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VOL 13 | JUNE 2022 | `100
EFFICIENT MANUFACTURING
Rise of the
ROBOTS
Also available in China, Taiwan, Singapore, Malaysia, Thailand & Hong Kong
Material Handling P. 22
Industrial Automation P. 28
EM - Interview
Mahesh Wagle,
Co-founder & Director,
Additive Manufacturing P. 34
Industrial Safety P. 40
Cybernetik (p. 20)
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VOL 10 | OCT 2019 | ` 100
www.industr.com/en
EFFICIENT MANUFACTURING
CUSTOMER SATISFACTION
With reliable manufacturing processes
Also available in China, Taiwan, Singapore, Malaysia, Thailand & Hong Kong
EM - Interview
FOCUS Cutting Tools P. 38
Petr Novotny,
Managing Director SPECIAL FEATURE Industrial Maintenance P. 54
Scania Commercial
Vehicles India (p. 30)
7410009435/36
E D I TO R I A L
Man to Machine: The
remarkable metamorphosis
Industry 4.0 may seem like a jargon to many but the way the
manufacturing industry is transforming is a proof enough that we
are heading towards technology in lighting speed. Manufacturers are
exploring and nurturing new ideas to make their facilities, processes,
products and performance more efficient. The industry is already
“Embracing new embracing new age techniques like Additive Manufacturing and 3D
Printing to be a part of the Industry 4.0 revolution.
technologies is the best With this backdrop, this issue of the magazine has explored
way to secure our future” interesting aspects of manufacturing like robotics & industrial
automation, industrial safety and Additive Manufacturing with
regards to the technologies driving them. Applications and R&D in
robotics is driving industrial automation and the Cover Story of this
issue highlights and discusses every side of it. Manufacturers are also
changing conventional industrial safety systems with automated ones
to make manufacturing more efficient and performance-oriented.
With technology driving the core manufacturing areas, other
related aspects like industrial maintenance, material handling, etc
cannot be forgotten. The articles in this issue will also give you
advancement updates in these areas. The industry experts that
bring all of this together are another important part of the technical
transformation the industry is going through. The articles and
interviews in this issue also focus on their expectations and fears
when it comes to applying new technologies to manufacturing.
Stay tuned for our upcoming issue as we will uncover the how
manufacturers are exploring 5G to make manufacturing more
efficient. Let’s get reading.
Vidisha Sonone
Assistant Editor
vidisha.sonone@publish-industry.net
EDITORIAL ADVISORY BOARD
Raghavendra Rao Dr Ravi M Damodaran Ramesh T K Vineet Seth Dr Wilfried Aulbur
CEO, Chief Technology Officer, MD & CEO, Managing Director, Managing Partner,
Kaizen Hansei LLP Greaves Cotton Micromatic Machine Tools Mastercam India Roland Berger Pvt Ltd
Dr N Ravichandran Dr P N Rao Dr K Subramanian Sonali Kulkarni Satish Godbole
Former Executive Director, Professor of Manufacturing President, STIMS Institute, President & CEO, Vice President,
Lucas-TVS Technology, Department of USA Fanuc India Motion Control Div,
Chief Mentor, Technology, University of Training Advisor, IMTMA Siemens Ltd
UCAL Fuel Systems Northern Iowa, USA
Overseas Partner:
China, Taiwan, Hong Kong & South-East Asia
EM | Jun 2022 5
CONTENTS 22
MATERIAL HANDLING
Revolutionising material
handling systems
MARKET
10 NEWS
12 “ Technology has become easy,
efficient & affordable”
Interview with Deepak Razdan,
Director, JFY Business in India and JFY International
(Member of the TRUMPF Group)
13 “ The society needs to share the
responsibility to reduce climate change”
Interview with Jonathan Carrier,
Co-founder, Zip Charge
COVER STORY
14 Rise of the robots
The Cover Story brings to light the promising
robotics industry and the future it holds
MANAGEMENT
INTERVIEW
20 “ Robots will become modular with software
14
COVER STORY
being their central component” Rise of the robots
Mahesh Wagle,
Co-founder & Director, Cybernetik
FOCUS
MATERIAL HANDLING
22 Revolutionising material handling systems
The article highlights the company’s future
plans and industry predictions regarding material
32
handling systems
TECHNOLOGY RESOURCE MANAGEMENT
ERP and improved business efficiency
INDUSTRIAL MAINTENANCE
24 Ensuring quality through optimal
cleaning processes
The article sheds light on the significance of
the right cleaning processes
INDUSTRIAL AUTOMATION
28 Control cabinet-free automation solution-
an innovative approach
The article explores innovation in control
cabinets and its advantages
6 EM | Jun 2022
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its advantages and upcoming trends and
advancements technology, market and management
Cover image courtesy: shutterstock
aspects of manufacturing
TESTS & MEASUREMENTS
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Columns
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EM | Jun 2022 7
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GUEST EDITORIAL
COMMENTS & COMMENTARY
Dr Neeraj Bhanot,
SCIENTIST AND ASSISTANT PROFESSOR,
CSIR NATIONAL PHYSICAL LABORATORY,
MINISTRY OF SCIENCE AND TECHNOLOGY,
GOVERNMENT OF INDIA, NEW DELHI
Negotiations regarding global climate metal-cutting tools and hazardous fluids.
