Make in India boosting domestic manufacturing, innovation, and sustainability

June 5, 2024 6:42 pm

According to Zurvan Marolia at Godrej & Boyce, industries are leveraging technology like never before to enhance production efficiency and competitiveness. Automation, data analytics, and AI are revolutionising manufacturing processes, paving the way for sustainable growth.

How are industries leveraging technology to scale up operations and stay competitive?

There is a growing focus on harnessing technology to expand operations while reducing costs and enhancing production efficiency. Industries are gravitating towards innovative solutions to address the complexities of a dynamic market. Adopting automation, data analytics, artificial intelligence, and additive manufacturing has emerged as essential for maintaining competitiveness and boosting sustainable growth. 

Incorporating automation and robotics into production processes streamlines operations, diminishes reliance on manual labour, and heightens precision. It translates to augmented productivity and reduced operational costs over time. 

Furthermore, embracing advanced data analytics and artificial intelligence (AI) solutions offers invaluable insights into production workflows. These insights enable predictive maintenance, accurate demand forecasting, and real-time decision-making, optimising resource allocation and mitigating downtime. 

Implementing IoT devices and connectivity throughout the manufacturing ecosystem fosters simple communication among machines. It enhances visibility into supply chains and facilitates remote monitoring and control, improving efficiency and responsiveness. Customer needs are constantly evolving, and as we build systems, we need to keep in mind these changing needs and build systems that can keep pace with change and address these needs. Nowadays, customers are more discerning as they get exposed to global offerings, one reflection of which is the need for customised offerings. 

Ensuring precise fulfilment of customer orders amidst component-based manufacturing presents unique challenges. It necessitates tracking components from raw materials to delivery to guarantee zero errors for each customer order. It is where digitalisation and MES (Manufacturing Execution Systems) play an invaluable role. Further, customers today appreciate being proactively informed about the progress of their order execution. Factors such as these enhance the value added to the customer, thereby improving competitiveness.

The other significant sector of the market is the mass market, where technologies enable the use of data analytics to understand customer preferences. It helps to ensure that the right products are available on the shelves in the right places and at the right time, as needed. Here again, large volumes of data can be analysed to help minimise costs and reduce the probability of damage/spoilage due to the material being in stock at the wrong places apart from the opportunity cost of the suitable material not being available.

 What strategies are essential for robotic integration to improve assembly precision and productivity? 

A combination of strategies can be integrated effectively to leverage advanced robotics for precise assembly and improved productivity. First, investment in cutting-edge robotic systems with advanced sensors and vision technologies is paramount. These enhancements empower robots to perceive and manipulate objects,  ensuring precise assembly and minimising errors.  Implementing comprehensive training programs for employees operating and maintaining robotic systems is equally critical. Well-trained operators can effectively maximise the potential of robots, swiftly address any issues that arise, and ensure seamless operations, thus contributing to enhanced productivity.

Moreover, the continual monitoring and analysis of performance metrics using data analytics and AI technologies play a pivotal role. The manufacturers can pinpoint areas ripe for optimisation through diligent analysis of data-derived insights. By leveraging these insights, they can fine-tune robotic processes, identify avenues for improvement, and drive sustained enhancements in assembly precision and overall productivity.

How does Godrej & Boyce scale up innovation while minimising implementation challenges?

At Godrej & Boyce, we are continuously embracing advancements in manufacturing operations. We prioritise asset utilisation and improve Overall Equipment Effectiveness (OEE) through technology integration. Our commitment to innovation is evident through our Center of Excellence at the Electronics & Electricals Business Unit (BU), which leads cutting-edge technology into our manufacturing plants. Additionally, we have a central digital team that collaborates with technology providers to drive innovation.

Over the years, we have developed technology implementation roadmaps across most plants. We prioritise ease of implementation and potential impact, as well as piloting and proof of concept before scaling up. For instance, at Godrej Material Handling, we introduced SafeLog, a fleet management system providing live data and analysis to optimise MHE operations for our customers. Furthermore, we have revolutionised traditional manufacturing processes with additive manufacturing or 3D printing technology. At Godrej Construction, we showcased the benefits of 3D Construction Printing (3DCP) with projects like – The Cocoon – a 500 sq. ft. office space in Khalapur, installed within 48 hours. 

We also invest in IoT-enabled devices and connectivity to create a connected manufacturing ecosystem. We enhance visibility and optimise supply chain management by leveraging IoT sensors and real-time monitoring systems. Our deployment of IoT and MES enhances speed, accuracy, and efficiency across factories. 

How does G&B balance innovative approaches and technological advancements to scale up processes across its operations? 

Odd as it might sound, the reality is that the first line of action in addressing manufacturing challenges to scale up processes is at the drawing board. Designs need reviewing from the point of view of automation of the manufacturing processes in reducing the number of components through standardisation. Using innovative technologies, we are better placed to minimise costs by ensuring First Time Right and reducing the number of setups and the time taken in changeovers. This will also contribute to meeting the need for customisation through parametric design rather than addressing each requirement from scratch.

On the shop floor, overcoming manufacturing challenges to scale up processes requires a strategic blend of innovative approaches and technological advancements. Implementing automation and robotics streamlines operations reduces manual labour, and boosts efficiency, while advanced data analytics and AI solutions offer insights into production workflows, aiding predictive maintenance and resource optimisation.

Leveraging IoT devices enhances communication between machines, improves supply chain visibility, and enables remote monitoring. Addressing workforce development ensures employees should be trained with the skills required to operate and maintain advanced technologies effectively.

 Please count on the benefits of Make in India for the world to scale up manufacturing.

The Make in India initiative offers advantages for scaling up manufacturing domestically. Prioritising local production diminishes reliance on imports, fostering self-sufficiency and fortifying the industrial landscape. Streamlined regulations and incentives attract foreign investment, enhancing infrastructure and technological advancement, thus elevating competitiveness and operational efficiency. Additionally, Make in India spurs innovation and entrepreneurship, empowering startups and small businesses to pioneer new products and industries, driving growth and diversification. Moreover, the initiative underscores sustainability by encouraging adoption of eco-friendly practices and renewable energy, aligning with global standards and broadening market access.

It needs to be understood that the aim of ‘Make In India’ is to diminish our reliance on imports and foster self-sufficiency. It also provides an environment which nurtures our manufacturing sector and prepares us to ‘Make in India for the World’.