Impact of Digitalization in Discrete Manufacturing IMTMA Symposium on Appropriate Automation in Indian Context
Indian Context, 2017 to 2022 2017 2022 Population 1.3 Billion 1.4 Billion Youth coming into Employment age 1 Million per month 1.3 Million per month Employment Rate & new Jobs required 52% & 100 Million GDP 2.6 Trillion USD 4.0 Trillion USD Contribution of Manufacturing to GDP 16% (400 Billion USD) 25% (1 Trillion USD) WEF Ranking – Manufacturing 30 (Legacy) Should enter top 10 (Leading) Readiness for the future Leading, High Potential, Legacy, Human capital Development & Nascent Sustainable Resources are two challenges Manufacturing has a key role to play in GDP growth, and socio-economic health of our country
Indian Manufacturing – Current Conditions are Positive
Why Digitalize? • Demand for small batch quantities and several variants • Quick Turnaround times expected • High penalties for non-conformation (Quality / Time) • Traceability requirements mandated by Safety laws / Governments • Global opportunities also mean Global competition • Requirements of Mass Customization / Personalization • Manufacturing Data will grow exponentially Improve and sustain productivity, quality and turn around times while still being cost competitive!
Productivity = Profits! $ € ¥ ₹ £
Business Processes Production Engineering Sales Manufacturing Operations CAE, PLM, CAD.. Order fulfilment visibility Shop floor connectivity Modelling & Simulation Flexible Pricing Model Manufacturing Analytics Rapid Prototyping Customer feedback … ….. …. Smart Steps Decentralized Decision Making Communication Smart Manufacturing Real-time decisions Connected Factory Mass customization Transparency Real time data Scalability Autonomous Decision making Mobility Flexibility & Agility ….. ….. …..
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Sample Deployment for OEE, Energy, Digital Factory & Shop ANDONS
Journey drivers • Change Management • How to enable this? • Culture • Can a company think 19 th century, and adopt Digital? • Competency • What are the new competencies?
Impact of Digitalization: Plug in your own data, and check! My Company Description Value Avg. machine hour rate ₹ $ € ¥ 800 10% Improvement in productivity 80 Increase in machine hour rate Work hours in a month 600 Regular monthly revenue 4,80,000 Monthly productivity increase 48,000 Total revenue, after increase 5,28,000 Increase in Annual revenue 5,76,000 Investment, 1-time 2,00,000 Months for full realization 4 288% Your 1st Year R.O.I.
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