change have emphasised on the concept Further, microorganisms used as cutting
of sustainable manufacturing for the
“EXPLORING BIOMACHINING tools are self-cultured and self-renewable,
conclusive growth for all. Globally, the aim PROSPECTS IN SUSTAINABLE thus making this a sustainable, cost-effective
of sustainable manufacturing is to increase MANUFACTURING CONTEXT” and energy-efficient green manufacturing
the efficiency of the manufacturing processes process. In this context, a study was conducted
by employing green manufacturing practices in collaboration with Tanveer Singh Jhajj
(GMPs) having negligible impact on breeding ground for pathogens that are (PG student at GNDEC, Ludhiana) & Dr.
environment and to utilise GMPs to have dangerous to man, machine and material. Amanpreet Kaur Sodhi (faculty at GNDEC,
zero production defects, thus leading to This issue not only has an effect on health Ludhiana) to identify the potential of fungus
both economic and environmental benefits. but creates concerns about safety too. It also i.e. Aspergillus niger by considering the
Manufacturing industries dealing with metal affects in terms of macroeconomics because physiochemical parameters such as shaking
machining are important from a socio- a heavy cost is associated with their disposal rate, pH, microbial concentration and
economic point of view. Among available which in turn adds to the production cost. temperature for bio-machining of EN 19
metal machining operations, the turning Further, the high density of electric energy alloy steel due to its high wearing capacity
process is widely favoured and has a lion’s consumed while doing metal machining with applications in strategic places like
share in cutting and shaping of metal. is also an indirect environmental concern, aircrafts, tanks, axle of army trucks, etc.
Although technical advancement in adding up to the production cost. For machining of EN-19 alloy steel, dry
metal machining makes the turning process To tackle health and environmental machining has been considered more
highly efficient, nevertheless, some social and risks along with retaining efficiency-based favourable over wet machining.
environmental aspects are associated with it competitiveness, various ecological-friendly, However, the tooling cost of dry
that continue to pose serious concern and sustainable, and green manufacturing machining is higher, which is not good from
probably have negative consequences on the technologies and strategies are evolving an economic point of view. Simply put, the
surroundings. The metal machining process with a vision of incorporating sustainable machining of this material is an important
generates a lot of waste in the form of by- manufacturing approaches. Bio-machining consideration & efforts have thus been made
products in solid, liquid and gaseous forms is one amongst such green manufacturing to explore the potential of microorganism
which pose a threat to our environment as techniques in which a microorganism is in a sustainable way. The study, however,
well. Even though cutting fluids enhance used as a cutting tool for the purpose of metal reflected continuous weight reduction of
the metal removal operation and ensure removal from a metallic work piece. This is the work piece, proving the machining effect
surface quality, they have a harmful impact a carbon-neutral process leading to decrease on alloy steel produced by Aspergillus niger
on human health and environment. in carbon footprint. The bio-machining and highlighted the need for optimisation
Cutting fluids, when mixed with metal process depends on the enzymatic activity of physiochemical parameters in order to
chips, become sludge that is hard to separate of microorganisms to machine metal surface further scale up the process for precision
and the accumulation of which becomes a which can replace the use of conventional machining applications in the near future.
8 EM | Jun 20226
MARKET NEWS
HIGHLIGHTS
MoUs, events, collaboration: a lot has happened in the manufacturing sector in this past
month. Among other things, Dassault Systèmes’ 3DEXPERIENCE WORKS helps WAE
while Southco Inc from US acquired Darshana Industries from Pune. Also, Vitesco
Technologies celebrated second anniversary of its Pune facility. Similarly, Meghmani
Finechem signed an agreement with Renew Green Energy Solutions and Jupiter Wagons
launched Jupiter Electric Mobility. LAMIERA 2022 ended with a positive outcome.
1 2 3
4 5 6
10 EM | Jun 2022NEWS MARKET
Dassault Systèmes’ Southco Inc acquired Vitesco Technologies aims
3DEXPERIENCE Works Darshana Industries to achieve 100% carbon
helps WAE to reduce Southco Inc recently announced its procurement
of Darshana Industries, Pune. This acquisition
neutral production by 2030
customer plastic usage positions Southco as a leading access hardware
Vitesco Technologies recently celebrated
the second anniversary of its Pune facility. Dr
Dassault Systèmes recently announced that they manufacturer and supplier in this vital region,
Hans-Jürgen Braun, Senior VP – Operations,
have strengthened their six year partnership with which is poised for strong business growth.
Vitesco Technologies, visited the facility to
WAE for bringing innovative products to the market. Read more: https://bit.ly/3NuHBrv commemorate the occasion.
Read more: https://bit.ly/3mpMarh
Read more: https://bit.ly/3zngxX0
1 2 3
Meghmani Finechem Jupiter Wagons forays Over 19,000 visits
forays into green energy into EV segment registered at LAMIERA
Meghmani Finechem (MFL) recently announced
that it has entered into an agreement with
Jupiter Wagons (JWL) recently entered the 2022
electric mobility market with the launch of
Promoted by UCIMU-SISTEMI PER PRODURRE
Renew Green Energy Solutions for setting up a ‘Jupiter Electric Mobility’ (JEM) focusing on
and organised by CEU-CENTRO ESPOSIZIONI
wind-solar hybrid power project. commercial EV vehicles. The company has
UCIMU, LAMIERA took place at FieraMilano,
Read more: https://bit.ly/3aHZ9lO formed a joint venture with EA GreenPower.
