of introducing new product on a manufacturing line, reducing the time to scale & hence faster time to market and the ability of assets and processes to predict undesired events around maintenance and quality, thereby, improving the overall asset utilisation & production efficiency. Security: It is paramount that the enterprise architecture

A&D India | Dec’15-Jan’16

T E C H N O L O G Y | M A N U FA C T U R I N G D I G I TA L

enables the ability to safeguard all data communicated across the supply chain.

helps in achieving single version of truth through communication standardisation and effective master data management for flexible scaling and higher process efficiency. The resultant data set can be used to create effective process Realising IDE models, which can be deployed online to analyse the realTo achieve Integrated Digital Enterprise, one needs to time data elements to predict future events, which can be realise four key integration scenarios. They include: leveraged to plan for contingencies, thereby, improving the Horizontal Integration – across the value chain overall asset utilisation. Horizontal integration is the seamless connection among Engineering Integration – from design to manufacture systems across suppliers, plant(s), utilities, warehouses, and Engineering integration is the closed loop between the customers, which helps in overcoming the fundamental Engineering Systems (Product) and the Execution Systems current challenges in visibility. This is done through (Process) for continuous improvements. This can be achieved integration standardisation and effective detailing of the through constant feedbacks from the execution to the master data at each party across the value chain. This on- engineering system triggering analysis and enhanced demand visibility leads to dynamic resource optimisation for simulations, resulting in further optimised process definitions. reduced production costs, improved order fulfillment rate, These renewed process definitions are then effectively effective energy consumption and sustainable enterprise. channelised back to the execution systems and controllers on Vertical Integration – from top floor to shopfloor the shopfloor to realise optimised execution processes. Such Vertical integration is the tight coupling between a channel enables seamless flow of data and information Information Technology and Operational Technology by across the engineering & execution systems, which compresses connecting shopfloor systems with business & execution the time to scale. Thus, through this integration, manufactures systems. This enables intra-operability across the enterprise, can effectively reduce the time to market.

Advt

A&D India | Dec’15-Jan’16

D I G I TA L M A N U FA C T U R I N G | T E C H N O L O G Y

Integrated Digital Enterprise

Integration for manufacturing analytics – from reactive to predictive When multiple systems across the enterprise digitally interact via a standard, secured Industrial IoT Framework, huge volume of data is generated at a high velocity with varying data structures, which can be leveraged for predictive alerts that trigger prescriptive workflows and, therefore, automated corrective processes, leading to process intelligence. Effective mining of this big data is the key for advanced analytics, which has the potential to not only improve the bottom line through improved productivity, but add new service offerings with direct impact on the top line, for example, the smart sensors on a turbine can be used to not only monitor the health of the asset remotely & provide predictive maintenance alerts to its owner but also introduce new service lines whereby the manufacturer can offer asset as a service, whereby, they can commit to performance pay models (possibly leveraging self-learning engines). The mined data can then be used to generate better visibility via reports, dashboards & alerts using intuitive tools & apps, which can be seamlessly accessed across various form factors.

Planning transformation In order for manufacturers to realise IDE, it is essential to

plan for the transformation in three key stages. First, one needs to be informed by standardising enterprise wide data, then, to be integrated through the first three (vertical, horizontal as well as engineering) integration scenarios discussed and, lastly, by being intelligent through the integration for manufacturing analytics.

Benefits An Integrated Digital Enterprise helps manufacturers realise three key benefits. The first one being return on equity. Here, through flexibility and agility gained from IDE, new product introductions become faster and the time to scale is reduced, thus, leading to an increased market share and returns on equity. Second is the return on capital employed. Here, increased efficiency leads to increased quality, asset utilisation and reduced waste. These in turn, lead to increased inventory turns and increased returns on capital employed. The third one is cash flow. Here, the increased capital utilisation as a result of efficiency leads to lower capital expenditure, increasing the cash flow. Achieving the Integrated Digital Enterprise is fundamental to a manufacturer’s vision for the factory of the future and to realise the concept of source from anywhere, make from anywhere, sell from anywhere, and support from anywhere. ☐

A&D India | Dec’15-Jan’16

T E C H N O L O G Y | M A N U FA C T U R I N G I T

I ma ge C o urt esy: iStockphotos

5 steps to an effective ERP-MES integration Manufacturing Execution Systems (MES) and Enterprise Resource Planning (ERP) solutions have been at the forefront of manufacturing for several years. Despite this, both technologies have tended to co-exist. The article highlights the integration of these systems for manufacturers to digitise processes and gain fast access to vital data. A recent study from BearingPoint has claimed that a correctly deployed MES system will become a strategic necessity for those manufacturers that are paving the way towards a digital future. 88% of the companies surveyed said they expect MES to become increasingly important, with almost three-quarters planning to invest in the technology within three years. BearingPoint’s study suggests that the emerging popularity of MES systems is due to their ability to act as a bridge between ERP technologies and machine controls. Indeed, the integration of these systems allows manufacturers to digitise processes and gain fast access to vital data such as lead times, stock levels and profits. MES is a market force to be reckoned with –

A&D India | Dec’15-Jan’16

Anish Kanaran Channel Director Epicor Software – India, Middle East & Africa akanaran@epicor.com

especially when it’s integrated with ERP. The following section explains how to make this possible.

