Consuming Responsibly

As manufacturing processes evolve, customers are also on the lookout for additional functionality in the form of manufacturing intelligent tools to address key manufacturing requirements and improve the overall efficiency of their operations. Smart manufacturing involves use of sensors and automation and  digital technologies for a more efficient manufacturing system with an ability to adapt to changing demands. It connects manufacturing and logistics to gather, visualize, analyze, and monitor machine, process, and sensor data.

Saving energy

In an era where industries are adopting methods to reduce their energy footprint, usage of machine tools with features to reduce energy consumption and increase operational efficiency are gaining importance. Usage of electric drives (which reduce energy consumption), integrated hydraulic systems to increase the operational efficiency and capacity, effective design to enhance effective heat dissipation, thereby reducing the cooling requirements are some areas where machine tool manufacturers globally are focusing on. Integrating automation systems with energy intelligence systems help users monitor the performance of the machines and provide them with key data on energy consumption.

Facilitating real-time decision making

Inter-connected machines, which can leverage seamless real-time machine-to-machine (M2M) communication, can adapt and respond faster to changing customer needs. Multiple field devices connected on the same control network, such as Programmable Logic Controller (PLC) or Distributed Control System (DCS) would be able to unite various processes across the value chain. The control system is connected to the Level 3 manufacturing execution system to communicate to the central purchase or production system. Enterprise Resource Planning (ERP) or the Product Lifecycle Management (PLM) integrate the various divisions and allow exchange of data and communication through the network. IoT brings in interconnectivity within the field devices and increases collaboration between equipment and users. Adoption of these advanced manufacturing systems will lead to high levels of data availability, which will also facilitate creation of intelligent control resulting in improved operational excellence. Real-time decision making will enable higher productivity, operational efficiency, and better utilization of current assets.

Automation as an efficiency enabler

Automation, in a manufacturing scenario, aims at using control systems for operating equipment to reduce human intervention and provide data for real-time performance management. Seamless integration and connectivity between multiple equipment including machine tools can lead to an integrated shop floor. M2M integration will also allow mass customization and mass production of customized products where all manufacturing systems are agile to adapt to changing requirements.

Furthermore, automation of workplaces and machines including robotics can help in increasing productivity and utilization levels. Automation of the overall production process provides added advantages such as reduction in errors, along with reduced downtime of the machine, while also reducing manual labor in the process.

Flexible Manufacturing Systems

Flexible Manufacturing System (FMS) refers to an extremely automated Group Technology (GT) machine cell, comprising processing workstations, mostly CNC machine tools, attached to an automated material handling and storage system, and controlled by distributed computer systems. The FMS is capable of processing a range of different parts or products at various workstations concurrently. The desired quantities of production can be achieved according to the changing demand patterns; hence, it is referred to as flexible manufacturing system.

With better implementation, the FMS can lower the manufacturing cost, reduce the cost per unit, provide higher labor productivity and enhance machine performance, improve reliability, reduce the lead time, lower the inventories, and provide a more sustainable manufacturing ecosystem.

Smart and Sustainable Manufacturing – Integration with levels of automation

Additive manufacturing

Additive manufacturing, also referred as 3D printing, is the process of attaching layers upon layers to create products from 3D model data, as opposed to subtractive manufacturing, which involves cutting away what is not needed from larger pieces of the material. Additive manufacturing has massive potential in almost every market ranging from automotive to aerospace, whereas subtractive manufacturing is becoming obsolete.

However, the combination of both subtractive and additive manufacturing into a single machine provides economical parts or products, with minimum assembly requirements, lower lead time, lesser skilled labor, and lower wastage of materials.

Working towards the goal

The machine tool industry is a crucial aspect of the manufacturing sector as it acts as a differentiator that helps in building the competitive edge. Technology-driven manufacturing is poised to build the confidence and faith of global customers, bringing in large-scale investments for development of manufacturing sourcing and knowledge center to India. For successful smart manufacturing systems implementation, existing and upcoming manufacturers have to embrace new technologies and the older generation has to invest their vast experience to ensure higher returns on investment.

Developing synchronized policies and frameworks for higher adoption of machine tools, strategically tied to technology transfer can revive and transform the domestic manufacturing sector and project it as a global manufacturing hub.

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