Italy from May 18 - 21 2022, ended with a
Read more: https://bit.ly/3tiN3Ww positive outcome.
Read more: https://bit.ly/3O2MKY0
4 5 6 Advt
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EM | Jun 2022 11MARKET INTERVIEW
“Technology has
become easy,
efficient & affordable”
...says Deepak Razdan, Director, JFY Business in India
and JFY International (Member of the TRUMPF Group), in this
interview with Vidisha Sonone. He discusses new technologies
in the metal forming industry and the upcoming trends in the
Indian manufacturing industry. Excerpts...
What scope does automation Indian metal forming industry has been largely dependent on the conventional methods & machines
have in the metal forming and to start with I would suggest something like a pick and place kind of automation in the critical
industry? Any specific technology areas. In the sheet metal industry, we will see a surge in this area which also means that machine tool
you would like to point out? makers will have to be creative to get affordable solutions to customers. Specifically talking about this
industry, automating loading, unloading, and sorting work could be a good start.
Which part of the While metal cutting has seen many advancements in past decades, metal forming will see huge
manufacturing industry do growth in the coming years. In my opinion, a lot of traditional companies will invest in modern
you think needs the most machine tools that can help them automate their process making it more sustainable and efficient.
advancements? Also, unlike the metal cutting industry metal forming is not largely dependent on automotive or
any one industry. Because sheet metal has very diverse applications, we can expect lots of
technological advancements to take place in the industry in the coming days.
What are the new advancements Metal forming or the metal fabrication industry as we usually refer to consists of many processes such as
in metal forming technologies cutting, bending, punching, welding, marking, etc and all the processes need specific technologies to
such as laser processing, carry out the operation. For last few years, I have seen these machines have become highly efficient with
bending, punching, and the integration of IoT and other connected technologies. However, if I must point out one technology that
welding, among others? has changed dramatically in the last decade then it is fibre lasers. Technology has become easy, efficient,
and affordable. Also, limitations on cutting thickness and materials we can cut are going away. I expect
this to continue, and we will see much wider use of fibre lasers across the industries and applications.
What changes do you think the The Indian manufacturing industry is catching up fast with the global markets and in many cases
Indian manufacturing industry at par with global giants. However, there are certain areas of improvement that the industry
needs to go through to keep up needs to work on collectively, such as, technology adoption. Indian MSMEs need to speed up
with the new trends? their technology adoption to be able to compete with global companies. Though there have
been considerable improvements in recent years still we have to go a long way. Secondly, skill
development. Finding skilled manpower in the core manufacturing industry is a daunting task for any
company. Industry-academia partnership should be encouraged, and companies need to join hands
to overcome this challenge. Others I would say capacity expansion and business-friendly policies.
You will be participating in We are showcasing our latest fiber laser cutting machine BFC along with TPR8 in bending. Both
IMTEX, in June 2022, what are these machines are build considering the expectation of the Indian customers and we hope to
your expectations from the event? attract many potential customers.
12 EM | Jun 2022S TA R T- U P INTERVIEW
“The society needs to
share the responsibility to
reduce climate change”
…says Jonathan Carrier, Co-founder, Zip Charge to Huned
Contractor.With plans to market the product in India too,
Carrier talks about the product and how the company plans to
distribute it. Excerpts…
Could you elaborate on We are delighted to have found two strategic partners in ICEE Managed Services and Graphite. Together
the ‘Go’ hub concept? we will deliver the Go hub, a revolution in public charging provision, providing a community-based solution
that can be installed anywhere, at a much lower cost and at a much faster rate, while enabling any parking
space to be a charging spot. Both the companies have a cumulative experience of eight years in engineering,
manufacturing and installing public infrastructure, including Brompton Bike Hire docks throughout the United
Kingdom. The ability to roll out EV charging infrastructure at speed is essential to allow national and local
governments to deploy it at a faster rate where it is needed the most to support mass EV adoption.
What triggered the idea The company’s co-founder Richie Sibal first came up with the idea for a portable EV charger in early
for a portable charger? 2020. His brother is an EV driver and lives in Twickenham, London without off-street parking. Richie
saw the need to develop a portable charging solution that could help his brother charge his electric
vehicle. I joined later in 2020, and working together we developed the technical and product concept
into the Zip Charge ‘Go’. We went through a detailed concept phase over six months to understand
the market, identify the customer pain points and iterate our solution to arrive at the Go we launched.
What kind of research During our concept research we discovered that the inability to access reliable, convenient and affordable
and development did charging at home was holding back widespread EV adoption. It’s a common problem that is amplified around
this entail? the world. Working together we pooled our expertise in electronic systems, vehicle electrification, product
development & commercial understanding from decades of experience working for a wide range of automotive
manufacturers and created the Zip Charge Go. In doing so, we believe Zip Charge is a game-changer in EV
charging and will help accelerate the transition towards electric mobility so that the world can become a cleaner
and more sustainable place for generations to come. We are driven in our mission to build a company that
helps society transition to net zero and share a responsibility to reduce climate change. Our commitment is to
create technology that has a positive impact – for customers, society, and the way everyone charges EVs.