Evaluate how you use ERP For many manufacturers, when they first implemented ERP, the goal was to drive cost savings. The goalposts have since shifted, and ERP now plays a major role in promoting business growth. It does this by making it possible to share data quickly and effectively across the business; facilitating cross-departmental cooperation and reducing the ‘silo mentality’ that has previously been synonymous with the shop floor versus management manufacturing structure.

M A N U FA C T U R I N G I T | T E C H N O L O G Y

Today’s ERP systems offer comprehensive collaboration capabilities, providing tools for social collaboration on a project-by-project basis. They are also accessible via mobile devices and provide visual analytics to simplify decisionmaking. Because of this, they make it easy for manufacturers to react to change and adapt to specific customer requirements; ultimately aiding new business development. Evaluate what you currently use ERP for, and think about what you want to achieve with your ERP solution before you start to implement anything new.

precise scheduling, planning, monitoring, procurement and cost accounting. In addition, the integration provides accurate reports, converting data into a consistent, bidirectional information environment. With this, users get metrics on delivery dates, labour and material use. They also get business intelligence as a result of close networking and instantaneous feedback between their ERP and MES.

Encourage a cultural change

Educate corporate management

Before investing in MES and ERP systems, manufacturing companies need to define their objectives for integrating It’s not uncommon for senior management to be unaware two systems, which may previously have been entirely of the tremendous business benefits they can derive from separate entities. One of the hurdles in this processes the MES solutions. In many cases, the technology is regarded fact that both systems may have previously been owned and only as a tool in day-to-day manufacturing processes – operated by different divisions - MES by management and essential, yes – but not strategic. However, MES actually has ERP by the IT and finance department. It is therefore the potential to transform production into a “business important that all parties collaborate during the integration, centre of excellence.” Those companies that understand this in order to understand the opportunities, goals and are the ones that will become market leaders in the future, outcomes. Often a cultural change within the company is so it’s important to educate your senior managers. necessary for this type of collaboration to take place. MES can provide predictive, preventive maintenance capabilities and improve “just-in-time” responsiveness for Use digital transformation as a competitive less downtime, less waste and higher product quality. With advantage consistent, accurate metrics, MES shows which systems are In markets that require a high rate of responsiveness, MES operating under average and which are performing above average, in order to optimise the use of machinery and avoid data can help management to better understand the causes of bottlenecks. As a result, the production rates and profitability gains and losses to foresee developments, evaluate alternatives of existing plants can increase. Manufacturers gain a clear and act accordingly. Investment in ERP-MES integration is understanding of what is needed where, and when, making therefore only a technical investment at first glance. However, in the long run it’s actually a strategic move. the best use of materials and machinery at all times. With the digital landscape constantly evolving, and with manufacturers rushing to embrace big data, mobile Develop a business case technologies and the Internet of Things (IoT), the While the business benefits of ERP and MES solutions time is rife for these technologies to be integrated in a way are undisputed, it is necessary to develop a business case for that will improve business processes and provide integrating the systems. Firstly, manufacturing companies competitive advantage. that integrate ERP with MES obtain a holistic view of their In today’s fast-paced environment, competition and business processes. They benefit from production data for opportunity can arise at any moment. The key is for better operational control and as a result they can maximise manufacturers to be able to take advantage of this. Having the efficiency of their production. The “single voice” of integrated MES and ERP technology in place can make this the integrated systems delivers accurate data for production possible; providing data visibility and facilitating and management. This data visibility allows for collaborative business decisions. ☐

A&D India | Dec’15-Jan’16

NEWS | TECHNOLOGY

Secure remote maintenance component

Online data portal

B&R has introduced SiteManager remote maintenance component that makes diagnosing and maintaining machinery and equipment easier than ever. The remote maintenance solution utilises the latest IT and security standards and allows for significant savings with low investment costs. Service technicians can access machines from anywhere in the world. In addition, a certified SiteManager and encrypted VPN connection is established between the SiteManager on the machine and a gateway, which is usually located at the machine manufacturer's service centre. There, all access rights for up to 10,000 machines are stored. The SiteManager has integrated digital inputs and outputs. These could be used to connect a key switch, for example, that must be actuated to permit access for maintenance. An integrated firewall provides protection against unauthorised third-party access. In order to avoid conflicts with plant firewalls, communication to the internet is handled using firewall-compatible encrypted web protocols. The SiteManager can be connected via LAN, WLAN or mobile network.