When will the product We will be announcing more detailed specifications later in 2022, alongside country roll-out, pricing and
be delivered in the ordering information. First deliveries will be in Q2 2023 starting with the UK, Europe and then rolling out
Indian market? markets after that. We can’t confirm a release date for India currently.
What are the challenges There have been challenges but being in the automotive industry we also struggled to get hold of
that you have overcome in chips and connectors. Supply chain issues have had a significant impact on the delivery of our
developing the product? prototype units due to the unavailability of components and very long lead times.
EM | Jun 2022 13R O B OT I C S TECHNOLOGY
Rise of the robots
I m ag es co u r tes y : shutterstock
With India’s automotive, electronics and white goods sectors witnessing
phenomenal growth in recent years, the demand for industrial robots is also
soaring. Both international and domestic automotive manufacturers use robots
these days for a range of activities on the shop floor, especially repetitive and
monotonous tasks. Increasingly, other industries are following suit. The Cover
Story brings to light the promising robotics industry and the future it holds.
14 EM | Jun 2022TECHNOLOGY R O B OT I C S
Globally, the industrial robotics
market is estimated to grow to
about $81.4 billion by 2028
Robots and art? Why not? ABB Robotics has collaborated with using a start-up’s robot. Power generation at the Tata plant had
two world-renowned artists, eight-year-old Indian child prodigy come to a halt after a hammer fell into a high-pressure steam
Advait Kolarkar and Dubai-based digital design collective Illusorr, pipe. A start-up was called to pull out the hammer using one of
to create the world’s first robot-painted art car. ABB’s award- its robots. The operation cost the plant around ₹16 lakhs. The
winning PixelPaint technology has, without human intervention, expenditure would have spiked to the tune of ₹5 crore had the
perfectly recreated Advait’s swirling, monochromatic design as engineers at the plant decided to retrieve the hammer themselves.
well as Illusorr’s tri-colour geometrical patterns. Equipped with The start-up, Gridbots Technologies, was set up by
1,000 nozzles in printer head, ABB’s IRB 5,500 paint robots were entrepreneurs Pulkit Gaur and Govind Godara. The duo made
able to complete highly complex artworks in less than 30 minutes. modifications to the robot at their office in Ahmedabad and spent
The PixelPaint technology demonstrates unprecedented a whole day rehearsing their plan of action, before heading out to
precision and speed, capturing intricate, elaborate detail that Mundra. “As soon as we reached there, we realised a serious
would be impossible to achieve by hand. Sami Atiya, President – modification was required in the robot’s gripper to pull out the
Robotics and Discrete Automation Business area, ABB, said, hammer from a depth of 15 metres. What made work difficult was
“ABB’s PixelPaint technology is more than an evolution – it is a the 90 degree curvature of the pipeline. However, we could locate
revolution. It’s a shining example of how robotic automation and the hammer within 30 minutes of commencing the operation,”
our RobotStudio® software can not only pave the way for more Gaur had then said. Of course robots have come a long way since
sustainable manufacturing but can also perfectly replicate delicate then and the latest developments in this field would be on show at
pieces of art that celebrate the originality and beauty of the human Automatica 2022 to be held in Munich from June 21-24. One of
spirit. At a time when consumers want more customised products, the leading companies in this sector, KUKA Robotics would be
PixelPaint is a game-changer and allows any design to be replicated displaying a wide range from new robots to digital twins.
in a manner that is both sustainable and affordable.” “This year, Automatica is the driving force for industrial
ABB’s ground-breaking PixelPaint technology reimagines the production after the crisis triggered by the pandemic,” said
paint application process and reflects the growing demand for Wilfried Eberhardt, Chief Marketing Officer, KUKA Robotics.
sustainable personalisation in automotive industry, particularly in “Automation, robotics and digitisation are the growth drivers of
exterior paint. Multi-coloured car painting has traditionally been our time – and KUKA Robotics is an ideal partner for their
a laborious and costly process involving multiple stages of masking implementation,” he added. The trade fair audience will get
& unmasking, but ABB’s technology allows for a detailed, colourful, exclusive insights into the new operating system iiQKA.OS and
and exact replication of any design. Carefully controlled, the paint the digital iiQKA Ecosystem. The new operating system is the
can quickly be applied in a single application. This breakthrough future way to work with KUKA robots: intuitive, fast and
in the automation of the paint process opens the door to specialised powerful. The Cobot LBR iisy is the first of its kind to run on the
and personalised designs to the automotive market. basis of the new operating system and can thus be configured and
programmed within minutes. The automation specialist is thus
Industrial applications also expanding its portfolio in the field of lightweight robotics.
“With the complete system of hardware and software, KUKA
While the use of robots in creating artistic expressions may Robotics is lowering the entry threshold for robotics, especially
be new, their application in industry is of course widely for smaller and medium-sized companies – and opening up great
acknowledged. One may recall here an incident from the year automation potential, even for beginners. Intelligent connected
2017 when a power plant in Gujarat saved millions of rupees production is essential for fast-growing markets. KUKA Robotics
EM | Jun 2022 15R O B OT I C S TECHNOLOGY
Creating the world’s first
robot-painted art car
meets the enormous demand for automation with suitable automating key processes, such as bag-packing and palletising,
products and its own portfolios for sectors such as the electronics to produce over 4,000 logs an hour, far more than earlier. They
and consumer goods industries, as well as automation solutions also work with players across segments in India, such as BASF,
for electro-mobility. At Automatica, interested visitors can get to Sanofi, Bayer, and automobile and automotive component
know the new small robot series, such as the ultra-compact KR leaders such as Bajaj Auto and Bharat Forge, to help automate
SCARA and the hygienic robot KR DELTA, which will be key processes, and keep employees safe.
presented in a cell by the first KUKA Robotics’ system partner
Koch Robotersysteme,” a press note states. Research is the key
KUKA Robotics is placing a special focus on digital
transformation, paving the way to ‘digital factory’ – to be Another major investment area is research and development
experienced in presentations during the trade fair. Visitors will for providing solutions related to Industry 4.0. Laboratories for
learn which solutions KUKA Robotics offers for today’s this purpose are being set up in collaboration with industries,
production requirements. This already starts with the planning educational institutions & the government. One such is the Centre
of new systems. The simulation software KUKA.Sim, for for Industry 4. 0 based in Pune. It regularly holds engagement and
example, makes it possible to program robotic applications capacity-building sessions with both small and large players. It
offline, commission them virtually, save time and work more works with industries to help them adopt new manufacturing
efficiently. For this purpose, KUKA.Sim creates a digital twin – technologies. Their most recent session was with a number of
an image of the subsequent production process – for maximum start-ups in sensing technology space. The domestic manufacturing
planning reliability. The digital twin maps the production sector spent about $5.5-6.5 billion on Industry 4.0 solutions in
process and ensures planning reliability before commissioning. 2020-21, accounting for half of all technology spending by Indian
manufacturers, states a report on the Industry 4.0 scenario of the
A symbiotic relationship Indian industry, published by NASSCOM and Capgemini.
Much of that investment was by the automotive, electronics
In addition to hardware, software is also becoming and electricals, chemicals and pharmaceutical segments. For
increasingly important, including the AI-based KUKA AIVI instance, power and automation solutions major ABB has
master controller. It is revolutionising intra-logistics, where it implemented its Industry 4. 0 solutions at some of its own
ensures the optimal flow of materials to the production line factories in India, and is doing the same for customers like JSW
and the perfect utilisation of automated guided vehicle systems. and Sterling and Wilson. For Ola’s new massive factory in
All this goes to show that Industry 4.0 definitely has created Krishnagiri, Tamil Nadu, ABB robots built in Bengaluru are
more room for robotics. There were less than 100 robots made used on the painting and welding lines and for the battery and
annually for industries in India about 15 years ago, and now motor assembly lines. The automation solution ensures remote
5,000 to 6,000 robots are built every year. Yet, India is still digital connectivity and monitoring of the robots. Interestingly,
around 5-6 years behind China in automation, which implies India was the 11th largest market among the world’s 15 largest
the scope that lies ahead. Consider for example the Pune-based industrial robot installation markets, outpacing Singapore,
Cybernetik Technologies, an automation and robotics firm. Canada, Thailand and the Czech Republic, prior to the pandemic.
It was recently reported that the company has worked with
Green Mountain Firewood, which supplies synthetic logs, Robots take the lead
primarily in the US market. It integrated a cooling tunnel in
the processing line to help eliminate bottlenecks, while also India’s robotic start-up ecosystem has been seeing a lot of
16 EM | Jun 2022WHAT’S IN YOUR
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kennametal.comR O B OT I C S TECHNOLOGY
Research and development for
providing robotic solutions related to
Industry 4.0 is now gaining momentum
traction. For example, in July 2019, US global aerospace and Market forecast
defence company Lockheed Martin signed a MoU with a Kochi-
based robotic start-up to develop robots to test the avionics According to a report published by India Brand Equity
display of their fighter jets, including the F-21. The robotic Foundation (IBEF), the Indian market for industrial robots is
Indian start-up Sastra Robotics, which builds innovative robotic expected to double over the next three to four years. The
platforms for product testing and review in the manufacturing primary reason for using robots in India is to get consistent
industry, will be mentored by this US giant and probably become quality that is ensured by the repetitive accuracy of the robot.
their supplier in the near future. Last year, the Walmart-owned Another reason is flexible manufacturing of multiple product
Flipkart, announced that for the first time they have deployed models and the need to ramp up production significantly to
100 robots to help sort out packages according to their location meet market demands. Most of the industrial robots that are
at one of its delivery hubs in Bengaluru. bought by companies are used for a variety of operations,
The robots were able to process over 4,500 packages in an including welding, paint finishing and material handling
hour, helping the e-commerce firm to streamline its supply operations. Considering the tremendous potential for growth
chain. German automotive component maker, Bosch’s Bidadi in India, ABB set up a robotics application centre for body-in-
plant has cobots or collaborative robots, working alongside white (BIW) systems in Bengaluru. The centre has been set up
humans. As robots gain ground in India steadily, many deep- to locally design, engineer and deliver BIW lines in India for
tech robotic start-ups are emerging on the Indian start-up automobile OEMs. KUKA Robotics has also established a
landscape. Indian start-ups, which are growing at 12-15% with presence in Gurugram in national capital region. Japanese
a cumulative valuation of $56-62 billion, are seeing a surge in automation and robots major Fanuc also has a strong presence
deep tech start-ups, says a NASSCOM study. There are 30+ across India, providing technical support for factory
robotic start-ups in multiple fields such as health technology, automation, and marketing its robots and industrial
automotive, industrial manufacturing, financial technology, automation products. Globally, the industrial robotics market
consumer robotics and defence. was worth around $41.7 billion in 2021 and is estimated to
The innovations are varied: there is weed spraying robotic grow to about $81.4 billion by 2028, with a compound annual
solutions for small cotton farmers from a Bengaluru-based growth rate of approximately 11.8% over the forecast period.