Eplan has made available EPLAN Data Portal, a web service, built into the EPLAN Platform, which provides online access to valuable device data from numerous component manufacturers. Based on Excel technology, manufacturer data can now be made available more easily in the portal and at the push of a button. Manufacturers don't need any special know-how – the technology can also distinguish between the commercial and graphics data within the listed EPLAN Data Portal allocations and collate it all together intuitively. Over ten manufacturers of clamps, cables, connectors and sensors have already experienced the simplicity of this new integration. Over 100 manufacturers – many of them from the European, Asian and US-American markets will have integrated their manufacturer data into the portal. In 2015 alone, the company was able to gain 30 new manufacturers. One factor contributing to this extraordinary success is the new parts data wizard for manufacturers, among other things.

B&R Industrial Automation | Pune Email: shyam.padwal@br-automation.com | Tel: +91-020-4147-8999

Rittal India | Bengaluru Email: krishnappa.s@eplan.in | Tel: +91-80-3324 0700

Power plug connector

Retraction system

HUMMEL’s new power plug connector, M12 Power, is setting completely new standards with a transmission speed of 16A at a nominal voltage of 630V. As a result, miniaturisation in automation engineering has taken a major step forward. To date in the M12 sphere of automation engineering, only sensor connectors for signal transmission have been in use, but in the future power plugs will also be introduced. To date a lack of space and tight installation spaces have not permitted any plug connections, but with the M12 Power, power transmission will suddenly become a possibility. The M12 Power has 4 different encodings (S, T, K or L), M12 Power each available in a moulded or free to assemble version. The metallic cases are implemented with shieldable modifications and, therefore, are suitable for standard EMC. They fulfil the IP67 and IP 69K types of protections. For particular uses stainless steel varieties made from INOX AISI 316L are available.

igus has developed a lightweight and affordable triflex RSE retraction system for the automatic retraction of energy chains allowing further advances in robotics. Besides carrying energy, data and media cables, industrial robots nowadays also frequently carry supply hoses for rivets or screws. The new triflex RSE system prevents looping of the energy chain, allowing these materials to be safely supplied to the end of the robot arm. The triflex RSE triflex R series has been designed by the company specifically for highly dynamic industrial robotic applications and as a multi-axis energy chain, it can move in all directions in space. The universal triflex chains made from highperformance plastics work in even the most demanding industrial environments, are easy to install and can quickly be filled with cables from the outside. With its linear retraction of the e-chain, the triflex RSE retraction system offers an efficient and cost-effective solution that requires no curve, spring rods or deflecting rollers.

HUMMEL Connector Systems | New Delhi

igus (India) | Bengaluru

Email: d.singh@hummel.com | Tel: +91-11-4300 7521

Email: Harish@igus.in | Tel: +91-80-4912 7880

A&D India | Dec’15-Jan’16

TECHNOLOGY | NEWS

Remote PLC

Corrosion-proof titanium transmitters

Crouzet Automation offers em4, a perfect control system for specific markets and applications. A small PLC able to communicate as part of the Internet of Things, em4 is more than just an innovative, highem4 performance and easy-to-use nano-PLC. It constitutes a real growth platform for OEMs and integrators who are looking for an easy way to move their application into the digital era. It opens up a new ready-to-use infrastructure to them, plus an ecosystem of online tools and services, creating new added value for their customers. The entire range of em4 lab includes em4 soft—the most intuitive PLC software in the market; remote access platform—“em4 web” and “em4 app” to remotely control from a PC or a mobile device. With its exceptional performance, uniquely precise analog I/Os and easy connectivity, em4 is particularly adapted to segments such as water and waste treatment, access control, small industrial machines and embedded applications.

KELLER has offered titanium versions of its products for use in heavily corrosive media. This metal has a host of advantages for applications under very special conditions. Titanium is used as a replacement for steel in the aerospace industry, mainly for reasons of weight. In the medical devices sector, the fact that titanium is chemically & biologically neutral is especially important. Pressure transmitters & sensors This property is due to a permanent layer made of corrosion-proof titanium of oxide on the surface of the material. Thanks to its presence, components made of titanium will not corrode even in salt water or chlorinated water, unlike the high-grade steels that are normally used in the sector. This is why titanium is more frequently chosen for process measurement technology applications involving wastewater that may be contaminated with unknown corrosive substances. At Keller, titanium is increasingly used to manufacture high-quality transmitters that meet the most demanding stability requirements. Titanium housing makes it possible to carry out hydrostatic level measurements.

InnoVista Sensors | Bengaluru Email: india@cstsensors.com | Tel: +91-080-4113 2205

Inductive switches

Diagnostic system

Leuze electronic has expanded its line of inductive switches and, as a result, now has a well-matched line of sensors for its core industries, such as intralogistics, packaging systems, the wood products industry, robotics and tool manufacturing. Depending on the metal to be detected, the operating range of an inductive switch varies (reduction factor). The company now offers Sensor-based inductive switches universal sensors for metalindependent object detection (reduction factor 1) with large scanning ranges and a high switching point stability over the entire temperature range. Both the scanning ranges as well as the variety simplify the choice for the user. Now also available – complementing the cubic and miniature designs are versions with thread sizes from M8 to M30 in robust metal housing. For use in environments with higher requirements on the housing material, the company also offers cylindrical stainless steel designs. Moreover, sensors are now available in the wide AC/DC operating voltage range from 20 to 240 volt.