agritech and robotics platform start-up Tartan Sense; robots
for waterless cleaning of solar panels from Nocca Robotics; a Catching investors’ interest
manual scavenger robot called Bandicoot by Genrobotic
Innovations; robots to entertain kids like Miko from Mumbai- Investors are banking on these start-ups since they anticipate
based creator Emotix and humanoid robots to greet visitors at momentum to pick up in this sector due to India’s large and
banks, restaurants and technology events in India by promising engineering and technology talent pool. Robotics
Bengaluru-based Invento Robotics. A big success story has requires talent in multiple streams like computer science with
been that of Grey Orange, which designs and manufactures AI- electrical and mechanical engineering. Experts say that software
powered robots for flexible automation in fulfilment centres. such as AI, natural language processing and computer vision that
This company started by BITS Pilani graduates Samay Kohli provide differentiation drives the industry. When it comes to data
and Akash Gupta in 2011, deploys its advanced robots in analytics, AI & Machine Learning, India has a lot to offer, industry
fulfilment centres across India, Japan, Europe, Latin America experts point out. Of course, there are challenges too such as the
and the US and has carved a niche for itself in the global lack of a hardware ecosystem, financial incentives, critical human
warehouse automation and robotics circuit. resources and willingness to deploy robots. ☐
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kennametal.comMANAGEMENT INTERVIEW
“Robots will become
modular with software being
their central component”
…predicts Mahesh Wagle, Co-founder & Director, Cybernetik, in an interview
with Vidisha Sonone. The interview explores the upcoming trends in robotics for
manufacturing, how young manufacturers can be ready for the future and why
robotics is essential for high-performance manufacturing. Excerpts...
How has robotics transformed industrial automation? A 2015 McKinsey report noted that 64% of working hours
Flexibility and scalability are the two main advantages of robots. of a pool representing 80% of the global manufacturing
They can easily adapt to changes in product, volume and other workforce can be automated. This is not surprising
layout changes in facilities. Other plus points of robotics are considering the consistent output quality that automation
improved space utilisation and safety. Tedious tasks, such as delivers and the human labour it frees from hazardous
packaging, which involve high levels of repeatability and speeds areas and non-ergonomic tasks. Manual processes
are better handled by robots. This also prevents repetitive motion also involve a higher degree of risk to the labour force,
injuries. Integration of Artificial Intelligence (AI), Machine prompting companies to opt for automation processes
Learning (ML), robotic vision that can ensure that tasks can be carried out in a manner
systems, and other Industry that is error-free and safe.
4.0 technologies will further On the employment front, I don’t think it will hamper
reinforce these advantages the labour force. Over the years I’ve seen that when a
as robots get smarter. process is automated, it leads to a change of skillsets.
Automation also is normally focused on tasks that are
Do you think 100% either repetitive, hazardous or where the biological load
transformation of on the product is to be limited. The increasing demand for
manufacturing processes quality products also makes a case for automation. This
from traditional to is where robotics and automation come in handy, saving
automated is organisations from the entire hassle.
possible? Will Automation is already creating fresh jobs that
it hamper require upgraded skills. As long as upskilling is feasible,
the labour automation is a solution, not a problem. Besides,
force? automation frees up humans for value-added tasks such
as R&D and process control.
Which manufacturing industries do you think have the
most potential to embrace automation?
As mentioned earlier, manufacturing is only second to
accommodation and food service in terms of automation
potential. Automation holds natural advantage over
manual labour for hazardous, repetitive, and complex
20 EM | Jun 2022INTERVIEW MANAGEMENT
Mahesh Wagle is the Co-founder & Director of
Cybernetik – an industrial automation company that
has been undertaking the designing, building, and
end-to-end installation of turnkey automation systems
for the food, agro, pharmaceutical, and chemical
industries for over three decades. He is an alumnus of
the prestigious Indian Institute of Technology (IIT)-
Madras, and the University of Buffalo in New York.
operations such as welding, packaging, industrial adhesive skilled technicians should not be in short supply.
dispensing, and assembly lines. This is why the automobile,
consumer electronics, chemicals, plastics, and metal & What major transformations do you think you will see in the
machinery industries hold a large automation potential. manufacturing industries in a decade?
Manufacturing will be more data-driven than before. As Industry
What are the upcoming trends in robotics that manufacturers 4.0 technologies such as Artificial Intelligence (AI), Machine
need to look out for? Learning (ML), Virtual Reality (VR), Industrial Internet of
‘‘
Robots are taking over operations earlier Things (IIoT), predictive data analytics,
handled by conventional machines. We Augmented Reality (AR), get more
recently replaced such machines with sophisticated, manufacturing will also
robots for root-end machining of wind AS LONG AS UPSKILLING move from automation to autonomous. The
turbine blades. In the not-to-distant data-driven model will not only streamline
future, AI, ML, connectivity, and vision
IS FEASIBLE, AUTOMATION manufacturing processes but also the
systems will enable robots to make fast and IS A SOLUTION, NOT A supply chain thereby improving resource
intelligent decisions on their own when PROBLEM utilisation and associated efficiencies.
responding to unexpected scenarios.
Robots will be increasingly modular What automation challenges do we
with software being their central component. Smart and need to be ready for in the coming future?
interchangeable robot modules will be customisable for As technology unleashes the ever-improving capabilities of
numerous applications. They will also be easy to install, automation, customers will demand solutions with the least
configure, and integrate. Mass customisation is, of course, one cost and footprint that deliver high throughput. And, they will
of the principal features of Industry 4.0. AI will make human- ask for this with minimal delivery durations. Engineers have
robot interactions more sophisticated, a phenomenon referred their tasks cut out when balancing these requirements.
to as Industry 5.0 or collaboration.
Any advice you would like to give to young manufacturers?
Do you think we are skilled enough to adopt industrial Take a holistic view of things over the long term. This applies
automation or we need to upgrade in that area? to both – manufacturers looking to automate & companies
With automation getting smarter, operators will find it looking to provide them with automation solutions. Piecemeal
simpler to handle them. Training courses for the same are and short-sighted solutions escalate expenses over time while
short-duration ones. Provided the manual-to-automated also failing to optimise quality, productivity, safety, and
or automated-to-autonomous process is correctly mapped, resource utilisation. ☐
EM | Jun 2022 21M AT E R I A L H A N D L I N G FOCUS
I m ag e s c o u rte s y : shutterstock
Revolutionising material
handling systems
With companies across industries moving towards renting equipment and outsourcing
material handling requirements to expand their operations, Godrej RenTRUST has added
more than 1,000 material handling equipment to its rental fleet. This article highlights the
company’s future plans and industry predictions regarding material handling systems.
Godrej and Boyce, the flagship company of the Godrej Group, demand for warehousing equipment. Companies across
announced that its business Godrej RenTRUST is targeting a industries, especially project-based firms, are moving towards
growth of 23% YoY in providing rental solutions for complex renting equipment and outsourcing material handling
material handling needs. The business has surpassed the pre- requirements to expand their operations and focus on other core
pandemic level revenues and is growing steadily. Godrej competencies. To address this need, Godrej RenTRUST has
RenTRUST is the only Indian rental solutions provider that added more than 1,000 material handling equipment to its rental
manufactures and provides Indian origin material handling fleet. The business customises end-to-end rental solutions such as
equipment to its clients, thereby encouraging the government’s equipment and maintenance, skilled operators, administration
push for self-reliance with its ‘vocal-for-local’ operation strategy. and value-added solutions for their clients.
The current industry value is approximately ₹600-650 crore with Commenting on this, Anil Lingayat, Executive VP and
an addressable market of ₹200-250 crore for the business. Business Head, Godrej Material Handling, says, “Today’s
This is against the backdrop of industries focusing on complex material handling environment requires industry
outsourcing complex and high-end material handling work. As expertise to increase productivity, optimise costs and deliver
the e-commerce sector in tier - 3 & 4 markets grows, so does the quick results for customers. Godrej RenTRUST has become a
22 EM | Jun 2022FOCUS M AT E R I A L H A N D L I N G
Material handling
vehicle fleet
leading organised player owning 23% of the market share among build a resilient supply chain supported by advances in equipment
rental players and offering a decade of experience to its clients in technology. The development of the One Belt One Route initiative
delivering rental solutions for their material handling by China, also known as the Belt & Road Initiative, is also expected
requirements pan-India. Our mid-term goal for FY25 is to target to be lucrative for the materials handling equipment industry.
about 2,500 material handling equipment in our rental fleet.” The initiative to connect a network of rail and road routes from
“Going forward, we look forward to partnering with Indian as China to Europe via the Middle East will provide growth
well as global players to provide the best end-to-end material opportunities. Similarly other initiatives will bode well for the
handling rental solutions,” he adds. Fuelled by the heavy reliance material handling equipment industry over the next few years.
of companies on the rental industry for their seasonal demand, The 2021 Automation Solutions Survey Study stated that the
heavy loads and unexpected rise in their respective markets, the pandemic triggered the demand for a fully automated solution in
industry players offering rental solutions for material handling the manufacturing sector, with companies increasing investments
equipment have witnessed a major boom as the pandemic has in automated solutions over the next few years. Further,
hastened the process for essential services. companies project to upgrade their conveyor and sorting systems
in the next two years. However, due to the pandemic, several
Material handling industry overview medium-sized businesses have altered plans to purchase or
modernise new equipment. The industrial trucks segment
According to a report published by Grand View Research, the dominated the market and accounted for the largest revenue
global material handling equipment market size was valued at share of over 30% in 2020 and is estimated to witness steady
$26.3 billion in 2020 and is expected to expand at a compound growth over the forecast period.