KELLER AG für Druckmesstechnik | Switzerland Email: info@keller-druck.com | Tel: +41-(0)52 235 25 25

Leine & Linde offers, since a couple of years back, the diagnostic system ADS online in order to determine the remaining lifetime of each installed encoder. New this year is the ADS upgrade unit, which can be bought as a separate module and installed at a later stage on an already running encoder in the 800 series. ADS online gives an overview of the service need of the encoders in the machine, so the maintenance can be planned well in time to avoid a standstill. In an ideal installation the 800 series encoders has a documented lifetime of over ten years. But it is not easy to predict the lifetime of ADS online upgrade unit each unique unit, as it is affected by a number of operational and environmental factors – for example the alignment and speed of the motor shaft as well as temperature and vibration. ADS online monitors a number of parameters that are fundamental for the encoder function.

Leuze electronic | Bengaluru

Leine & Linde | New Delhi

Email: info@leuze.in | Tel: +91-080-4121 9334

Email: s.mukherjee@leinelinde.in | Tel: +91-11-2617 2506

A&D India | Dec’15-Jan’16

NEWS | TECHNOLOGY

Confocal chromatic controller

Motor protection relay

Micro-Epsilon has extended the confocal chromatic controller range with the new confocalDT IFC2461. Enhanced, optical components, more powerful measurement characteristics, no external light source – in short, these are the three key attributes that accurately describe the new confocalDT IFC2461 confocal chromatic controller. The range of controllers for confocal sensors has been extended by a further model. Not only does confocalDT IFC2461 the confocalDT IFC2461 provide higher measuring rates up to 25kHz for faster measurements and control of dynamic processes, but also delivers stable measurement results. Compared with a Xenon light source, the integrated light source is more durable, resulting in reduced maintenance and purchase costs. An active exposure time regulation feature allows different surface types to be measured. Two different controller versions are available: the standard version and a multi-peak version. The latter provides six peaks, enabling one-sided thickness measurement of up to five layers. The IFC2461 is primarily used in the production of glass, bottles and displays.

Prok dv’s make motor protection relay PD-MMPR-303 uses the state-ofthe-art microcontroller-based measurement techniques for providing protection for motors up-to 85 HP. The comprehensive protection features of the relay make it ideal for motor protection. The heart of the relay is microcontroller based reliable hardware with special algorithms to calculate the tripping time. The relay continuously monitors the three phase currents to build the thermal replica of the motor. This thermal replica is used to protect the motor against thermal PD-MMPR-303 overloads. The microcontroller based motor protection relay does not require external current transformer (CT) for its operation. The three phase R, Y and B cables are made to pass through the CT hole, which is in the relay. The built-in CT’s takes care of stepping down of the currents to the required level. The stepped down three phase currents are continuously monitored by the relay to detect any abnormal behavior of the motor and to make tripping decision.

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

Prok Devices | Bengaluru Email: shivaram@prokdvs.com | Tel: +91-80-4348 7777

Safety devices

Pneumatic rotary units

Schmersal offers various safety devices for food and beverages industries, specially pertaining to machineries that must meet special requirements, which are primarily related to hygiene. The company offers the following features for such applications. UL and ECOLAB tested to suit hygiene requirement. This means not only the material of the switch, but also the connecting cables shall be suitable for foodstuff area. High degree of ingress protection – this shall be IP 67 as per IEC standards or IP 69K as DIN standards. Corrosion resistance material – this means no material shall be used which can lead to corrosion in contact with such harsh detergents and hot steam. The material shall Safety devices for food & be preferably stainless steel or food grade beverages industry thermos plastic. Smooth design – this is required so that the surfaces can be cleaned easily. Non-contact operating principle – this will ensure that there are no slots, pockets, opening on switches where foodstuff can accumulate and form bacterial contamination.

SCHUNK has introduced SRM high-performance rotary unit that sets a new benchmark in the area of pneumatic rotation. Even the outer features of the unit are different from other rotary modules on the market. The most striking features are the low interfering contour, the specially developed internal high-capacity dampers for maximum performance in a compact space and the large center bore for the feed-through of cables, hoses, workpieces or for the use of a camera. The SRM inner workings of the unit are just as impressive: the torque, mass moment of inertia and rotating time of the SRM significantly exceed predecessor, the SCHUNK SRU-plus. In the size 40 version, for example, the torque was increased by 25%. The increased mass moment of inertia is impressive. The compact SRM 16, for example, can rotate loads three times higher than the SRU-plus 20. The screw connection pattern of the new high-performance module is accordingly large and robust.

Schmersal India | Pune

SCHUNK Intec India | Bengaluru

Email: info-in@schmersal.com | Tel: +91-2138-614700

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

A&D India | Dec’15-Jan’16

EVENT | REPORT

Redefining Industrial Internet of Things… The recently held 12th edition of NIDays conference at Bengaluru showcased advanced technical innovations required to meet the real-world engineering challenges. These innovations are enabling today's engineering community by revolutionising the Industrial Internet of Things. A post-event report… National Instruments, the provider of systems that enable engineers and scientists to solve the world’s greatest engineering challenges, recently hosted its 12th edition of NIDays conference in Bengaluru, India. The daylong conference witnessed the launch of 10 new products & solutions including the latest version of the company’s flagship product – LabVIEW, with enhancement in speed and memory usage. It offered 18 technical sessions and tutorials with over 30 products and application demonstrations. Speakers and exhibitors from various industries including

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

automotive, telecom, semiconductor, smart machines, aerospace and defense, etc had joined the event to discuss and discover how to accelerate productivity for software-defined systems in test, measurement and control. At the event, visitors learnt about the latest hardware platforms and applications in the industry. Speaking on the significance of the event, Shelley Gretlein, Director—Software Product Marketing, National Instruments, said, “The primary goal of the event is networking ideas between user community, connecting engineers with other engineers and also hands-on

A&D India | Dec’15-Jan’16

REPORT | EVENT

demonstration of our latest products and technologies. We share technical best practices, architectures and codes for the users to perceive the technology and work with each other.”

Event highlights ‘Redefining Industrial Internet of Things (IIoT)’ was the main theme observed during the conference. Highlighting this, Robert Morton, Vice President—EMEIA, National Instruments, said, “We are excited about using the Internet of Things in a way that benefits the society at large, through connected devices and by incorporating the generated data into meaningful usages. We are investing heavily into technology that makes this process easier for scientists and engineers to not only rapidly prototype this, but also to deploy systems.” The conference witnessed the launch of a wide array of products that include highest bandwidth CompactDAQ chassis to date with new 14-slot USB 3.0 chassis, which can stream measurement data at over 225 MB/s; world’s first PXI chassis with PCI Express 3.0 technology that can stream with system bandwidth of up to 24 GB/s each direction; world’s first Intel Xeon-based 8-core PXI Express Embedded Controller that can turn 24 GB/s of data into valuable insight; the newest Single Board RIO controllers based on dual core ARM processor and ARTIX-7 FPGA technology, which runs the new security enhanced distribution of NI Linux Realtime, and NI Wireless Test System (WTS), which dramatically lowers the cost of high-volume wireless manufacturing test for the increasing number of things with a wireless connection and high-performance. Emphasising the usage of these products, Gretlein shared, “We provide the platform for different applications and solutions not restricted to specific field. Our Alliance Partner Network is a program of more than 900 independent, third-party companies including system integrators and value added resellers worldwide that provide engineers with complete solutions and high-quality products based on graphical system design.”

Engineering Impact Awards NI’s annual technical application contest – Engineering Impact Awards, enables NI customers to showcase innovative projects based on NI software and hardware. The contest this

A&D India | Dec’15-Jan’16

year had a total of 67 teams and the winners will get a chance to participate in the Global Engineering Impact Awards to be held in Austin during NIWeek. This year’s winners were ARAV Technologies for their vision-based pre-dispatch inspection from the SME category, Mahindra & Mahindra for their automated infotainment systems testing solution from the systems category, SRM University for their full duplex cognitive radio implementation using NI USRP RIO 2943 from the academics category and Digilogic Systems for their portable DRFM based radar echo simulation system from the alliance partner category.

NIYantra awards In order to foster the spirit of innovation in engineering students and expose them to the essence of experiential education through contest, NI hosted its annual Graphical System Design contest NIYantra. This contest helps undergraduate engineers to design their project ideas and convert them into working models using NI hardware and software over a period of six months. Emplacing this, Jayaram Pillai, Managing Director – IndRAA, National Instruments, said, “We are extremely excited and motivated to witness the breadth and sophistication of applications that 2015 NIYantra participants have created. Aiding in improving the education system and providing hands-on experience to students and engineers is a reward for the years of our efforts.” NIYantra 2015 witnessed abstract submissions from 204 teams spread across engineering colleges in India. The winners were from Veermata Jijabai Technological Institute, Mumbai, for their project development of a scavenger bot, which is an autonomous street cleaner and Ajay Kumar Garg Engineering College, NCR, for the development of a smart bin, which is aimed at being a solution to Swachh Bharat. The runners up were from Kumaraguru College of Technology, Coimbatore, for the development of a tennis tutor. The conference also included a panel discussion on ‘Make in India’ program from industry thought leaders, analysts and influencers who shared their insights on how the ecosystem that exists in the country enables this initiative. The event was attended by over 500 engineers, academicians and researchers who witnessed the launch of a wide range of products that are designed to revolutionise the Industrial Internet of Things (IIoT). ☐