annual growth rate (CAGR) of 7.4% from 2021 to 2028. Apart These trucks are a preferred choice due to their wide area of
from the uncertainties created by the pandemic, favourable application in an industrial setting. Transport of heavy containers
government initiatives are now supporting new infrastructure or crates in several end-use markets is undertaken using industrial
development worldwide, creating growth opportunities in the trucks, thereby contributing to a larger market share. As logistic
market for material handling equipment over the forecast period. companies move towards adopting sustainable products, the
Economies such as India, China and Southeast Asia are attracting demand for battery-operated trucks will gain traction over the
foreign investments promoting infrastructure and industrial forecast period. Although the pandemic hindered sales in 2020,
development, subsequently creating avenues for growth. the market may reach the pre-pandemic levels by the end of 2022,
The development of public infrastructure includes airports, registering a CAGR exceeding 7% over the next seven years. The
rail networks, seaports and power plants, among others. automated storage and retrieval system segment accounted for a
Meanwhile, although the demand for industrial applications significant revenue share of 28.2% in 2020. This growth is
witnessed a minor setback in 2020, unprecedented growth in the attributed to warehouses enforcing social distancing amid the
e-commerce sector helped upkeep market growth through the pandemic. These systems were preferred during the period as
pandemic. Healthy demand for delivery and distribution of they promoted efficiency and aligned with the social distancing
grocery items amidst the lockdown came as a respite for market norms. Over the forecast period, investments in automated
growth. In addition to the OEMs, the pandemic has driven several equipment will increase, creating lucrative opportunities in the
supply chains firms to explore tools that aid in making informed market for material handling equipment. The automated storage-
decisions with AI implementation to analyse large amounts of retrieval systems segment is estimated to register CAGR exceeding
data they generate periodically. 8 from 2021 to 2028, slightly higher than the global average. ☐
A combination of data-driven insights and hindsight will help Courtesy: Godrej RenTRUST
EM | Jun 2022 23INDUSTRIAL MAINTENANCE TECHNOLOGY
Ensuring quality through
optimal cleaning processes
To determine exactly which cleaning medium is best for effectively removing the
contaminants adhering to the respective parts, cleaning trials with original contaminated
parts are recommended. In its technology centres around the world, Ecoclean GmbH
disposes of a variety of cleaning systems for all types of media. This article sheds light on
the significance of the right cleaning processes.
Today, component cleanliness is just as much a quality the critical processes in manufacturing. For one, parts must
criterion as dimensional accuracy. It is defined by given be sufficiently clean for subsequent processing steps like
particulate – and increasingly also thin film – cleanliness coating, printing, heat treatment and assembly.
specifications. Meeting these reliably can be quite a task. For For another, product quality and functionality are
operations to be cost-effective, it is becoming ever more crucially dependent on clean components. In recent years,
important to design cleaning processes in line with user the focus has been on removing particulate contamination,
requirements and for reproducible cleaning results. Regardless including chips produced in machining and forming
the industry sector, parts’ cleaning today has become one of processes, but also burrs and particles generated from
24 EM | Jun 2022TECHNOLOGY INDUSTRIAL MAINTENANCE
Solvent cleaning system
abrasion. Meanwhile, thin film contamination has also taken hydrophilic properties and are therefore capable of removing
on a more prominent role. This is because the tiniest residues both non-polar and polar contaminants to a certain extent.
of machining oils and emulsions, cleaning media, drawing, To determine exactly which cleaning medium is best for
forming and release agents, etc. can impair the quality of the effectively removing the contaminants adhering to the
joints in joining processes such as laser welding, soldering respective parts, cleaning trials with original contaminated
and bonding. parts are recommended. In its technology centres around the
When it comes to thin film contamination, cleanliness world, Ecoclean GmbH disposes of a variety of cleaning
specifications are often defined in terms of surface energy or systems for all types of media. They are used to conduct tests
surface tension. Compliance can be checked comparatively on parts made of metallic materials, plastics, ceramic
easily with test inks and by measuring contact angles. For a materials, glass and combinations thereof. In addition to the
vast majority of parts, specifications regarding particulate achievable cleaning result, the team also checks that the
and filmic cleanliness can be met using wet chemical cleaning materials of the components to be cleaned are compatible
processes. The parts are generally cleaned in batches, either with the cleaning media used.
in bulk or arranged in part carriers. However, a stable and
reproducible process quality and consistently good results Minimising cleaning costs
can only be attained if the cleaning chemicals as well as the
system engineering and process technology are optimally The faster and more effectively the predefined cleanliness
tailored to the cleaning task. specifications are met in the cleaning process, the lower the
proportion of costs that are incurred for each cleaned part.
Choosing the right medium The cleaning effect of the medium is therefore enhanced by
various physical process technologies such as spraying, vapour
When selecting the cleaning medium, the chemical degreasing, dipping, ultrasonics and injection flood washing,
principle of ‘like solves like’ can serve as a guideline. This as well as high-pressure cleaning, which is used to deburr the
means polar contaminants such as cooling emulsions, parts at the same time. During spray cleaning, the kinetic
polishing pastes, salts, particles from abrasion and other solids energy of the jet boosts the effect of the cleaning chemicals
are normally removed using water as a polar cleaning medium used and removes impurities from the component surface.
in conjunction with pH-neutral, acidic or alkaline cleaners. Pressures between 2 and 20 bars are applied to all or
For mineral oil-based (organic, non-polar) contaminants such specific areas, as for example boreholes and blind holes.
as machining oils, greases and waxes, solvents like non- Especially with pinpointed spray cleaning, the cleaning result
halogenated hydrocarbons or chlorinated hydrocarbons are depends on how the nozzles are directed at the surface to be
generally used. Modified alcohols have lipophilic and cleaned. The result can be improved if the part is moved
EM | Jun 2022 25You can also read