EVENT | REPORT

Taking manufacturing a notch higher The recently concluded CII Industrial Automation Summit witnessed the presence of many experts and leading companies from the manufacturing sector across the country. The event not only highlighted the role of automation in the manufacturing industry, but also discussed essential elements for successful manufacturing for the next decade. A post-event report… Attended by over 250 corporates across various industry verticals, the CII Industrial Automation Summit showcased how industrial automation will play an important role for efficient planning of industrial growth in India. Addressing the summit, Rajiv Gandhi, Vice Chairman, CII Haryana State Council & Executive Director – Plants, Maruti Suzuki India, said that with India’s emergence as a ‘global manufacturing hub’, economic reforms and various policy initiatives have made India one of the fastest-growing

economies in the world today. “The manufacturing sector has played a significant role in the growth of the Indian economy, contributing nearly 15% to the country’s GDP over the last few years,” he averred.

Highlights The summit witnessed speakers from various organisations namely Omron Automation, ATS Conveyors India, Stratasys

A&D India | Dec’15-Jan’16

REPORT | EVENT

India, SCHUNK Intec India, Precision Automation & Robotics India (Pari), Fanuc India, Maini Precision Products, Siemens Industry Software India, Kansai Nerolac Paints and Robert Bosch Engineering and Business Solutions. Speaking on the industrial robots, Gandhi said, “The growing demand for industrial robots has attracted leading global manufacturers of robots to set up facilities in India to serve the Indian market.” In a complementing response to the Prime Minister’s vision of ‘Make in India’, he shared Suzuki’s statement, “If you want to make in India, it should be ‘Quality in India’.” He further said that speed, quality, service, flexibility and global focus are identified as the essential elements for successful manufacturing for the next decade and that the manufacturers are measured by their ability to respond quickly to sudden, often unpredictable changes in customer needs and wants. He also mentioned that the ease of maintenance & running cost has to be a major factor in the design of automations to ensure that the usage is sustainable. “With multiple industry initiatives as well as opportunities arising out of the fast growing manufacturing sector, automation market participants with their global expertise and vast resources have the potential to transform current Indian manufacturing practices and bring these at par with global standards. This will enable manufacturers to attain global manufacturing competitiveness even as they capitalise on India’s inherent strengths,” he added.

Moving ahead, Ashwani Dubey, Managing Director & CEO, Comau India, threw light upon the key issues in the sector pertaining to the very high attrition rates and lack of competent and skilled manpower. He also focused on the measuring tool, i.e. Intelligent Quotient to analyse the demographic dividend. His suggestions to the industry were to define competency and have a structured program to bridge the competency gap with skill development, quality and Intelligent Quotient. While focusing on Industry 4.0, Ramesh C Jain, Past Chairman, CII Haryana State Council & Former Group Vice Chairman, Eicher Group, stressed on Industry 4.0 or the fourth industrial revolution, which involves data exchange, cyber fiscal norms and Internet of Things. He said, “The key part of a manufacturing strategy is the definition of whether products will continue to be produced at the traditional manufacturing sites, or if the cost advantages make it beneficial to set up manufacturing in geographic areas with a lower cost base. Automation has had a notable impact in a wide range of highly visible industries beyond manufacturing. Telecom sector is one such example. Even medical processes are carried out at much greater speed and accuracy by automated systems.” All these factors clearly indicate the need for creating focused platform for deliberations on the issues in various sectors including the users & suppliers. For industrial automation to grow, sustainability plays a key role. Chandan Chowdhury, Managing Director, Dassault Systems, in his presentation stressed upon the same. He Role of industrial automation explained that collaboration, integration of the process of Speaking at the session, Makoto Yokoyama, Director – production with green and sustainability is the key criteria Factory Automation & Industrial Division, Mitsubishi Electric for robust growth in industrial automation. He also shared India, said, “India is one of the most promising destinations for various projects that his company has been undertaking in investment today.” He also added that the Government too the past few years and how people are now talking about seems to be more passionate towards industrial growth with the transformation enabled by technology. “In the automobile recent ‘Make in India’ campaign. Industrial automation will play sector, the consumer wants smart, safe and connected cars. an important role for efficient planning of industrial growth in As the cost of making a defect in the physical world is very India. On this, Yokoyama touched upon the point that his high and companies can actually create a digital twin before company is running several skill development programs as an the final product, companies should launch the product in outcome of the industrial strategy, to make it cost effective for 3D,” he concluded. ☐ Courtesy : CII the customers through 6 technical centres in India.

A&D India | Dec’15-Jan’16

EVENT | PREVIEW

13-17 FEBRUARY 2016

Bangalore International Exhibition Centre Bengaluru, India

MAKE IN INDIA »

WHO SHOULD ATTEND ELECRAMA

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The MAKE IN INDIA campaign by the Government of India includes major new initiatives designed to facilitate investment, foster innovation, protect intellectual property and build best in class manufacturing infrastucture.

Exploring electricity ecosystem Organised by IEEMA, the 12th edition of ELECRAMA will be held on February 13-17, 2016 at Bengaluru. The event will witness product previews, technology presentations, concepts and pure business interactions. A post-event report… ELECRAMA has evolved along the contours of the sectoral landscape to reflect the dynamic changes in the ecosystem. Today, the summit is poised to take a leadership position of a truly global platform for technology, product and knowledge-sharing amongst all key stakeholders of the electricity ecosystem. The 12th edition of ELECRAMA will take place on February 13-17, 2016 at Bengaluru, India. Speaking on the upcoming event, Aaditya Dhoot, Chairman, ELECRAMA 2016, said, “The Government of India has been gracious to extend its complete support to make ELECRAMA 2016 a truly superlative event. It is a great responsibility on us to deliver only but the best, which can be of the stature of a world electricity forum. We believe that together we can build a great confluence that brings together the world of electricity under one roof.”

Highlights The five-day event will witness the largest congregation of power sector ecosystem in the geography. It will display widest choice of product and technology across the spectrum on display with over 221 transformers, 321 cables & conductors, 202 control & switchgear, 113 instruments & instrumentation amongst others. There will be a presence of global majors to small scale manufacturers—the entire value chain to strengthen supply chain, logistics & vendor capability assessment. Also, there will be a preview of new and upcoming product & technology, new specs & standards, while exploring investment opportunities & closer view of US$ 250 billion Indian power sector opportunity. In addition, knowledge-sharing & career advancement sessions will be

A&D India | Dec’15-Jan’16

PREVIEW | EVENT

“It is a great responsibility on us to deliver only but the best, which can be of the stature of a world electricity forum” Aaditya Dhoot, Chairman, ELECRAMA 2016

organised through seminars, symposia and conferences. The summit will witness four special pavilions for renewables, railways & defense, energies of tomorrow and 125 years of electricity. While the renewable pavilion will have largest display of electrical equipment & technology for evacuation and integration of the renewable power into consumption systems and connecting with the grid, the energies of tomorrow will have a focus of all that’s happening on the pioneering research all around the world that decides the energies of tomorrow. Also on display would be a smart village demo installation. The pavilion for 125 years of electricity will have a visual treat of a journey tracing down the path of history, tracing the evolution of electricity through the ages to the present times.

support of CIGRE (The council on large electric systems) is an international non-profit association for promoting collaboration with experts from all around the world by sharing knowledge & joining forces to improve electric power systems of today and tomorrow. Innovation Day: The event to be held on February 17, foresees the future of electricity at the ENGINEER INFINITETM pavilion from the eyes of young innovators from the leading technical educational institutions of India. This is an initiative on the lines of a national level engineering talent contest and the entries are selected by an eminent panel of technologists for display & awards at ELECRAMA.

Co-located events

Concurrent events

The summit will orgnanise two co-located events: World Utility Summit: ELECRAMA in collaboration with Reverse Buyer Seller Meet: The event, to be held from IEEE PES as lead partner and in association with global February 14-16, 2016, offers unparalleled market access partners, has conceived and developed a thought leadership opportunities for small & medium manufacturers who are platform for global utilities to share knowledge, experience, seeking to reach out to buyers in key markets. This is an best practices, on ground issues and management of change initiative supported by the Ministry of Commerce & amongst themselves. The platform would also set an agenda Industry, Department of Commerce, Government of India. for the future, acting as a key enabler for the eco-system to CEO Summit: The event, to be held on February 13, 2016, develop optimal solutions, technology & products. hosts a business leader’s summit, which brings together the International T&D Conclave: This will be the third edition captains of the Indian electrical industry to discuss and of the IEEMA International T&D Conclave. It is a platform deliberate on challenges in the power sector and the for business partnership between the T&D industry and its direction to shape the contours of the future power networks. stakeholders across the value chain. It brings together The last edition was attended by 200+ CXO level executives renowned technologists, global and Indian manufacturing of the Indian electrical equipment industry. companies with R&D operations, component suppliers and Network 2 Networth: The event to be held on February 16, their customers namely the utilities, EPC contractors and 2016, will be an exclusive interaction platform for finance consultants. fraternity to interface with industry to explore investment From its moderate beginnings in 1990, ELECRAMA has opportunities in the electrical industry, featuring some of grown from strength to strength and over the last 25 years it prominent names in finance sector. has been the largest standalone Electrical T&D Exhibition CIGRE Tutorials: The event to be held on February 15-16, in the world. ☐ 2016, will include technically-inclined participants with the Courtesy: IEEMA

A&D India | Dec’15-Jan’16

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 - Feb/Mar 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

» Pharma & Packaging As per recent reports, the Indian pharmaceutical market has already crossed the 100,000 crore mark. With this in the background, the next edition will feature the latest automation case studies and technologies catering to the emerging requirements of this growing industry. The next issue will also focus the latest technologies in packaging automation, while discussing latest innovations and R&D in this domain.

» Drives & Components With a consistent programming structure and common operator interface, there is an ease of programming and configuration, and reduce set-up time, training, and operation. Today’s drives offer a broad range of control modes, features, options, and packaging, as well as global voltages and many power ratings. The next issue will feature latest drives & components with details on the current developments in this area.

» Software & Engg Tools Software & engineering tools automate project management activities; manage all work products produced throughout the process, and assist engineers in their analysis, design, coding and testing work. The next issue will see how these tools can provide for better productivity and efficiency.

COMPANY INDEX

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Overseas Partner Ringier Trade Media Ltd China, Taiwan & South-East Asia Tel: +852 2369 - 8788 mchhay@ringier.com.hk

Hannover Messe 2016, the world’s leading show for industrial technology will take place on April 25-29, 2016. The five-day exhibition will showcase innovations and groundbreaking solutions in sectors like industrial automation and IT, energy and environmental technology, industrial supply, production engineering and services, as well as research and development.

Name . . . . . . . . . . . . . . . . . . . . . . . . . Page HBC Radiomatic India . . . . . . . . . . . . . . . . . 19 HMS Industrial Networks . . . . . . . . . . . . 16, 41 Hummel Connector Systems . Back Cover, 8, 71 ICP Das . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Ifm electronic India . . . . . . . . . . . . . . . . . . . 53 igus India . . . . . . . . . . . . . . . . . . . . . . . 2, 71 IMTMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 InnoVista Sensors . . . . . . . . . . . . . . . . . 8, 72 ISA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Janatics . . . . . . . . . . . . . . . . . . . . . . . . . . 15 JK Fenner India . . . . . . . . . . . . . . . . . . . . . 11 Keller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Kubler Automation . . . . . . . . . . . . . . . . . . . 57 Lapp India . . . . . . . . . . . . . . . . . . . . . . . . 10 Leine & Linde . . . . . . . . . . . . . . . . . . . .21,72 Leuze Electronic . . . . . . . . . . . . . . . . . 63, 72 Micro-Epsilon . . . . . . . . . . . . . . . . . . . . 5, 73 Mifa Systems . . . . . . . . . . . . . . . . . . . . . . 67 Moxa . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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HANNOVER MESSE 2016

Name . . . . . . . . . . . . . . . . . . . . . . . . . Page Altair Engineering India . . . Back Inside Cover, 26 Ansys . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 ARC Advisory Group . . . . . . . . . . . . . . . . . 36 B&R Industrial Automation . . .Cover, 6, 7, 8, 71 Burkert Fluid Control Systems . . . . . . . . . . . 42 CGN Associates . . . . . . . . . . . . . . . . . . . . . 48 CII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Cognex . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Contrinex Automation . . . . . . . . . . . . . . . . . 13 CST Sensors . . . . . . . . . . . . . . . . . . . . . . . 23 Delcam . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Delta India Electronics . . . . . . . . . . . . . . . . . 3 Electronic Relays India . . . . . . . . . . . . . . . . 37 Epicor . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 EtherCAT Technology Group : . . . . . . . . . . . . 8 Festo Controls . . . . . . . . . . . . . . . . . . . . . . . 4 Ford Motor Company . . . . . . . . . . . . . . . . . 24 Hannover Messe . . . . . . . . . . . . . . . . . . . . 45 Harting . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Advertising Sales Sagar Tamhane (Regional Head - North & East) Contact: +91 9820692293 sagar.tamhane@publish-industry.net

Name . . . . . . . . . . . . . . . . . . . . . . . . . Page Murrelektronik India . . . . . . . . . . . . . . . . . . 29 National Instruments . . . . . . . . . . . . . . . 10, 74 Nord Drivesystems . . . . . . . . . . . . . . . . . . . 12 Omron Automation . . . . . . . . . . . . . . . . . 9, 12 Phoenix Contact . . . . . . . . . . . . . . . . . . . . 52 Pilz India . . . . . . . . . . . . . . . . . . . . . . . 61, 62 Prok Devices . . . . . . . . . . . . . . . . . . . . . . . 73 Renu Electronics . . . . . . . . . . . . . . . . . . . . 55 Rittal India . . . . . . . . . . . . . . . . . . . . . . . . . 71 Schmersal . . . . . . . . . . . . . . . . . . . . . . . . 73 Schunk Intec India . . . . . . Front Inside Cover, 73 Sick India . . . . . . . . . . . . . . . . . . . . . . . . . 31 Siemens . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Siemens PLM . . . . . . . . . . . . . . . . . . . 26, 32 SMC Pneumatics . . . . . . . . . . . . . . . . . . . . 39 TCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Titan Industries . . . . . . . . . . . . . . . . . . . . . 47 Vega India . . . . . . . . . . . . . . . . . . . . . . . . 51

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